Service - Manual

BW 216 D-4 / BW 216 PD-4

S/N 101 583 23...... S/N 101 583 24

Single drum roller

Catalogue number.
008 911 83 08/2007
Table of Contents

General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 26
Maintenance 31
2.1 General notes on maintenance 32
2.2 Fuels and lubricants 33
2.3 Table of fuels and lubricants 36
2.4 Running-in instructions 37
2.5 Maintenance chart 38
Technical data 41
3.1 Technical data 42
Connection overview 47
4.1 Connection overview 48
Tests and adjustments 51
5.1 Special tools, tests and adjustments 52
5.2 Checking / adjusting the neutral positions of the travel pump 56
5.3 Pressure tests in the travel circuit 58
5.4 Checking / adjusting the vibrator shaft speeds 60
5.5 Pressure measurements in the vibration circuit 61
5.6 Check the leakage rate of the vibration motor 62
5.7 Pressure test in steering circuit 63
Flushing and bleeding 65
6.1 Special tools for flushing 66
6.2 Flushing - general 71
6.3 Flushing schematic travel circuit (distribution travel pump) 73
6.4 Flushing the travel circuit (travel pump distribution) 75
6.5 Flushing schematic travel circuit (distribution axle motor) 81
6.6 Flushing the travel circuit (axle motor distribution) 86
6.7 Flushing schematic for vibration drive 91
6.8 Flushing the vibration circuit 92
6.9 Bleeding the travel circuit 96
6.10 Bleeding the vibration circuit 98
Fundamental electrics 101
7.1 Understanding circuit diagrams 102
7.2 Terminal designations 106
7.3 Current and voltage 110
7.4 Resistance 114
7.5 Series / parallel connection 116
7.6 Ohm's law 118
7.7 Electrical energy 118
7.8 Formula diagram 119
7.9 Metrology 120
7.10 Diodes, relays, fuses 122
7.11 Batteries 125

008 911 83 BOMAG 3

Table of Contents

7.12 Three-phase generator 128

7.13 Electric starter 136
7.14 Telemecanique switch 139
7.15 Inductive proximity switches 142
7.16 Angle sensor with current output 143
7.17 Plug connectors 144
7.18 Deutsch plug, series DT and DTM 145
7.19 Plugs and terminals in spring clamping technology 151
Special tools, electrics 155
8.1 Special tools, electrics 156
Electronic modules 165
9.1 Electrics BEM (BOMAG Evib-meter) 167
9.2 Seat contact module 229
Speedometer Module 237
10.1 Speedometer module 238
Service Training 241
11.1 Service Training Machine 243
Engine 305
12.1 Diesel engine 306
12.2 Engine description TCD 2012 307
12.3 Engine description TCD 2013, 4 and 6 cylinder 309
12.4 Lubrication oil circuit TCD 2012 / 2013 313
12.5 Coolant circuit TCD 2012 / 2013 314
12.6 Fuel system TCD 2012 / 2013 315
12.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 319
12.8 Sensors TCD 2012 / 2013 325
12.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013 340
12.10 Exhaust gas recirculation TCD 2012 / 2013 345
12.11 Engine monitoring, instrument cluster TCD 2012 / 2013 346
12.12 Fault diagnosis TCD 2012 / 2013 348
12.13 EMR3 List of fault codes 350
12.14 SerDia Service-Software TCD 2012 / 2013 360
12.15 General trouble shooting chart TCD 2012 / 2013 363
12.16 Valve adjustment TCD 2012 / 2013 365
12.17 Ribbed V-belt - fan drive TCD 2012 / 2013 368
12.18 Special tools, Deutz engine (TCD 2012 2V) 369
12.19 Special tools, Deutz engine (TCD 2013 2V) 384
Air conditioning system 403
13.1 Physical basics 404
13.2 Refrigerant R134a 407
13.3 Compressor oil / refrigeration oil 408
13.4 Working principle of the air conditioning system 409
13.5 Monitoring devices 409
13.6 Description of components 410
13.7 Checking the compressor oil level 416
13.8 Checking the magnetic clutch 417
13.9 Inspection and maintenance work 418

4 BOMAG 008 911 83

Table of Contents

13.10 Checking, replacing the refrigerant compressor V-belt 418

13.11 Service the air conditioning 419
13.12 Drying and evacuation 422
13.13 Emptying in case of repair 422
13.14 Leak test 423
13.15 Filling instructions 424
13.16 Trouble shooting in refrigerant circuit, basic principles 427
13.17 Trouble shooting, refrigerant circuit diagram 431
13.18 Trouble shooting procedure 432
13.19 Steam table for R134a 442
13.20 Heating control / air conditioning control 447
Replacing the cab window panes 453
14.1 Assembly of window panes 454
14.2 Special tools 455
14.3 Auxiliary materials 456
14.4 Removing and installing the window pane 458
Drum 463
15.1 Special tools, drum, single drum rollers 464
15.2 Repair overview for drum 466
15.3 Removing and installing the drum 475
15.4 Repairing the drum 481
15.5 Dismantling, assembling the change-over weights 512
15.6 Changing the rubber buffers and adjusting the pretension 515
Oscillating articulated joint 519
16.1 Special tools 520
16.2 Repair overview oscillating articulated joint 522
16.3 Removing and installing the oscillating articulated joint 525
16.4 Dismantling the oscillating articulated joint 527
16.5 Assembling the oscillating articulated joint 532
Suppliers documentation 543
17.1 Travel pump series 90R 545
17.2 Travel drive series 51 635
17.3 Vibration pump 42R 041 717
17.4 Vibration motor A10FM 755
17.5 Transmission CR 779
17.6 Axle DANA 193 805
Circuit diagrams 895
18.1 Wiring diagram 897
18.2 Wiring diagram 933
18.3 Hydraulic diagram 969

008 911 83 BOMAG 5

Table of Contents

6 BOMAG 008 911 83

1 General

008 911 83 BOMAG 7

1.1 Introduction

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

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

Documentation
For the BOMAG machines described in this training
manual the following documentation is additionally
available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Wiring diagram*
4 Hydraulic diagram*
5 Service Information

You should only use genuine BOMAG spare parts.

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

Danger
!

Please observe strictly the safety regulations in

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

8 BOMAG 008 911 83

Safety regulations 1.2
Important notes Mark a machine that is defective or being repaired
1.2 Safety regulations
l

by attaching a clearly visible warning tag to the

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

Repair work shall only performed by appropriately

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

Workshop equipment and facilities as well as the

l Be careful with cleansing agents. Do not use easily
use and waste disposal of solvent, fluids, gases inflammable or harmful substances, such as gaso-
and chemicals are subject to legal regulations, line or paint thinners for cleaning.
which are intended to provide a minimum on safe- l Cleaning or repair work on the fuel tank is very dan-
ty. It is obviously your own responsibility to know gerous. Do not smoke or allow any ignitable sparks
and adhere to these regulations. or open fire in the vicinity when cleaning or repairing
This manual contain headers like "Note", "Attention", a tank. .
"Danger" and "Environment", which must be strictly l
When performing welding work strictly comply with
complied with in order to avoid dangers for health and the respective welding instructions.
for the environment.
Precautions and codes of conduct for
Danger
! welding work
Paragraphs marked like this highlight possible Welding work should only be performed by specially
dangers for persons. instructed expert personnel.

Caution
! Danger
!
Paragraphs marked like this highlight possible Electric shock!
dangers for machines or parts of the machine.
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
i Note
eyes!
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine. Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
Environment grease or solvent residues, etc.!
Paragraphs marked like this point out practices l Check welding equipment and cables for damage
for safe and environmental disposal of fuels and before use (also the validity of inspection stickers).
lubricants as well as replacement parts.
l Ensure good conductivity between earth cable and
Observe the regulations for the protection of the work piece.
environment.
l Start the extraction fan before starting work and
guide with the progressing work as required.
General
l
Always isolate the burner when laying it down (re-
l
Before starting repair work stand the machine on move possible electrode residues).
level and solid ground.
l Protect cables from being damaged, use cables
l Always secure the machine against unintended roll- with insulated couplings.
ing.
l
Ensure sufficient fire protection, keep a fire extin-
l Secure the engine reliably against unintentional guisher at hand.
starting.

008 911 83 BOMAG 9

1.2 Safety regulations

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

Behaviour in case of faults

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

10 BOMAG 008 911 83

Safety regulations 1.2
Reattach all guards and safety installations after plastic material, a so-called fluoroelastomer. Under
all work has been completed. normal operating conditions this material is safe and
does not impose any danger to health.
Environment However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
It is strictly prohibited to drain off hydraulic oil
caustic hydrofluoric acid, which can cause severe
into the soil, the sewer system or into natural wa-
burns in contact with skin.
ters. Entrust special companies with the waste
disposal of old oil. If in doubt you should consult l If the material is in such a state it must only be
your local authorities. touched with special protective gloves. These
gloves must be disposed of directly after use.
Fuels l If the material has contacted the skin despite these
measures, take off the soiled clothes and seek
medical advice immediately. In the meantime wash
Danger
!
the affected parts of the skin for 15 to 60 minutes
Repair work on fuel systems must only be per- with cold water or lime water.
formed by appropriately trained personnel.
The following notes refer to general safety precau- Poisonous substances
tions for danger free handling of fuel. These notes are
Some of the fluids and substances used are toxic and
only general instructions; in case of uncertainties you
must under no circumstances be consumed.
should consult the person responsible for fire protec-
tion. Skin contact, especially with open wounds, should be
strictly avoided.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu- These fluids and substances are, amongst others,
tion with air creates an easily inflammable mixture. anti-freeze agents, hydraulic oils, washing additives,
The vapours are heavier than air and therefore sink lubricants and various bonding agents.
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por- Engine
tion of spilled fuel is therefore potentially dangerous.
l Fire extinguishers charged with FOAM, SCHAUM, Danger
!
CO2 GAS or POWDER must be available wherever
Do not work on the fuel system while the engine is
fuel is stored, filled in, drained off, or where work on
running - danger to life!
fuel systems is performed.
After the engine has stopped wait until the pres-
l The vehicle battery must always be disconnected,
sure has dropped (on Commonm Rail engines ap-
BEFORE work in the fuel system is started. While
prox. 5 minutes, other engines 1 minute), because
working on the fuel system you should not discon-
the system is under high pressure - danger to life!
nect the battery, because this could generate
sparks, which would ignite explosive fuel vapours. Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
l
Wherever fuel is stored, filled, drained off or where
leaks - danger to life!
work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed. When performing work on the fuel system make
Search lights must be fire proof and well protected sure that the motor cannot be started unitention-
against possible contact with running out fuel. ally - danger to life!
l Maintenance and cleaning work on the engine must
Hot fuels onyl be performed with the engine stopped and
cooled down. Make sure that the electric system
Before draining fuel off the tank for repair work, you
has been switched off (ignition key pulled out).
must strictly apply the following measures:
l Observe the accident prevention regulations for
l Allow the fuel to cool down, to prevent any contact
electric systems (e.g. -VDE-0100/-0101/-0104/-
with a hot fluid.
0105 Electric precautions against dangerous con-
l Vent the system, by removing the filler cap in a well tact voltages).
ventilated area. Screw the filler cap back on, until l Cover all electric components properly before wet
the tank is finally emptied.
cleaning.

Synthetic rubber
Many O-rings, hoses and similar parts, which are ap-
parently made of natural rubber, are actually made of

008 911 83 BOMAG 11

1.2 Safety regulations

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

12 BOMAG 008 911 83

Safety regulations 1.2
l Always shield eyes and face towards the battery. l Do not heat up oil higher than 160 °C because it
l Do not use battery chargers or jump leads without may ignite.
following the operating instructions. l Wipe off spilled oil and fuel.
l Keep the cell plugs closed. l Do not smoke when refuelling or when checking the
l After an accident with acid flush the skin with water acid level in the battery.
and seek medical advice. l Do not check the acid level of the battery with a na-
l Do not allow children access to batteries. ked flame, danger of explosion!
l When mixing battery fluid always pour acid into wa- l Old batteries contain lead and must be properly dis-
ter, never vice-versa.
posed of.
l
There is a danger of scalding when draining off en-
Poisonous substances
gine or hydraulic oil at operating temperature.
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
l on machines with rubber tires a tire may busr if in-
correctly assembled. This can cause severe injury.
Skin contact, especially with open wounds, should be
strictly avoided.
l Do not exceed the specified highest permissible tire
pressure.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, washing additives,
lubricants and various bonding agents.

Special safety regulations

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

008 911 83 BOMAG 13

1.3 General repair instructions

General Electrics
1.3 General repair instructions

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

Diagnostics according to plan

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

14 BOMAG 008 911 83

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

Electrical system and welding work

l
Surge voltages in the electric system must be strict-
ly avoided:
l
When performing welding work always fasten the
earth clamp of the welding unit in the immediate vi-
cinity of the welding location.

!Caution
Switch off the main battery switch, doisconnect
the generator and pull the plug out on the control
unit before starting welding work.

008 911 83 BOMAG 15

1.3 General repair instructions

Hydraulic system l After changing a component perform a high and

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

16 BOMAG 008 911 83

General repair instructions 1.3
Air conditioning system damp air is drawn into the component by the differ-
ence in temperatures.
CFC - halon prohibition l Damaged or leaking parts of the air conditioning
The CFC - halon prohibition from May 06, 1991 regu- must not be repaired by welding or soldering, but
lates the withdrawal from the use of CFC and the han- must generally be replaced.
dling of these refrigerants.
l Do not fill up refrigerant, but extract existing refrig-
Contents: erant and refill the system.
Since 1995 CFC (R12) is no longer permitted for use l Different types of refrigerant must not be mixed.
in new systems.
Only the refrigerant specified for the corresponding
In operation, during maintenance and repair work and air conditioning system must be used.
when taking refrigeration systems our of service it is l Refrigerant circuits with refrigerant type R134a
not permitted to let refrigerant escape into the atmos-
must only be operated with the compressor oil / re-
phere, which would contradict the current status of
frigeration oil approved for the compressor.
technology.
l Used compressor oil / refrigeration oil must be dis-
Work on refrigeration systems must only be carried
out by persons with well founded knowledge about posed of as hazardous waste.
such systems and who have the necessary technical l Due to its chemical properties compressor oil / re-
equipment available. frigeration oil must never be disposed of together
The use of refrigerant must be documented. with engine or transmission oil.

Old systems should be converted to refrigerants

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

008 911 83 BOMAG 17

1.3 General repair instructions

tion colouring matter makes any warranty claims Notes on cleanliness for Common Rail
null and void. engines
l Tools used on refrigeration circuits must be of ex- Special requirements with respect to cleanliness in
cellent condition, thus to avoid the damage of any the fuel system do apply for commissioning, mainte-
connections. nance and repair work, particularly for TEIRIII engines
l The dryer is to be installed last, after all connections with the DEUTZ Common Rail System. Contamina-
in the refrigerant circuit have been tightened. tion like dirt, welding residues or similar can lead to the
failure of individual components and adversely affect
l After completion of repair work screw locking caps engine operation.
(with seals) on all connections with valves and on
the service connections. Start up of the air condi-
tioning system. Observe the filling capacity.
l Before start up of the air conditioning system after a
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle
speed and maximum cooling power.
l
Never operate the compressor over longer periods
of time with high engine speeds without a sufficient
amount of refrigerant in the system. This could
probably cause overheating and internal damage.

Fig. 1
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.

18 BOMAG 008 911 83

General repair instructions 1.3
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.

008 911 83 BOMAG 19

1.3 General repair instructions

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.

20 BOMAG 008 911 83

General repair instructions 1.3
Gaskets and mating surfaces threads or splines. If no assembly sleeve is availa-
ble, you should use a plastic tube or adhesive tape to
Leaking or failing seals and gaskets can in most cases
prevent the sealing lip from being damaged.
be tracked down to careless assembly, causing dam-
age not only to the seal or gasket, but also to the mat-
ing surfaces. Careful assembly work is mandatory if
good results are to be achieved.
l Before assembling replacement seals make sure
that the running 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 Sealing compound should only be used if specially
requested in the instructions. In all other cases
these joints should be assembled in dry condition.
l Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the Fig. 4
compound does not enter into oil galleries or blind l Lubricate the outer rim 1 (Fig. 4) of the seal and
threaded bores.
press it flat on the housing seat.
l
Before assembly remove any residues of old seal-
ing compound. Do not use any tools that could dam-
age the sealing surfaces. i Note
If possible, use a "bell" 1 (Fig. 4), to make sure that
l
Examine the contact faces for scratches and burrs,
the seal will not skew. In some cases it may be ad-
remove these with a fine file or an oilstone; take
visable to assemble the seal into the housing first, be-
care that no grinding dust and dirt enters into
fore sliding it over the shaft. Under no circumstances
tapped bores or enclosed components.
should the full weight of the shaft rest on the seal.
l
Blow lines, ducts and gaps out with compressed air,
If you have no proper service tools at hand, use a suit-
replace any O-rings and seals that have been dis-
able drift punch with a diameter which is about 0.4mm
lodged by the compressed air.
smaller than the outer diameter of the seal. Use VERY
Assembly of radial seals LIGHT blows with the hammer if no press is available.
l
Press or knock the seal into the housing, until it is
flush with the housing surface.

Fig. 3
l
Lubricate sealing lips 1 (Fig. 3) with clean grease; in
case of double seals fill the space between the seal-
ing lips with a generous amount of grease.
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 pro-
tect the lip from being damaged by sharp edges,

008 911 83 BOMAG 21

1.3 General repair instructions

Feather keys and keyways Ball and roller bearings

!Caution !Caution
Feather keys must only be reused if they show no Ball and roller bearings must only be reinstalled
differences to new feather keys, any notches must after it has been assured that they are in perfect
be considered as initial signs of wear. condition.

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

Fig. 6
l Remove any lubricant residues from the bearing to
be examined by washing it with gasoline or any oth-
er appropriate degreasing agent. Cleanliness is of
utmost importance for all related work.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. If necessary replace the bearing with
a new one, since these symptoms are first signs of
wear.
l
Hold the bearing with you thumb and the index fin-
ger by the inner race, rotate the outer race and
make sure that it runs without friction. Hold the
bearing by the outer race and repeat this test with
the inner race.
l
Move the outer race gently to and fro while holding
it by the inner race; check for resistance while rotat-
ing and replace the bearing if it does not work cor-
rectly.
l Lubricate the bearing with an appropriate lubricant
before reinstalling.

22 BOMAG 008 911 83

General repair instructions 1.3
l Check shaft and bearing housing for discolouration Screws and nuts
or other signs of movement between bearing and
seats. Tightening torque
l Make sure that shaft and housing are free of burrs
before assembling the bearing. !Caution
l If a bearing of a pair of bearings shows any defects, Always tighten nuts or screws to the specified
we highly recommend the replacement of both tightening torque. Tightening torques deviating
bearings. from the ones in the table are specially mentioned
in the repair instructions.
l On greased bearings (e.g. wheel bearings) fill the
space between bearing and outer seal with the rec- Damaged screws must under no circumstances
ommended type of grease before assembling the be used any longer. Recutting threads with thread
seal. cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
l Always mark the individual parts of separable bear-
roded thread pitches can cause incorrect torque
ings (e.g. taper roller bearings) to enable correct re-
value readings.
assembling. Never assemble the rollers to an outer
race that has already been used, replace the com- Self-locking nuts must be generally renewed.
plete bearing instead. The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
specified tightening torque you should first relieve
by a quarter turn and then tighten to the correct
torque.
l Before tightening you should lightly oil the thread, in
order to ensure low friction movement. The same
applies for self-locking nuts.
Fig. 7 l Make sure that no oil or grease will enter into tapped
bores. The hydraulic power generated when turning
in the screw could cause breakage of the effected
Caution
!
part.
When assembling the bearing to the shaft load
must only be applied to the inner race 1 (Fig. 7).
When fitting the bearing into the housing load
must only be applied to the outer race (2).

008 911 83 BOMAG 23

1.3 General repair instructions

Strength classes of metric screws Strength classes of metric nuts

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

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

6, 8, 10, 12)

Fig. 9 Identification of nuts

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

Strength class of Strength class of associated

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
Fig. 8 Identification of screws 6 6.8
8 8.8
Example: A screw is identified with 12.9.
9 9.8
The first number corresponds with 1/100 of the nomi- 10 10.8
nal tensile strength (minimum tensile strength) in N/ 12 12.8
mm2.
Nuts for screw joints with limited load factor (04,
l
The nominal tensile strength is 12 X 100N/mm2 = 05)
1200 N/mm2.
The preceding "0" indicates that, due to their low
The second number specifies 10-times the ration be- height, nuts 2 (Fig. 9) in this group are only able to
tween lower yield point and nominal tensile strength withstand the force of a screw to a limited extent.
(yield point ratio). Nut height below 0.8 d (d = nominal dimension).

Nuts for screw joints without specified load factor

i Note
(11H, 14H, 17H, 22H)
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas- This standard contains strength classes (hardness
tic deformation). classes) for nuts 3 (Fig. 9), for which no load values
can be specified, e.g. because of their shape and di-
When exceeding the upper yield point the material will mensions, but which can only be classified by their
not restore its original shape after being relieved. hardness.
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.

24 BOMAG 008 911 83

General repair instructions 1.3
Identification in clock system

Fig. 10 Identification of nuts in clock system

For small nuts (Fig. 10) the clock system can be used
for identification.
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).

008 911 83 BOMAG 25

1.4 Tightening torques

The values specified in the table apply for screws:

1.4 Tightening torques

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

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

Tightening torques for screws with metric unified 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

26 BOMAG 008 911 83

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 83 BOMAG 27

1.4 Tightening torques

The values specified in the table apply for screws:

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

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

Tightening torques for screws with UNC thread, 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

28 BOMAG 008 911 83

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 83 BOMAG 29

1.4 Tightening torques

30 BOMAG 008 911 83

2 Maintenance

008 911 83 BOMAG 31

2.1 General notes on maintenance

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

Danger
!
Notes on the engine performance
Health hazard!
Combustion air and fuel injection rates of the diesel
engine have been carefully adjusted and determine

32 BOMAG 008 911 83

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

Approved engine oils

Deutz DQC II-05 DQC II-05
ACAE E3/96/E5-02/ E4-99/E6-04
E7-04
API CG-4/CH-4/CI- -
4
DHD DHD-1 -

The exact assignment of the approved oil qualities

and oil change intervals can be taken from the follow-
ing section "Lubrication oil change intervals".
Consult your local service station if in doubt.

Oil viscosity
Multi-purpose oils should be generally used.
Since lubrication oil changes its viscosity with the tem-
perature, the ambient temperature at the operating lo-
cation of the engine is of utmost importance when
choosing the viscosity class (SAE-class) .
Optimal operating conditions can be achieved by us-
ing the opposite oil viscosity chart (Fig. 11) as a refer-
ence.
Occasionally falling short of the temperature limits will
impair the cold starting ability, but will not cause any
engine damage. In order to keep the occurring wear
as low as possible, occasional exceeding of the limits
should not happen over a longer period of time.

008 911 83 BOMAG 33

2.2 Fuels and lubricants

content of more than 1% you should consult the

responsible service agency.

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

Oil change intervals Danger

!

The longest permissible time a lubrication oil should Fire hazard!

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

34 BOMAG 008 911 83

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

Coolant, anti-freeze agent Hydraulic oil

The correct quality of water is highly important when The hydraulic system is operated with hydraulic oil HV
preparing coolant. Clear and clean water within the 46 (ISO) with a kinematic viscosity of
boundaries of the following analysis values should 46 mm2/s at 40°C. For topping up or for oil changes
generally be used. use only high-quality hydraulic oil, type HVLP accord-
ing to DIN 51524, part 3, or hydraulic oils type HV ac-
cording to ISO 6743/3. The viscosity index (VI) should
Water quality
be at least 150 (observe information of manufacturer).
Analysis values min. max.
pH-value at 20 °C 6,5 8,5 Bio-degradable hydraulic oil
Chloride ion content [mg/dm3] - 100
On request the hydraulic system can also be filled with
Sulphate ion content [mg/dm3] - 100 ester based biodegradable hydraulic oil (Panolin HLP
Total hardness*1 [°dGH] ] 3 12 Synth. 46). The biologically quickly degradable hy-
*1Proportion of carbonate hardness on the total hard- draulic oil meets all demands of a mineral oil based
ness min. 3 dGH hydraulic oil according to DIN 51524.

Information concerning the water quality can be ob- In hydraulic systems filled with Panolin HLP Synth. 46
tained from the waterworks. always use the same oil to top up. When changing
from mineral oil based hydraulic oil to an ester based
A test case for checking the water quality can be or- biologically degradable oil, you should consult the lu-
dered from the engine manufacturer. brication oil service of the oil manufacturer for details.
If the values of the analysis deviate, the water must be Check the filter more frequently after this change.
treated accordingly.
l
pH-value too low
! Caution
Adding of caustic lye of soda or caustic potash so-
lution. Oil change bio-degradable hydraulic oil:
l
Total hardness too high: Perform regular oil analyses for content of water
Mixing with dehardenede water. and mineral oil.
l
Total hardness or carbonate hardness too low: Replace the hydraulic oil filter element every 500
Mixing with harder water. operating hours.
l Chlorides and/or sulphates too high:
Mixing with dehardenede water.
Oil for drive axle
For the drive axle use only multi-purpose transmission
As a protection against frost, corrosion and boiling
oil of API-class GL5 with viscosity class SAE 90.
point anti-freeze agents must be used under any cli-
matic conditions. The additives in this oil ensure low wear lubrication
under all operating conditions.
The proportion of cooling system protection agent
must be between min. 35% and max. 45% to the wa-
ter. Lubrication grease
For lubrication use only EP-high pressure grease, lith-
ium saponified (penetration 2).

008 911 83 BOMAG 35

2.3 Table of fuels and lubricants

2.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil ACEA: E3-96/E5-02 or approx. 15,5 litres incl. oil
filter

API: CG-4/CH-4

SAE 10W/40

(-20 °C to +40 °C)

SAE 15W/40

(-15 °C to +40 °C)

Fuel

Diesel Winter diesel fuel approx. 340 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres

46 mm2/s at 40 °C

Vibration bearings Engine oil SAE 15W/40 approx. 2 x 0,8 litres

Drive axle Gear oil SAE 90, API GL5 approx. 11 litres

Wheel hubs Gear oil SAE 90, API GL5 approx. 2 litre per side

Axle reduction gear Gear oil SAE 90, API GL5 approx. 1,9 litres

Drum drive gear Gear oil SAE 90, API GL5 approx. 3,2 litres

Air conditioning system Refrigerant R134A 1400 g

Engine cooling system Cooling system protection agent approx. 16 litres

Tires Water approx. 295 litres

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

(MgCl2)

36 BOMAG 008 911 83

Running-in instructions 2.4
2.4 Running-in instructions
The following maintenance work must be per-
formed when running in new machines or over-
hauled engines:

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

After a running-in time of 30 minutes

l Retighten the V-belt

After 250 operating hours

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

After 500 operating hours

l 2. Oil change vibration bearings
l
2. Oil change, drum drive reduction gear

008 911 83 BOMAG 37

2.5 Maintenance chart

2.5 Maintenance chart

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 6000 operating hours

every 250 operating hours

every 500 operating hours

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

as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Check the dust separator X
5.12 Check the tire pressure X
5.13 Clean the cooling fins on engine X
and hydraulic oil cooler
5.14 Check the oil level in the drive axle X
5.15 Check the oil level in the wheel X
hubs
5.16 Check the oil level in the axle re- X
duction gear
5.17 Check the oil level in the drum re- X
duction gear
5.18 Check the oil level in the vibration X
bearings
5.19 Change engine oil and oil filter car- min. 1x per year X X
tridge1
5.20 Change the fuel filter cartridge X
5.21 Drain the sludge from the fuel tank X
5.22 Battery maintenance Pole grease X
5.23 Change the fuel pre-filter cartridge X
5.24 Check, replace the refrigerant X
compressor V-belt
5.25 Service the air conditioning X
5.26 Check, adjust the valve clearance Intake = 0,4 mm X
Exhaust = 0,6 mm
5.27 Adjusting the control piston play X

38 BOMAG 008 911 83

Maintenance chart 2.5

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 6000 operating hours

every 250 operating hours

every 500 operating hours

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

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

008 911 83 BOMAG 39

2.5 Maintenance chart

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 6000 operating hours

every 250 operating hours

every 500 operating hours

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

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

40 BOMAG 008 911 83

3 Technical data

008 911 83 BOMAG 41

3.1 Technical data

3.1 Technical data

Fig. 12

Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 216 D-4 2960 2250 1500 2268 2972 490 5808 60 60 35 2130
BW 216 PD-4 2960 2250 1500 2268 2972 490 5808 60 60 25 2130

1 BW 216 D-4 BW 216 PD-4

Weights
Operating weight (CECE) kg 15700 16200
with ROPS and cabin
Axle load, drum (CECE) kg 10400 10900
Rear axle load (CECE) kg 5300 5300
Static linear load kg/cm 48,8 -

Travel characteristics
Travel speed (1) km/h 0 ... 4 0 ... 4
Travel speed (2) km/h 0 ... 5 0 ... 5
Travel speed (3) km/h 0 ... 7 0 ... 7
Travel speed (4) km/h 0 ... 11 0 ... 11
Max. gradability (depend- % 45 48
ing on soil)

Engine
Engine manufacturer Deutz Deutz
Type TCD 2013 L04 2V TCD 2013 L04 2V
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO kW 119 119
3046
Rated speed rpm 2200 2200
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Permissible ambient tem- °C -20 ... +50 -20 ... +50
peratures

42 BOMAG 008 911 83

Technical data 3.1
1
BW 216 D-4 BW 216 PD-4
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.

Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic

Vibration
Vibrating drum 1 1
Drive system hydrostatic hydrostatic
Frequency Hz 30/36 30/36
Amplitude mm 1,8/0,95 1,64/0,82

Tires
Tire size 23.1-26/12 TL R3 23.1-26/12 TL R3
Air pressure bar 1,4 1,4

Filling capacities
Engine Litres 15 15
Fuel Litres 340 340
Hydraulic oil Litres 60 60
Coolant Litres 16 16
1 The right for technical modifications remains reserved

Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 700 - 800
High idle speed rpm 2200 - 2250
Spec. fuel consumption g/kWh 226
Valve clearance intake mm 0,4
Valve clearance exhaust mm 0,6
Injection valves opening pressure bar DRC / 1600

Travel pump
Manufacturer Sauer
Type 90R 075
System Axial piston/swash plate
Max. displacement cm3/rev. 75
Max. flow capacity l/min 163,65
High pressure limitation bar 400 + 26
Charge pressure, high idle bar 26

Drum reduction gear

Type CR 31
Transmission ratio 45,6

Drum drive motor

Manufacturer Sauer
Type 51C 110
System Axial piston – swash plate
Displacement (stage 1) cm3/rev. 110
Displacement (stage 2) cm3/rev. 55
Perm. leak oil rate l/min 2

008 911 83 BOMAG 43

3.1 Technical data

Flushing rate l/min 10

Flushing limitation bar 16

Axle drive motor

Manufacturer Sauer
Type 51D 110
System Axial piston – bent axle
Max. displacement (stage 1) cm3/rev. 110
Min. displacement (stage 2) cm3/rev. 69
Perm. leak oil rate l/min 2
Flushing rate l/min 16
Flushing limitation bar 16

Vibration pump
Manufacturer Sauer
Type 42R 041
System Axial piston/swash plate
Max. displacement cm3/rev. 41
Start up pressure bar 345 + 26
Operating pressure (soil depend- bar approx. 100
ent)

Vibration motor
Manufacturer Bosch-Rexroth
Type A10FM 45
System Axial piston/swash plate
Displacement cm3/rev. 45
Flushing rate l/min 6
Flushing pressure limitation bar 13

Check steering/
Type HY/ZFFS11/16
System Gear pump
Displacement cm3/rev. 16
Max. steering pressure bar 175 + 26

Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve

Rear axle
Manufacturer Dana
Type CHC 193/66LD
Differential No-Spin
Degree of locking % 100
Reduction ratio 65,08

44 BOMAG 008 911 83

Technical data 3.1
The following noise and vibration data acc. to

- EC Machine Regulation edition (98/37/EC) and

- Noise Emission Regulation 2000/14/EC

were determined at nominal speed of the drive engine and with vibration running. The machine was
standing on an elastic base.

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

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

sound pressure level at the work place of the operator (with cabin):
LpA = 82 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 = 107 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 11204
for sound pressure level (LpA) at the place of the operator.

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

Vibration of the entire boy (driver’s seat)

The weighted effective acceleration value determined in accordance with ISO 7096 is γ ≤0.5 m/sec2.

Hand-arm vibration values

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

008 911 83 BOMAG 45

3.1 Technical data

46 BOMAG 008 911 83

4 Connection overview

008 911 83 BOMAG 47

4.1 Connection overview

Fig. 1 Travel pump

48 BOMAG 008 911 83

Connection overview 4.1
1 Control solenoid, high frequency 21 Connection D, charge pressure to filter
2 Control solenoid, low frequency 22 Multi function valve 345 bar (boost check and
3 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive high frequen-
pressure relief valve), travel system cy
4 Connection, charge pressure to brake solenoid 23 Connection S, suction line charge pump from hy-
valve, travel speed range selection and charge oil draulic oil tank
supply for vibration pump 24 Multi function valve 345 bar (boost check and
5 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive low frequen-
pressure relief valve), travel system cy
6 Setscrew, mechanical neutral position 25 Charge pressure relief valve, vibration pump
(blocked)
7 Connection L, leak oil connection to vibration
pump 26 Connection E, charge oil from travel pump
8 Lever, travel control 27 Connection L1, leak oil connection to travel pump
9 Pilot pressure test port 28 Pressure test port MB, high pressure reverse
10 High pressure port B, high pressure reverse 29 Charge oil from filter
11 Charge pressure relief valve, 26 bar 30 Pressure test port MA, high pressure forward
12 Adjustment screw, low frequency 31 High pressure port A, high pressure forward
13 Connection L2, leak oil to tank 32 Setscrew, mechanical neutral position, vibration
14 Pressure test port MB, high frequency 33 Leak oil connection D, leak oil from axle drive mo-
tor
15 High pressure test port MA, low frequency
34 Leak oil connection A, leak oil from travel pump
16 High pressure port A, low frequency
35 Leak oil connection G, leak oil from drum drive
17 High pressure port B, high frequency
motor
18 Charge pump, internal
36 Leak oil connection F, leak oil from vibration motor
19 Connection L2, to drum drive motor (flushing)
37 Radiator inlet
20 Adjustment screw, high frequency

008 911 83 BOMAG 49

4.1 Connection overview

50 BOMAG 008 911 83

5 Tests and adjustments

008 911 83 BOMAG 51

5.1 Special tools, tests and adjustments

5.1 Special tools, tests and adjustments

1. Vibration reed frequency meter
1000 - 4000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80

Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
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

52 BOMAG 008 911 83

Special tools, tests and adjustments 5.1
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 83 BOMAG 53

5.1 Special tools, tests and adjustments

9. Hydraulic test case, small

BOMAG part-no.: 079 930 01

i Note
1X 25 bar pressure gauge
1X 150 bar pressure gauge
2X 400 bar pressure gauges
4 pressure test hoses

Fig. 9
10. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03

Fig. 10
11. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04

Fig. 11
12. Adapter for pressure test hose

BOMAG part-no.: 055 439 02

Fig. 12

54 BOMAG 008 911 83

Special tools, tests and adjustments 5.1
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 83 BOMAG 55

5.2 Checking / adjusting the neutral positions of the travel pump

5.2 Checking / adjusting the neutral posi-

tions of the travel pump
Special tools
Hydraulic test case

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Block drums and wheels with suitable chocks
(Fig. 1).

Fig. 1
2. Unhook the travel cable (Fig. 2) from the pump.

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

Fig. 3

56 BOMAG 008 911 83

Checking / adjusting the neutral positions of the travel pump 5.2
4. Connect 600 bar pressure gauges to high pres-
sure test ports MA and MB (Fig. 4).

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

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

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

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

Fig. 6
Evaluation of test

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

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

Fig. 7

008 911 83 BOMAG 57

5.3 Pressure tests in the travel circuit

5.3 Pressure tests in the travel circuit

Special tools
Hydraulic test case

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Block drums and wheels with suitable chocks
(Fig. 1).

Fig. 1
2. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.

Fig. 2
3. Connect 600 bar pressure gauges to the high
pressure test ports for "forward travel" and "re-
verse travel" and a 60 bar pressure gauge to the
charge pressure test port (Fig. 2).
4. Start the engine and run it with maximum speed.
5. Read charge and high pressure gauges.

Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = charge pressure at high
Fig. 3 idle

Evaluation of test
If the nominal value is not reached, check the
steering/charge pump.

58 BOMAG 008 911 83

Pressure tests in the travel circuit 5.3
Measurement with quickly operated travel le-
ver
6. Move the travel lever (Fig. 4) quickly forward,
read the pressure gauge.

Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = pressure override

Evaluation of test

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

008 911 83 BOMAG 59

5.4 Checking / adjusting the vibrator shaft speeds

5.4 Checking / adjusting the vibrator shaft

speeds
Special tools
Vibration reed frequency meter

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

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

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

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

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

Fig. 3

60 BOMAG 008 911 83

Pressure measurements in the vibration circuit 5.5
5.5 Pressure measurements in the vibra-
tion circuit
Special tools
Hydraulic test case

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

Fig. 1
4. Connect a 60 bar pressure gauge (Fig. 2) to the
charge pressure test port.
5. Connect a 600 bar pressure gauge each to the
high pressure test ports for "high amplitude" and
"low amplitude".
6. Start the engine and run it with maximum speed.
7. Switch on vibration with high or low frequency.

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

Evaluation of test
If the charge pressure drops, check the compo-
nents individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one fre-
quency, check the high pressure relief valves.

008 911 83 BOMAG 61

5.6 Check the leakage rate of the vibration motor

5.6 Check the leakage rate of the vibration

motor

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

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

Fig. 2
4. Disconnect the leak oil hose (Fig. 3), connect a
measuring hose and hold it into a measuring
beaker.
5. Start the engine and run it with maximum speed.
6. Switch the vibration on and measure the running
out leak oil during one timed minute.

Nominal value
max. 1.5 litre/min

Evaluation of test
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
Fig. 3

62 BOMAG 008 911 83

Pressure test in steering circuit 5.7
5.7 Pressure test in steering circuit
Special tools
Hydraulic test case, gear pump testing equipment

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (approx. 50 °C).

Measurement 1
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).
2. Start the engine and run it at idle speed.

! Danger
Danger of crushing, do not access the articu-
lation area of the machine!
3. Turn the steering against an end stop.
4. Read the pressure gauge.

Nominal value

Fig. 1
see technical data, max. steering pressure of
steering/charge pump.

Evaluation of test 1
If the nominal value is reached, check the steer-
ing cylinder.
Measurement 2
5. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) (machines with one steering cylinder)
on the steering cylinder and close them with
plugs.

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

Nominal value
see technical data for steering/charge pump.

Fig. 3

008 911 83 BOMAG 63

5.7 Pressure test in steering circuit

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

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

Nominal value
see technical data for steering/charge pump.

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

Fig. 5

64 BOMAG 008 911 83

6 Flushing and bleeding

008 911 83 BOMAG 65

6.1 Special tools for flushing

6.1 Special tools for flushing

1. Filling and filtering unit with oil bag

BOMAG part-no.: 007 610 01

2. Filter element

BOMAG part-no.: 079 930 35

Fig. 1
3. Flushing filter (S connection)

BOMAG part-no.: 007 000 01

4. Filter element 1μ

BOMAG part-no.: 079 930 52

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

BOMAG part-no.: 055 509 19

6. Screw socket R1“ - 25S (2 pieces)

BOMAG part-no.: 055 400 52

Fig. 2
7. Flushing filter (L connection)

BOMAG part-no.: 079 390 29

8. Filter element

BOMAG part-no.: 079 390 14

9. Flushing hose 15L (2 pieces)

BOMAG part-no.: 055 510 09

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

BOMAG part-no.: 055 400 89

Fig. 3
11. SAE-flange 1“ - 20S

BOMAG part-no.: 058 142 60

12. O-ring

BOMAG part-no. 062 203 30

Fig. 4

66 BOMAG 008 911 83

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

BOMAG part-no.: 007 160 18

14. O-ring

BOMAG part-no. 062 202 22

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

BOMAG part-no.: 055 422 92

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

BOMAG part-no.: 055 422 98

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

BOMAG part-no.: 055 423 26

Fig. 8

008 911 83 BOMAG 67

6.1 Special tools for flushing

18. Connecting socket 15L

BOMAG part-no.: 055 426 55

Fig. 9
19. Connecting socket 18L

BOMAG part-no.: 055 426 06

Fig. 10
20. Connecting socket 16S

BOMAG part-no.: 055 459 43

Fig. 11
21. Connecting fitting 20S

BOMAG part-no.: 055 459 44

Fig. 12

68 BOMAG 008 911 83

Special tools for flushing 6.1
22. Connecting fitting 25S

BOMAG part-no.: 055 459 45

Fig. 13
23. Angular fitting 18L

BOMAG part-no.: 055 421 26

Fig. 14
24. Elbow fitting 16L

BOMAG part-no.: 055 421 36

Fig. 15
25. Elbow 20S

BOMAG part-no.: 055 421 37

Fig. 16

008 911 83 BOMAG 69

6.1 Special tools for flushing

26. Elbow 25S

BOMAG part-no.: 055 421 38

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

BOMAG part-no.: 493 301 01

Fig. 18
28. Connecting hose 15L

BOMAG part-no.: 055 510 09

Fig. 19

70 BOMAG 008 911 83

Flushing - general 6.2
6.2 Flushing - general Clean the hydraulic tank

Caution
!

Solid particles in the circuit will very quickly

cause damage to machine components.

Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.

Changing a component
Fig. 2
Caution
!

Always flush the complete oil circuit after !Caution

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

Fig. 3
Fig. 1

l Change the hydraulic oil filter element (1). l Always bleed closed hydraulic circuits if
lines had been removed or connected.

008 911 83 BOMAG 71

6.2 Flushing - general

Servicing the flushing filter kit

Fig. 4

l Replace the filter element of the flushing fil-

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

72 BOMAG 008 911 83

Flushing schematic travel circuit (distribution travel pump) 6.3

008 911 83 BOMAG 73

6.3 Flushing schematic travel circuit (distribution travel pump)

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

74 BOMAG 008 911 83

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

Flushing the drum drive

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

i Note
Observe the chapter "Flushing - General"
Installing the flushing filter

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

Fig. 2

008 911 83 BOMAG 75

6.4 Flushing the travel circuit (travel pump distribution)

Bleeding the travel circuit

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

Fig. 3
Flushing the hoses
4. Block drums and wheels with suitable chocks.

Fig. 4

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

Fig. 5

! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction forward.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the hydraulic hoses (12 and 13) to the
drum drive motor.
Fig. 6

76 BOMAG 008 911 83

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

! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
11. Pre-select the slow speed range.

Fig. 7

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

Fig. 8

! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
12. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
13. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
14. Shut down the engine.

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

008 911 83 BOMAG 77

6.4 Flushing the travel circuit (travel pump distribution)

Flushing the axle drive

Installing the flushing filter
16. Disconnect the high pressure hose 14 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 16) and connect
it with the flushing hose (18) (flushing filter inlet
"IN").
17. Connect the flushing hose (19) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.

Fig. 10
Disconnecting the axle motor
18. Take the axle drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (14 and
15) on the axle drive motor together.

Fig. 11

Bleeding the travel circuit

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

Fig. 12

78 BOMAG 008 911 83

Flushing the travel circuit (travel pump distribution) 6.4
Flushing the hoses
19. Block drums and wheels with suitable chocks.

Fig. 13

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

Fig. 14

! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
20. Start the engine and shift the travel lever to travel
direction forward.
21. Perform the flushing process at various engine
speeds for approx. 10 minutes.
22. Shut down the engine.
23. Reconnect the hydraulic hoses (14 and 15) to the
axle drive motor.
Fig. 15
Flushing the axle motor

!Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
24. Jack up the rear of the machine, so that the
wheels can rotate freely.
25. Secure the drum with wheel chocks.
26. Pre-select the slow speed range.

Fig. 16

008 911 83 BOMAG 79

6.4 Flushing the travel circuit (travel pump distribution)

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

Fig. 17

! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
27. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
28. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
29. Shut down the engine.

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

Bleeding the travel circuit

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

Keep circulating the tank content.

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

Fig. 19

80 BOMAG 008 911 83

Flushing schematic travel circuit (distribution axle motor) 6.5

008 911 83 BOMAG 81

6.5 Flushing schematic travel circuit (distribution axle motor)

82 BOMAG 008 911 83

Flushing schematic travel circuit (distribution axle motor) 6.5

008 911 83 BOMAG 83

6.5 Flushing schematic travel circuit (distribution axle motor)

84 BOMAG 008 911 83

Flushing schematic travel circuit (distribution axle motor) 6.5
1 Elbow union (tool) 13 High pressure hose (drum drive motor forward)
2 Connecting union (tool) 14 High pressure hose (B, axle motor reverse)
3 Drum drive motor 15 High pressure hose (A, axle motor forward)
4 Axle motor 16 High pressure hose (B, axle motor reverse)
5 Screw socket R1 - 25S (tool) 17 not used
6 not used 18 Flushing hose 25S - 20S (tool)
7 not used 19 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1μ (tool)
9 not used
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (drum drive motor reverse)

008 911 83 BOMAG 85

6.6 Flushing the travel circuit (axle motor distribution)

6.6 Flushing the travel circuit (axle motor

distribution)

Flushing the drum drive

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

i Note
Observe the chapter "Flushing - General"
Installing the flushing filter

! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
1. Disconnect the high pressure hose 14 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 16) and connect
it with the flushing hose (19) (flushing filter inlet
"IN").
2. Connect the flushing hose (18) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.

Fig. 2

86 BOMAG 008 911 83

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

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

Fig. 3
Flushing the hoses

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

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

Fig. 5

! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction forward.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the hydraulic hoses (12 and 13) to the
drum drive motor.
Fig. 6

008 911 83 BOMAG 87

6.6 Flushing the travel circuit (axle motor distribution)

Flushing the drum drive motor

! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
11. Pre-select the slow speed range.

Fig. 7

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

Fig. 8

! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
12. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
13. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
14. Shut down the engine.

Fig. 9

88 BOMAG 008 911 83

Flushing the travel circuit (axle motor distribution) 6.6
Flushing the axle motor
!Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
15. Jack up the rear of the machine, so that the
wheels can rotate freely.
16. Secure the drum with wheel chocks.
17. Pre-select the slow speed range.

Fig. 10

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

Fig. 11

! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
18. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
19. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
20. Shut down the engine.

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

Bleeding the travel circuit

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

Keep circulating the tank content.

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

008 911 83 BOMAG 89

6.6 Flushing the travel circuit (axle motor distribution)

Function test
24. Check the hydraulic oil level in the tank, fill up if
necessary.
25. Check all connections for leaks with the engine
running (visual inspection).
26. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
27. Check all ports and connections for leak tightness
(visual inspection).

Fig. 13

90 BOMAG 008 911 83

Flushing schematic for vibration drive 6.7

1 Elbow union (tool) 7 Flushing hose 25S - 20S (tool)

2 Connecting union (tool) 8 Flushing filter with filter element 1μ (tool)
3 Vibration motor 9 SAE flange (tool)
4 Vibration pump 10 High pressure hose (B, high frequency)
5 Screw socket R1 - 25S (tool) 11 High pressure hose (A, low frequency)
6 Flushing hose 25S - 20S (tool)

008 911 83 BOMAG 91

6.8 Flushing the vibration circuit

6.8 Flushing the vibration circuit

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

i Note
Observe the chapter "Flushing - General"

Installing the flushing filter

! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the vibration
pump in high frequency.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
Fig. 1
1. Disconnect the high pressure hose 10 (see chap-
ter "Flushing schematic - vibration circuit") from
the vibration pump (4) and connect it with the
flushing hose (7) (flushing filter inlet "IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port A) on the vibra-
tion pump.
Disconnect the vibration motor
3. Take the vibration motor out of the hydraulic cir-
cuit by joining the high pressure hoses (10 and
11) on the vibration motor together.

Fig. 2

92 BOMAG 008 911 83

Flushing the vibration circuit 6.8
Bleeding the vibration circuit

i Note
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".

Fig. 3
Flushing the hoses
4. Block drums and wheels with suitable chocks.

Fig. 4

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

Fig. 5

! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
5. Switch on vibration with high frequency.
6. Start the engine and run it with maximum speed.
7. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
8. Shut down the engine.
9. Reconnect the hydraulic hoses (10 and 11) to the
Fig. 6 vibration motor.

008 911 83 BOMAG 93

6.8 Flushing the vibration circuit

Flushing the vibration motor

10. Unscrew the fastening screws for the vibration
motor and pull the motor out of the coupling.

Fig. 7

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

Fig. 8

! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
11. Start the engine and run it with maximum speed.
12. Run the flushing procedure for approx. 10 min-
utes. Switch the vibration on and off at intervals of
approx. 30 seconds.
13. Shut down the engine.
14. Remove the flushing filter and reinstall the vibra-
tion motor.
Fig. 9
Bleeding the vibration circuit
15. Bleed the vibration circuit (see corresponding
chapter).

Keep circulating the tank content.

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

94 BOMAG 008 911 83

Flushing the vibration circuit 6.8
Function test
17. Check the hydraulic oil level in the tank, fill up if
necessary.
18. Test drive.
19. Check all ports and connections for leak tightness
(visual inspection).

Fig. 10

008 911 83 BOMAG 95

6.9 Bleeding the travel circuit

6.9 Bleeding the travel circuit

Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.

! Danger
The engine should not start.

Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Operate the starter motor for approx. 30 seconds.
Wait one minute and repeat this procedure, until
oil starts to run out from the pressure test hoses.
6. Remove the pressure test hoses.

Fig. 2
7. Unlock the emergency stop switch

Fig. 3

96 BOMAG 008 911 83

Bleeding the travel circuit 6.9
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.

Fig. 4

! Caution
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise the flushing filter will be subjected to
oil flow from the wrong direction.

!Danger
Run the engine with idle speed.
10. Start the engine.
11. Shift the travel lever (Fig. 5) approx. 1/3 to for-
ward direction.
Fig. 5 12. After approx. 1 to 2 minutes shut down the engine
for a minute.

i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.

008 911 83 BOMAG 97

6.10 Bleeding the vibration circuit

6.10 Bleeding the vibration circuit

Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.

Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Crank the engine approx. 10 seconds with the
starter motor. Wait one minute and keep repeat-
ing this procedure, until oil starts to run out from
the pressure test hoses.
6. Remove the pressure test hoses.

Fig. 2
7. Unlock the emergency stop switch

Fig. 3

98 BOMAG 008 911 83

Bleeding the vibration circuit 6.10
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-
cedure, until the pressure gauge shows a con-
stant charge pressure.

Fig. 4

! Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
10. For bleeding switch on vibration with high fre-
quency (Fig. 5).
11. Start the engine.
12. After running the engine 1 to 2 minutes pause for
approx. one minute.

Fig. 5 i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.

008 911 83 BOMAG 99

6.10 Bleeding the vibration circuit

100 BOMAG 008 911 83

7 Fundamental electrics

008 911 83 BOMAG 101

7.1 Understanding circuit diagrams

7.1 Understanding circuit dia- l The sequence in which current flows through the in-
dividual elements in the electric circuit.
grams l Connections between the examined, faulty electric
Wiring diagrams are graphical representations of cir- circuit and other circuits in the vehicle wiring sys-
cuitry conditions, related to the electrical system. They tem.
do not contain any information about the actual type of l Pin assignment of plug-and-socket connections.
wiring, they only serve the purpose of visualizing the
circuitry logics. Structure:
The wiring diagram is indispensable for effective and
l Table of contents
systematic trouble shooting in the vehicle wiring sys- l Function groups
tem. This plan provides the following information: l List of components
l Number and type of individual elements in the ex-
amined electric circuit, such as plug connectors, Table of contents
fuses, switches, consumers, relays, ... The table of contents lists all function groups.

Fig. 6 Table of contents

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

102 BOMAG 008 911 83

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

Fig. 7 Function groups Relay cross reference

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

008 911 83 BOMAG 103

7.1 Understanding circuit diagrams

Current paths
The pages of a circuit diagram are sub-divided into
current paths (Fig. 8) (0 ..... 20).

Fig. 8 Current paths

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

Fig. 9 List of components

Component cross references

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

104 BOMAG 008 911 83

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

Fig. 10 Graphic symbol

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

Fig. 11 Graphic symbol

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

008 911 83 BOMAG 105

7.2 Terminal designations

7.2 Terminal designations the individual connection terminals is determined by

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

Terminal designa- Meaning

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

2 Short circuit terminal (magneto ignition)

4 Ignition coil, ignition distributor high voltage

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

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

15a Output from dropping resistor to ignition coil and starter

17 Preheating starter switch, preheating

19 Preheating starter switch, starting

30 Battery plus direct

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

31 Battery minus direct or ground

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

32 Electric motors, return line

33 Electric motors, main connection

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

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

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

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

49 Input flasher relay

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

50 Starter, starter control

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

106 BOMAG 008 911 83

Terminal designations 7.2
Terminal designa- Meaning
tion
50c Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 1
Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 2
50d Start locking relay, input
50f Start locking relay, output
50g Start repetition relay, input
50h Start repetition relay, output

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

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

52 Trailer signals: further signals from trailer to towing vehicle

53 Wiper motor input (+)

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

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

55 Fog light

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

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

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

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

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

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

61 Generator control

71 Intermittent tone control unit, input

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

72 Alarm switch (flashing beacon)

008 911 83 BOMAG 107

7.2 Terminal designations

Terminal designa- Meaning

tion
75 Radio, cigarette lighter

76 Loudspeaker

77 Door valve control

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

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

82 Switch (maker), input

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

83 Switch (multi-position switch), input

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

84 Current relay, input drive and relay contact

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

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

86 Switching relay, input drive winding start

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

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

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

88 Relay contact for maker

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

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

108 BOMAG 008 911 83

Terminal designations 7.2
Terminal designa- Meaning
tion
DF2 Dynamo field 2 (generator excitation current)

U Three-phase generator, three-phase terminal

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

C Travel direction indicator (flasher relay) control light 1

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

008 911 83 BOMAG 109

7.3 Current and voltage

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

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

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

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

110 BOMAG 008 911 83

Current and voltage 7.3
Current Types of current
Electric current generally describes the directed Direct current (D.C.)
movement of charge carriers.
l The charge carriers may either be electrons or ions.
l Electric current can only flow if there is a sufficient
amount of free moving charge carriers.
l The higher the number of electrons flowing through
a conductor per second, the higher the amperage.
Current is measured with an ammeter.

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

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

Circuit

Fig. 2 Alternating current (A.C.)

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

Fig. 3 Pulsating direct current

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

008 911 83 BOMAG 111

7.3 Current and voltage

Pulse width modulation (PWM)

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

Caution
!

Solenoid valves must not be interference sup-

pressed with suppressor diodes.

112 BOMAG 008 911 83

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

Fig. 5 CAN Characteristics of CAN

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

008 911 83 BOMAG 113

7.4 Resistance

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

Bad

Fig. 1 Various size resistors

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

Fig. 2 Spring clamps

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

Symbol, R

Unit, Ohm 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.

114 BOMAG 008 911 83

Resistance 7.4
Sometimes the flanks of flat plugs bend open. If these
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.

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

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

Fig. 4 Balistol oil

008 911 83 BOMAG 115

7.5 Series / parallel connection

7.5 Series / parallel connection l In series connection the plus pole of the first battery
must be connected with the minus pole of the sec-
Series connection ond battery.
In a series circuit the resistors (consumers) are lined l The sum of all individual voltages is applied to the
up one after the other and the same current (I) passes free poles.
through each of the consumers However, series con- l The total capacity (Ah) is identical with the capacity
nection of consumers is not suitable in practice, as of the individual battery.
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).

Fig. 1 Series connection

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

Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3

Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3

Series connection of batteries

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

116 BOMAG 008 911 83

Series / parallel connection 7.5
Parallel connection l In parallel connection the plus pole of the first bat-
In parallel connection all resistances (consumers) are tery is connected with the plus pole of the second
connected between feed and return line. battery and the minus pole of the first battery with
the minus pole of the second battery.
l All resistances (consumers) are supplied with the
same voltage.
l Plus and minus poles have the voltage of the single
battery applied.
l Each of the resistances (consumers) draws as
much current as required.
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. 3 Parallel connection

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

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

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

Parallel connection of batteries

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

008 911 83 BOMAG 117

7.6 Ohm's law

7.6 Ohm's law 7.7 Electrical energy

In a closed electric circuit voltage, current and resist-
ance must always be considered in close relation.
This relation is represented by Ohm's Law.

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

118 BOMAG 008 911 83

Formula diagram 7.8
7.8 Formula diagram Example:
P = 150 Watt
Description:
U = 24 Volt
l Select the desired value from the inner circle.
Sought for = Current in Ampere
l Determine the formula variables in the quarter circle
l Calculate I = P : U = 150 W : 24 Volt = 6.25 Ampere

Fig. 1 Formula diagram

Resistance, R Ohm Ω

Voltage, U Volt

Current, I Ampere

Power, P Watt

008 911 83 BOMAG 119

7.9 Metrology

7.9 Metrology Multimeter

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

Fig. 1 Multimeter
In order to avoid damage:
Fig. 1 Test lamp
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.
Resistance and continuity measurement with mul-
timeter
The continuity tester of the multimeter can be used to
measure whether there is a connection between 2
measuring points. The following information should be
observed when measuring resistance and continuity:
l The component to be measured must not be con-
nected to the power supply during the measure-
ment.
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.

Fig. 2 Diode test lamp

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

120 BOMAG 008 911 83

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

Fig. 2 Voltage measurement

l The meter is always connected parallel to consum-
er, component or power source.
l Measurement at the voltage source measures the
currently available Voltage.
l A measurement at the consumer measures the volt-
age drop at this component.

Current measurement with the multimeter

Fig. 1 Clip-on measuring instrument

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

Fig. 3 Current measurement

l
During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened. The meter is connected in series
with the consumer.

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

008 911 83 BOMAG 121

7.10 Diodes, relays, fuses

Magnet tester 7.10 Diodes, relays, fuses

Diodes

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

122 BOMAG 008 911 83

Diodes, relays, fuses 7.10
Diode logics and free-wheeling diode Light emitting diodes

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

Fig. 3 Diode circuitry

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.

008 911 83 BOMAG 123

7.10 Diodes, relays, fuses

Relays 85 = Ground supply for coil

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

Fuses

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

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

Caution
!

Fuses must not be repaired or bridged.

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

Fig. 2 Relay circuitry

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

124 BOMAG 008 911 83

Batteries 7.11
7.11 Batteries Battery maintenance

Battery – accumulator
i Note
Maintenance free batteries are gaining more and
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during
Fig. 1 a subsequent charging process.
In vehicles batteries are used to start the engine. The In the worst case the accumulator can only be dis-
ability to start the engine depends on the charge con- posed of after such an exhaustive discharge.
dition of the batteries. The following therefore applies for longer downtimes:
Lead collectors or accumulators are secondary ele- 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.

Testing batteries with screw plugs

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

008 911 83 BOMAG 125

7.11 Batteries

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

used for this purpose. In a battery of good condition
the acid density should be the same in all cells.

Acid density at 27 °C in kg/dm3

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

Fig. 4 Battery and generator tester

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

Fig. 3 Reading the acid level

l
Maximum permissible tolerance between highest
and lowest measuring value of the 6 cells: 0.03 kg/
dm3.

Testing batteries without screw plugs

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

126 BOMAG 008 911 83

Batteries 7.11
Charge condition with hydrometer

Fig. 5 Charge condition

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

! Danger

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

low, the battery must no longer be charged.

008 911 83 BOMAG 127

7.12 Three-phase generator

7.12 Three-phase generator Design and function

In the generator the armature windings are located in-
General side the stationary stator, whereas the exciter winding
is arranged on the internally revolving rotor (Fig. 6).
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.

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

128 BOMAG 008 911 83

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

Charge control light

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

008 911 83 BOMAG 129

7.12 Three-phase generator

Checking the generator

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

130 BOMAG 008 911 83

Three-phase generator 7.12
Checking the pre-excitation circuit Measuring the charge current
The most common reason for a 3-phase alternator not l All plug-and-socket connectors must be free of cor-
charging is a too low pre-excitation current. The pre- rosion and intermittent contact.
excitation current through connection D+ depends on l The generator ground connection must be OK.
the connected consumer (resistance), e.g. charge l During the measurement switch on as many con-
control light or relay of a MD+ engine control.
sumers as possible.
The pre-excitation current should be approx. 250 mA 1 Attach the clip-on ammeter around the B+ line.
at 12 Volt. This corresponds with a 3 Watt light bulb or
an equivalent combination of light bulb + resistance or 2 Gradually increase the engine speed.
an LED + resistance. 3 The generator current must be at least as high as
the total current of all consumers.
The total resistance of the disconnected dead supply
line D+ max. should not exceed 48 Ohm.
In case of faults like
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. 10 Connections on the three-phase alternator (exemplary de-

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

008 911 83 BOMAG 131

7.12 Three-phase generator

Checking the rotor Checking the stator

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

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

132 BOMAG 008 911 83

Three-phase generator 7.12
Checking the regulator voltage with the generator Checking the regulator voltage with the multime-
tester ter
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.

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

008 911 83 BOMAG 133

7.12 Three-phase generator

Checking the regulator in disassembled state

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

Fig. 17

Fig. 18
Fig. 15
The illustrations (Fig. 17) and (Fig. 18) show two dif-
l If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).

134 BOMAG 008 911 83

Three-phase generator 7.12
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-
Remy generator the generator needs to be disas-
sembled and partly dismantled. The carbon brush
holder is located inside the collector ring bearing.

008 911 83 BOMAG 135

7.13 Electric starter

7.13 Electric starter l establish the gear connection between starter and
combustion engine.
The starter converts the electric energy stored in the l to maintain this connection.
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
l to switch on the starter current.
capacity is available. After starting the engine:
Duties of the starter: l to return the starter pinion to initial position.
l to accelerate the combustion engine to start speed l to switch off the starter current.
with lowest possible current consumption.

Fig. 1 Electric starter For purposes like e.g. purging the fuel systems,
1 Pinion starters may be operated for maximum 1 minute
2 Roller free-wheeling without interruption. Then you should wait for at
least 30 minutes (cooling down) until trying again.
3 Steep thread During the 1 minute starting period this process
4 Guide ring should not be interrupted.
5 Spring winding Starter motors must not be cleaned with high
6 Armature pressure steam cleaning equipment.
7 Pole shoe The contacts on starter terminals 30, 45, 50 must
8 Carbon brushes be protected against unintended shorting (jump
protection).
9 Armature brake
10 Collector When replacing the starter the ring gear on the en-
gine flywheel must be checked for damage and its
11 Magnetic switch number of teeth - if necessary replace the ring
12 Engagement lever gear.
Always disconnect the battery before starting as-
!Caution sembly work in the starter area of the engine or on
So-called jump starting (using an additional exter- the starter itself.
nal battery) without the battery connected is dan-
gerous. When disconnecting the cables from the
poles high inductivities (arcs, voltage peaks) may
occur and destroy the electrical installation.

136 BOMAG 008 911 83

Electric starter 7.13
Function of pre-engaged-drive starting motor
This type of starter uses a solenoid to engage the pin-
ion with the ring gear. The engaging solenoid contains
switching contacts for the starting current. When clos-
ing the starter switch, the relay holding winding is ac-
tive and current flows also through the series
connection of pick-up winding and electric motor. The
engaging solenoid picks up and moves the free-
wheeling with the pinion forward via the engaging le-
ver and the engaging spring. In case of a favourable
position of the pinion to the ring gear a tooth of the pin-
ion will directly engage in a tooth gap. In this case the
pinion will engage over the entire length of the screw
path, until the contact bridge in the engaging relay
touches the relay contacts. The starter motor is no
switched on. However, if the pinion does not directly Fig. 2 Switching position during engagement
find a tooth gap, the ring gear will block any further en-
gaging movement. The engaging lever in this case
compresses the engaging spring and the main contact
closes, even though the pinion and the ring gear are
not engaged. The electric motor keeps rotating the
pinion in front of the ring gear face, until a pinion tooth
gap matches a tooth on the ring gear and the preload-
ed engaging spring moves pinion and free-wheeling
forward. When switching the relay winding off, the re-
turn spring forces the relay armature and the pinion
with free-wheeling back to rest position. This disen-
gagement is supported by the steep thread.

Magnetic switch
The magnetic switch is normally arranged directly
above the starter. Fig. 3 Switching position during starting
With the starter switch switched on, both the pickup 1 Ground
winding and the holding winding are energized and 2 Battery
shift the iron core in axial direction. With a lever this
iron core pulls the starter pinion towards the engine 3 Starter switch
flywheel. 4 Pull-in winding
Once the gears are engaged the starter current is ap- 5 Holding winding
plied to the back through a large cross-section. At the 6 Exciter winding
same time the pickup winding is shorted via the starter 7 Restoring spring
current and thus switched off as a measure to reduce
8 Driver
the load on the energy household.
9 Pinion
10 Flywheel

008 911 83 BOMAG 137

7.13 Electric starter

Trouble shooting "Starter" Testing and measuring the electric starter

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

138 BOMAG 008 911 83

Telemecanique switch 7.14
7.14 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 83 BOMAG 139

7.14 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).

140 BOMAG 008 911 83

Telemecanique switch 7.14
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 83 BOMAG 141

7.15 Inductive proximity switches

7.15 Inductive proximity switches NPN circuitry

General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 10 NPN circuitry
proximity switches are today indispensable. Com-
pared with mechanical switches, they offer almost ide- On sensors with NPN-circuitry the output stage con-
al prerequisites: non-contact, wear free operation, tains a NPN-transistor, which switches the load
high switching frequencies and switching accuracies, against the negative operating voltage. The load is
as well as high protection against vibration, dust and connected between the output and the positive oper-
moisture. Inductive sensors detect all metals without ating voltage.
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.

Working principle

Fig. 8
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field. Fig. 11

This stray field leaks out from the active area of the Proximity switches are used as breaking or making
proximity switch. If metal or non-ferrous metal enters contacts. Depending on the design the switching dis-
into the response range energy is absorbed. The os- tances are 2 or 4 mm. The maximum amperage is 300
cillator is thus dampened and the resulting change in mA.
current consumption is evaluated. The LED (Fig. 11) lights up, when the initiator has de-
tected metal in its stray field.
PNP circuitry

Fig. 9 PNP circuitry

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

142 BOMAG 008 911 83

Angle sensor with current output 7.16
7.16 Angle sensor with current out-
put

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

008 911 83 BOMAG 143

7.17 Plug connectors

7.17 Plug connectors

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

144 BOMAG 008 911 83

Deutsch plug, series DT and DTM 7.18
7.18 Deutsch plug, series DT and DT Series
DTM

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

Fig. 1 DT plug connection

Fig. 3 Crimp connections

Fig. 2 DT Series
Caution
!

Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Fig. 3 Sectional drawing
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
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 83 BOMAG 145

7.18 Deutsch plug, series DT and DTM

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.

146 BOMAG 008 911 83

Deutsch plug, series DT and DTM 7.18
Disassembling DT contacts

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

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

008 911 83 BOMAG 147

7.18 Deutsch plug, series DT and DTM

DTM Series

Fig. 1 DTM plug connection

Fig. 2 DTM Series

Fig. 3 Sectional drawing

148 BOMAG 008 911 83

Deutsch plug, series DT and DTM 7.18
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.

008 911 83 BOMAG 149

7.18 Deutsch plug, series DT and DTM

Disassembling DTM contacts

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

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

150 BOMAG 008 911 83

Plugs and terminals in spring clamping technology 7.19
7.19 Plugs and terminals in spring ventional copper conductors (single, multiple or fine
stranded) with or without wire and ferrule.
clamping technology
! Caution
General
The spring clamp technology is not suitable for
extra fine conductors. Extra fine conductors can
be easily pulled out of the spring clamp!

Fig. 1
Spring clamp technology (Fig. 1) for quick, vibration
resistant and maintenance-free connection of all con-

Connecting terminal for quick repairs

Fig. 2 That's how it works

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 multi-
ple strand up to 2.5 mm². And this even without tools
(Fig. 3).

That's how it works

l Strip 9-10 mm of the lead. Fig. 3 Connecting clamp

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 termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.

008 911 83 BOMAG 151

7.19 Plugs and terminals in spring clamping technology

Series clamp

Fig. 4 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 termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.

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

Fig. 5 Test adapter

152 BOMAG 008 911 83

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

X-COM plug clamp

Fig. 6 That's how it works Measuring signals

That's how it works
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 termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.

Fig. 8 X-COM plug plugged onto the series clamp

Fig. 7 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).

008 911 83 BOMAG 153

7.19 Plugs and terminals in spring clamping technology

154 BOMAG 008 911 83

8 Special tools, electrics

008 911 83 BOMAG 155

8.1 Special tools, electrics

8.1 Special tools, electrics

Measuring equipment
14. Electric test case

BOMAG part-no.: 057 505 70

Fig. 9
15. Multimeter

BOMAG part-no.: 057 509 91

Fig. 10
16. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.

BOMAG part-no.: 079 900 53

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

BOMAG part-no.: 079 900 54

Fig. 11
18. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.

BOMAG part-no.: 079 900 51

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

BOMAG part-no.: 079 900 52

Fig. 12

156 BOMAG 008 911 83

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

BOMAG part-no.: 079 900 58

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

BOMAG part-no.: 079 900 59

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

BOMAG part-no.: 079 900 60

23. Measuring and connecting lines with 4mm plug,
Fig. 13 high flexible design, red, length 0.5 m.

BOMAG part-no.: 079 900 55

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

BOMAG part-no.: 079 900 56

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

BOMAG part-no.: 079 900 57

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

BOMAG part-no.: 079 900 63

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

BOMAG part-no.: 079 900 64

28. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 300 mm.
Fig. 14
BOMAG part-no.: 079 900 61
29. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 600 mm.

BOMAG part-no.: 079 900 62

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

BOMAG part-no.: 079 900 65

Fig. 15

008 911 83 BOMAG 157

8.1 Special tools, electrics

31. Magnetic coil tester

BOMAG part-no.: 057 555 54

Fig. 16
32. Clip-on measuring instrument

BOMAG part-no.: 079 900 50

Fig. 17
33. Battery - generator tester

BOMAG part-no.: 079 900 91

Fig. 18
Spring clamps (Wago or Weidmüller)
34. Cranked screwdriver (Fig. 19) to open spring
clamps (Fig. 20).

BOMAG part-no.: 972 024 68

Fig. 19

158 BOMAG 008 911 83

Special tools, electrics 8.1
35. Testing adapter to measure the signals from the
series spring clamps (Wago).

BOMAG part-no.: 057 564 26

Fig. 20
Deutsch contacts
36. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).

BOMAG part-no.: 079 900 84

Fig. 21
37. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm2 cable cross-section
AWG 16 = 1,5 mm2 cable cross-section
AWG 12 = 4,0 mm2 cable cross-section
BOMAG part-no.: 079 900 79

Fig. 22
38. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
AWG 8 = 10,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section

BOMAG part-no.: 079 900 69

Fig. 23

008 911 83 BOMAG 159

8.1 Special tools, electrics

39. Disassembly tool for Deutsch contacts of series

HDP.
AWG 20, BOMAG part-no.: 079 900 78
AWG 16, BOMAG part-no.: 079 900 71
AWG 12, BOMAG part-no.: 079 900 72
AWG 8, BOMAG part-no.: 079 900 73

Fig. 24
ITT contacts
40. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 80

Fig. 25
41. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 81

Fig. 26
42. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 82

Fig. 27

160 BOMAG 008 911 83

Special tools, electrics 8.1
Schaltbau contacts
43. Disassembly tool for Schaltbau contacts of series
M1, M2.

BOMAG part-no.: 057 509 95

Fig. 28
44. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm2.

BOMAG part-no.: 057 509 94

Fig. 29
FCI Burndy contacts
45. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO

BOMAG part-no.: 079 900 00

Fig. 30
AMP contacts
46. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).

BOMAG part-no.: 079 900 35

Fig. 31

008 911 83 BOMAG 161

8.1 Special tools, electrics

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

PER-SEAL with connecting cross-section 0.75 -
1.25 mm2.

BOMAG part-no.: 079 900 48

Fig. 32
48. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).

BOMAG part-no.: 079 900 23

Fig. 33
49. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 14 - 10.

BOMAG part-no.: 079 900 88

Fig. 34
50. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 16 - 14
and AWG 18.

BOMAG part-no.: 079 900 89

Fig. 35

162 BOMAG 008 911 83

Special tools, electrics 8.1
51. Disassembly tool for AMP-contacts of series CIR-
CULAR-CONNECTOR.
1.5 mm2, BOMAG part-no.: 079 900 74
2,5 mm2, BOMAG part-no.: 079 900 75
Spare sleeve 1.5 mm2, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm2, BOMAG part-no.: 079
900 77

Fig. 36
Universal tools
52. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 - 1.0 mm2.

BOMAG part-no.: 972 038 47

Fig. 37
53. Precision pressing pliers for non-insulated flat
male and female connectors0.5 - 6,0 mm2.

BOMAG part-no.: 079 900 70

Fig. 38
Measuring adapter
54. Current measurement adapter for Hirschmann
plugs.

BOMAG part-no.: 057 503 83

Fig. 39

008 911 83 BOMAG 163

8.1 Special tools, electrics

55. Voltage measurement adapter for Deutsch plugs,

8-piece (2 to 12 pole).

BOMAG part-no.: 079 900 68

Fig. 40
56. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.

BOMAG part-no.: 079 900 83

Fig. 41

164 BOMAG 008 911 83

9 Electronic modules

008 911 83 BOMAG 165

166 BOMAG 008 911 83
9.1 Electrics BEM (BOMAG Evib-meter)

008 911 83 BOMAG 167

9.1 Electrics BEM (BOMAG Evib-meter)

BOMAG Evib-meter (BEM)

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

168 BOMAG 008 911 83

Electrics BEM (BOMAG Evib-meter) 9.1

Service Training
Electrics
MESX

008 097 05 Version 4.00

Status: 05.06.2007 Page 1 of 59

Author: T.Löw / TE
Dateiname: p:\schulung\elektrik\wz\mesx_bvc\englisch\schulung elektrik mesx_v4.00_gb.doc

008 911 83 BOMAG 169

9.1 Electrics BEM (BOMAG Evib-meter)

Service Training MESX

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

Status:05.06.2007 Page 2 of 59
Author: T.Löw / TE

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Service Training MESX

1 Document alteration list

Version Date Description of changes resp.

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

Status:05.06.2007 Page 3 of 59
Author: T.Löw / TE

008 911 83 BOMAG 171

9.1 Electrics BEM (BOMAG Evib-meter)

Service Training MESX

2 Proof of software change MESX

Version Date Description of changes resp.

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

3.04 10.05.2005 Î Vibration detection for BW177DH/PDH and BW179DH/PDH Löw

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

Status:05.06.2007 Page 4 of 59
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Service Training MESX

Version Date Description of changes resp.

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

Status:05.06.2007 Page 5 of 59
Author: T.Löw / TE

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9.1 Electrics BEM (BOMAG Evib-meter)

Service Training MESX

3 Proof of software change BOP

Version Date Description of changes resp.

1.00 25.03.2004 first software version for series production Löw

1.01 13.04.2004 Revision of BVC diagnostics screen Löw

1.02 23.04.2004 2-stage jump information (yellow and red) Löw

3.00 15.10.2004 Î Realization of imperial display Löw

Î Simulation mode implemented on BOP
Î New TN 582 701 92

3.01 24.1.2005 Î Part-No. changed to 58 701 93 Löw

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

Status:05.06.2007 Page 6 of 59
Author: T.Löw / TE

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Service Training MESX

4 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.

Behaviour of machine Possible cause

During initial commissioning the display shows the Bit rate on bmfsa not set to 125 kbit
reading "ct0" => see "Setting the bit rate"

Status:05.06.2007 Page 7 of 59
Author: T.Löw / TE

008 911 83 BOMAG 175

9.1 Electrics BEM (BOMAG Evib-meter)

Service Training MESX

5 How to proceed when replacing components?

Each machine is adjusted individually during initial commissioning. This is mainly accomplished by
setting the correct machine type (see "5.4 List of machine types", or "7.1 Adjusting the machine type
(BOP)").

The following chapter describes the necessary adjustments to the control when replacing individual
components in the measuring system.

5.1 How to proceed when replacing an ESX control?

Attention: A machine must not be operated with a wrong type setting,

because in such a case the correct function of the control cannot
be assured!

You should therefore set the machine type first! see "5.4 List of
machine types, or "7.1 Adjusting the machine type (BOP)").

After setting the machine type check the following items:

Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
Set the machine serial number (only on machines with BOP), see: 7.5
Set the printer language (only machines with printer), see: 7.4

5.2 How to proceed when replacing a rear axle sensor?

Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.

5.3 Which components can be replaced without a subsequent

adjustment procedure?
BOP
Acceleration transducer
Valve block for exciter adjustment
Printer
Bmfsa display module
All switches in the dashboard

Note: A final function test of the complete machine is highly

recommended.

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5.4 List of machine types

Since the same control is used for all single drum rollers with the new measuring technology, it is
necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This
type adjustment is necessary, because the machines have e.g. different axle loads or different drum
widths, which requires the calculation of measuring values to be adapted. The adjustment procedure
is described under items "6.3 Changing the machine type (only via display module)" or "7.1 Adjusting
the machine type (BOP)".

The following machine types can be adjusted:

Machine type First serial number Last serial number Code Available from
version
177 D 101 582 20 1001 XXX XXX XX XXXX 7500 1.00
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7502 3.03
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7503 1.00
179 DH 101 582 24 1001 XXX XXX XX XXXX 7511 3.03
179 PDH 101 582 25 1001 XXX XXX XX XXXX 7512 3.03
211 D 101 582 40 1001 XXX XXX XX XXXX 7520 1.03
101 582 41 1001
101 583 09 1001
211 PD 101 582 45 1001 XXX XXX XX XXXX 7529 4.00
101 583 10 1001
213 D 101 582 50 1001 XXX XXX XX XXXX 7530 1.03
101 583 08 1001
213 DH 101 582 51 1001 XXX XXX XX XXXX 7531 1.03
101 583 14 1001
213 PD 101 582 46 1001 XXX XXX XX XXXX 7539 4.00
101 583 13 1001
213 PDH 101 582 52 1001 XXX XXX XX XXXX 7532 3.03
213 BVC 101 582 53 1001 XXX XXX XX XXXX 7533 1.02
101 583 16 1001
213 BVC plates 101 582 54 1001 XXX XXX XX XXXX 7534 3.00
101 583 06 1001
213 BVC DI 101 582 53 1001 XXX XXX XX XXXX 7535 1.05
101 583 16 1001
214 DH 101 582 58 1001 XXX XXX XX XXXX 7541 3.03
101 583 19 1001
214 PDH 101 582 59 1001 XXX XXX XX XXXX 7542 3.03
101 583 20 1001
216 D 101 582 62 1001 XXX XXX XX XXXX 7550 3.03
101 583 23 1001
216 DH 101 582 60 1001 XXX XXX XX XXXX 7551 3.03
101 582 64 1001
216 PD 101 582 63 1001 XXX XXX XX XXXX 7559 4.00
101 583 24 1001
216 PDH 101 582 61 1001 XXX XXX XX XXXX 7552 3.03
101 582 65 1001
219 D 101 582 72 1001 XXX XXX XX XXXX 7560 2.00
101 582 10 1001
219 DH 101 582 70 1001 XXX XXX XX XXXX 7561 1.05
101 582 77 1001
219 PD 101 582 73 1001 XXX XXX XX XXXX 7569 4.00
101 582 11 1001
219 PDH 101 582 71 1001 XXX XXX XX XXXX 7562 3.03
101 582 78 1001

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Machine type First serial number Last serial number Code Available from
version
226 DH 101 582 80 1001 XXX XXX XX XXXX 7571 3.03
101 582 83 1001
101 582 88 1001
226 PDH 101 582 81 1001 XXX XXX XX XXXX 7572 3.03
101 582 84 1001
101 582 89 1001
226 BVC 101 582 82 1001 XXX XXX XX XXXX 7573 3.01
101 582 85 1001
101 582 86 1001
226 BVC DI 101 582 82 1001 XXX XXX XX XXXX 7575 1.04
101 582 85 1001
101 582 86 1001
226 BVC RC 101 582 82 1001 XXX XXX XX XXXX 7576 3.03
101 582 85 1001
101 582 86 1001

Machine type First serial number Last serial number Code Available from
version
VARIOCONTROL 101 582 12 1001 XXX XXX XX XXXX 7537 4.00
VARIOCONTROL+ 101 582 13 1001 XXX XXX XX XXXX 7538 4.00

Machine type First serial number Last serial number Code Available from
version
177 D-40 101 582 26 1001 XXX XXX XX XXXX 7600 4.00
177 DH-40 101 582 27 1001
177 DHC-4 101 582 00 1001 XXX XXX XX XXXX 7601 4.00
177 PDHC-4 101 582 01 1001 XXX XXX XX XXXX 7602 4.00
177 PDH-40 101 582 28 1001 XXX XXX XX XXXX 7609 4.00
179 DHC-4 101 582 02 1001 XXX XXX XX XXXX 7611 4.00
179 PDHC-4 101 582 03 1001 XXX XXX XX XXXX 7612 4.00
211 D-40 101 583 02 1001 XXX XXX XX XXXX 7620 4.00
101 583 25 1001
211 PD-40 101 583 03 1001 XXX XXX XX XXXX 7629 4.00
101 583 26 1001
212 D-40 101 582 43 1001 XXX XXX XX XXXX 7680 4.00
212 PD-40 101 583 48 1001 XXX XXX XX XXXX 7689 4.00
213 D-40 101 582 44 1001 XXX XXX XX XXXX 7630 4.00
101 582 55 1001
101 583 07 1001
213 DH-40 101 582 56 1001
213 DHC-4 101 582 04 1001 XXX XXX XX XXXX 7631 4.00
101 583 11 1001
213 PDHC-4 101 582 05 1001 XXX XXX XX XXXX 7632 4.00
101 583 12 1001
213 PD-40 101 582 49 1001 XXX XXX XX XXXX 7639 4.00
213 PDH-40 101 582 57 1001
214 DHC-4 101 582 06 1001 XXX XXX XX XXXX 7641 4.00
101 583 17 1001
214 PDHC-4 101 582 07 1001 XXX XXX XX XXXX 7642 4.00
101 583 18 1001
216 DHC-4 101 582 08 1001 XXX XXX XX XXXX 7651 4.00
101 583 21 1001
216 PDHC-4 101 582 09 1001 XXX XXX XX XXXX 7652 4.00

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101 583 22 1001

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6 Possible adjustments on machines without BOP

6.1 Description of the Display Module

Note: The display module described next is only used in machines without the Bomag
Operation Panel (BOP). On machines with BOP the settings are made via the BOP!
(See item 7 "Adjustment/display possibilities on machines with BOP")

The display module consists of a 4-digit display and two keys, F1 and F2.
It is used for the output of fault codes and display values as well as for the input of code numbers.

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

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

057 667 72
15/54

The following description describes the input of code numbers.

6.2 Input of code numbers

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

Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
)The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
1. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure 9
is displayed and the left hand key (F1) is pressed again, the display will return to the value .
2. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.

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

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6.3 Changing the machine type (only via display module)

For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module of the central electrics when switching the ignition on. It can also be checked at any
time by entering code 7000.

Setting the machine type requires the following sequence:

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

Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type".

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

Select and enter the machine from the table above.

The display module now permanently shows the entered code. (e.g. 7 5 3 3 )

Enter code number 7 0 1 1 . This code number confirms the entered machine type.

After confirming the machine type the control initiates a restart, the display module shows the new
machine type for approx. 3 seconds.

Switch the ignition off and on again.

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

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

New controls are delivered with the default machine type setting 7 5 0 0 .

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6.4 Inverting the direction signal (only via display module)

Depending on the installation position, the axle sensor used delivers a 12 V output signal in forward and
reverse.

This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the the travel direction correspond with the actual travel direction.

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

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

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

Enter code number 7 6 0 1 . This code number inverts the direction signal.

The display module now permanently shows the code 0 0 0 1 (signal inverted), or the code 0 0 0 0
(signal not inverted).

In succession the code number 1 0 0 1 can be used to check whether the direction signal is correctly
interpreted (see item 14 "Input codes for ESX control").

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6.5 Changing the bit rate (only with display module)

The multi-function display can be operated with different CAN transmission speeds. For operation in
our machines the bit rate must be set to 125 kBit/s. The bit rate is changed as follows:

Hold both keys (F1 and F2) of the multi-function display depressed and switch on the ignition.
) The currently set bit rate is displayed, e.g. 0 1 0 0 .
The bit rate can now be changed in fixed steps by pressing the right hand key (F2). Hold the key
depressed until the display reads 0 1 2 5 .
By pressing the left hand key (F1) the bit rate is accepted and the display changes back to the
normal display mode.

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7 Adjustment/display possibilities on machines with BOP

7.1 Adjusting the machine type (BOP)

Setting the machine type requires the following sequence:

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

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

Press key "F2" to open the screen page "Adjust machine type". The following screen is displayed:

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The desired machine type can be selected by pressing the keys "F11" and "F12". (see "List of
machine types" under item "Item 5.4 "List of machine types" ).

After selecting the desired machine type press key "F14", until the symbol (F14) lights green for
confirmation (approx. 4s).

When releasing the key the start screen will automatically be displayed and the control will initiate a restart.

Switch the ignition off and on again.

BOP and MESX are now adjusted to the new machine type.

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7.2 Inverting the direction signal via the BOP control terminal
Depending on the installation position, the axle sensor used delivers a 12V output signal in forward
and reverse.

This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the travel direction correspond with the actual travel direction.

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

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

Press key "F1" to open the screen page "Invert direction signal". The following screen is
displayed:

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The direction signal can now be inverted or not inverted by pressing key "F5" ("Invert = 1" or
"Invert = 0").

After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.

Press "ESC" to leave the page.

Check on the printout or in the diagnostics menu whether the travel direction has been correctly detected.

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7.3 Accessing the diagnostics menu

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

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

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If an actual error is present the corresponding error code will be displayed in the field "Actual Errors".

Press "ESC" to leave the page.

By pressing key "A" you can change into a machine specific, more detailed diagnostics menu (see
below).

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7.3.1 Extended diagnostics on machines with circular exciter (BTMplus,

BTMprof)

4.23 V Ubv: actual voltage front acceleration transducer

4.24 V Ubh: actual voltage rear acceleration transducer

98 % Small Ampl: Triggering of solenoid valve for low amplitude in percent

0 % Big Ampl: Triggering of solenoid valve for high amplitude in percent

Direction: Status MESX input travel direction (LED on = 12 V)

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

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

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

+01234 Distance pulses detected by the MESX (10 cm steps). The actually detected
travel direction can be recognized by the roller symbol above.

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7.3.2 Extended diagnose BVC machines

4.25 V Uexciter: actual voltage of exciter position potentiometer

4.23 V Ubv: actual voltage front acceleration transducer

4.24 V Ubh: actual voltage rear acceleration transducer

98 % Ampl: Triggering of solenoid valve for vibration valve in percent

Direction: Status MESX input travel direction (LED on = 12 V)

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

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

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

+01234 Distance pulses detected by the MESX (10 cm steps). The actually detected
travel direction can be recognized by the roller symbol above.

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7.4 Changing the printout language

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

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

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The desired printout language can be selected by pressing the keys "F11" and "F12".

After selecting the desired language press key "F14" to save the setting. The symbol (F14) lights
green for a moment as a sign of confirmation.

Press "ESC" to leave the page.

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7.5 Setting the machine serial number

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

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

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The desired printout language can be selected by pressing the keys "F11" and "F12".

After the adjustment press key"F14" to save the setting. The symbol (F14) lights green for a
moment as a sign of confirmation.

Press "ESC" to leave the page.

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7.6 Teaching distance pulses

The distance pulses for the different machine types are already set by default after adjusting the
correct machine type. However, due to slippage on the rear axle the recorded distance measurement
may deviate from the actually travelled distance. In this case the distances pulses can be adjusted
accordingly.

Note: An adaptation of the distance pulses is only possible within a range of +/- 10%
of the preset value.

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

Press key "F8" to open the screen page "Distance pulses". The following screen is displayed:

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Pressing the key "F5" starts the teach mode. The following symbol appears:

Drive a distance of 10 m length in forward and press the key "F6" at the end. The following symbol
appears:

After the end of the measuring travel press key "F14" to save the adjustment. The following
symbol appears:

Press "ESC" to leave the page.

Note: If the following symbol is displayed after the end of the travel distance the
measured distance pulses are not in the range of +/- 10% of the preset value.
Saving is in this case not possible! The measurement must be repeated!

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7.7 Activating the amplitude limitation (only BVC machines)

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

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

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

After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.

Press "ESC" to leave the page.

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7.8 Changing the display mode (metric/imperial)

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

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

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

After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.

Press "ESC" to leave the page.

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7.9 Switching the GPS Receiver Voltage Supply Mode

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

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

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This function enables the GPS Receiver Power Supply to be controlled via MESX, so that the receiver
can be switched on and off in a defined way.

The GPS Mode can now be changed over by pressing the "F5"-key:

"0" OFF GPS Receiver always switched off

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

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8 Possible settings on the BCM05mobile

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

8.1 Reading the software version

Select "Configuration" at the right hand edge of the window.
The software currently installed in the BCM05mobile is displayed at the top left under the name BOMAG.

8.2 Changing the language

Note: This function is only available from software version 1.37!

Select "Configuration" at the right hand edge of the window.

Press the field "Language". A list with the available languages pops up. Choose the desired language
and confirm with "Select".

8.3 Changing the unit system (metric/imperial)

Open the service window: press the top switch of the three switches at the right hand edge of the
touch screen "Configuration" for about 5 seconds, until a roller symbol appears under the software
version number at the left hand side of the display. Release the "Configuration" switch and press the
symbol within 3 seconds. The touch screens now shows 4 switches near the right hand edge and
select the bottom switch "Service".

Note: After this setting the service window must be closed to avoid unauthorized
access. Press "Close window" at the bottom right in the service window.

Shift the switch in the "Unit" field to the desired position.

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008 911 83
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BOMAG
commande

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206
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10 Block diagram BTMplus / VARIOCONTROL

printer

BOMAG
commande

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008 911 83
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile

BCM 05
(mobile device
Electrics BEM (BOMAG Evib-meter)

with card reader)

USB CAN
interface

BOMAG
Printer

commandes

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12 Description of the signals on the ESX-control

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

ESX terminal Signal description Nominal values (voltage / current)

X44:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
joystick, speed range switch etc.)
X44:2

X44:3 Output Evib Display PWM signal (100Hz): ) approx. 0..6 V

PWM (max. 2.5 A)
X44:4 Interface RS 232 RxD, used for printer control. Measurement not possible!

X44:5 Interface RS 232 TxD, used for printer control. Measurement not possible!

X44:6

BOMAG
X44:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): ) 4,2..4,3 V

Analogue input / voltage input 0..8,5 V
X44:8

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

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008 911 83
ESX terminal Signal description Nominal values (voltage / current)
X44:10

X44:11

X44:12

X44:13

X44:14

X44:15 Input vibration 1 On Vibration on: ) >6V

Digital input active high Vibration off: )approx.0 V
Electrics BEM (BOMAG Evib-meter)

X44:16 Input button START (option) Button depressed: ) 12 V

Digital input active high Button not depressed ) 2V
X44:17 Input button STOP (option) Button depressed: ) 12 V
Digital input active high Button not depressed ) 2V
X44:18 Input button PRINT (option) Button depressed: ) 12 V

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

X44:21

X44:22

X44:23 Output voltage supply for sensors Nominal voltage = 8,5 V

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

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ESX terminal Signal description Nominal values (voltage / current)

X44:25

X44:26 Interface CAN-Bus Wire -, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:27 Interface CAN-Bus Wire +, is used to communicate with the BOP Measurement not possible!
operating unit.

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

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

Open circuit voltage (vibration off): ) 4,2..4,3 V

Analogue input / voltage input 0..8,5 V
X44:30 Input acceleration transducer VH/VR15g Acceleration signal (measured against AGND)

BOMAG
Open circuit voltage (vibration off): ) 4,2..4,3 V
Analogue input / voltage input 0..8,5 V
X44:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): ) 4,2..4,3 V

Analogue input / voltage input 0..8,5 V
X44:32

X44:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X44:34

X44:35 Input distance transducer Transducer delivers square-wave pulses Frequency depends on
machine type.
Digital input active high

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008 911 83
Electrics BEM (BOMAG Evib-meter)
Service Training MESX Description of signals

008 911 83
ESX terminal Signal description Nominal values (voltage / current)
X44:36

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

Digital input active high Engine stopped ) 0V
X44:38 Input vibration 2 On Vibration on: ) >6V
Digital input active high Vibration off: ) approx.0 V
X44:39

X44:40

X44:41
Electrics BEM (BOMAG Evib-meter)

X44:42

X44:43

X44:44

BOMAG
X44:45

X44:46 Output valve 1 front permissible current range: approx. 0..1,5 A

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

X44:49

X44:50

X44:51

X44:52

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ESX terminal Signal description Nominal values (voltage / current)

X44:53 Interface CAN-Bus2 Wire +, is used to communicate with the BCM05. Measurement not possible!
X44:54 Voltage supply for electronics Emergency stop not actuated ) 12 V
Emergency stop actuated ) 0V
X44:55 Ground connection electronics 0 V measured against ground

X44:56 Voltage supply for outputs approx. 12 V measured against ground

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

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

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

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

X44:61

BOMAG
X44:62

X44:63

X44:64

X44:65 Mouse port Baby Boards approx. 0 V

X44:66 Mouse port Baby Boards approx. 0 V

X44:67 Mouse port Baby Boards approx. 0 V

X44:68 Mouse port Baby Boards approx. 0 V

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008 911 83
Electrics BEM (BOMAG Evib-meter)
Electrics BEM (BOMAG Evib-meter) 9.1

Service Training Fault codes of the ESX control

13 Fault codes of the ESX control

13.1 Overview

Fault code Fault description

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

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13.2 Description of fault reactions

Fault reaction Description of fault reaction

1 Warning.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
2 Function affected, the faulty function is replaced by an emergency function.
Fault code is displayed.
Signal light in BOP (option) 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.
Signal light in BOP (option) lights in 5 second intervals.
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

BOMAG
) the diesel engine is shut down.
Fault code is displayed.
Signal light in BOP (option) lights in 1 second intervals.
5 Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
Error code is displayed.
Signal light in BOP (option) lights permanently.

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

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008 911 83
Electrics BEM (BOMAG Evib-meter)
Service Training MESX Description of fault codes of the ESX control

008 911 83
13.3 Detailed description of fault codes and their possible causes

Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
4 5 0 1 Input exciter potentiometer front ) Wire breakage in current path X44:09 5
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) Fuse FM ? has tripped or wire breakage in voltage supply
current path
) Potentiometer defective
4 5 0 2 Input exciter potentiometer front ) Current path has connection to +12 V / +8,5 V X44:09 5
Electrics BEM (BOMAG Evib-meter)

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

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -

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

4 5 2 3 Output proportional solenoid front ) Current path is interrupted X44:46 2

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

4 5 2 6 Output proportional solenoid front ) Current path has short circuit to voltage supply X44:47 2
Valve for exciter down ) Current path has non-permitted connection to another current

BOMAG
Output current too low. path
) Current path is interrupted
4 5 2 7 Output proportional solenoid front ) Current path has short circuit to ground X44:47 2
Valve for exciter down ) Current path has non-permitted connection to another current
Output current too high. path

4 5 2 8 Output proportional solenoid front ) Current path is interrupted X44:47 2

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

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Electrics BEM (BOMAG Evib-meter)
Service Training MESX Description of fault codes of the ESX control

008 911 83
Fault Fault description Possible cause Terminal Input - Fault -
code on ESX code for reaction
diagnose
4 5 3 1 Position controller positive limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low

4 5 3 2 Position controller negative limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
Electrics BEM (BOMAG Evib-meter)

) Air in hydraulic system, hydraulic pressure too low

4 6 0 1 Input acceleration transducer 1 ) Current path has no connection to +12 V / +8,5 V X44:29, 4601 2
The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X44:31

BOMAG
4 6 0 2 Input acceleration transducer 1 ) Current path has connection to +12 V / +8,5 V X44:29, 4601 2
The voltage applied to the input is above the ) Current path not connected to ground or
specified range (see signal description). ) Transducer defective X44:31

4 6 0 6 Input acceleration transducer 2 ) Current path has no connection to +12 V / +8,5 V X44:30, 4606 2
The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X44:07

4 6 0 7 Input acceleration transducer 2 ) Current path has connection to +12 V / +8,5 V X44:30, 4606 2
The voltage applied to the input is above the ) Current path not connected to ground or
specified range (see signal description). ) Transducer defective X44:07

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
8 0 0 0 Error message "Incorrect BOP Software - - 2
version" The software version of the BOP is too
old, i.e. various functions cannot be displayed.
This fault cannot be repaired on the machine.
The BOP needs to be replaced.
8 0 0 1 Fault message "severe software fault in control" - - - 5
- This fault cannot be repaired on the machine.
8 9 9 9 The control must be immediately replaced.
9 0 0 0 Error message "Communication via CAN bus ) Wire breakage in CAN bus lines X44:26 - 2
- disturbed" ) Short circuit between CAN bus lines X44:27-
9 1 9 9 The modules controlled via the CAN bus cannot ) One or both CAN bus line(s) has (have) connection to 12V or
be addressed by the main control (ESX). The ground
respective machine functions are not available

9 2 0 0 Fault message "Severe internal fault in control" - - - 5

BOMAG
- The control has automatically switched off. This
9 9 9 9 fault cannot be rectified on the machine. The
control must be immediately replaced.
Ct0 Display module has no connection to ESX- ) Wire breakage in CAN bus lines X44:26 - -
control. ) Short circuit between CAN bus lines X44:27
) One or both CAN bus line(s) has (have) connection to 12V or
ground
) Incorrect bit rate in display module (nominal value: 125 kBit)

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Electrics BEM (BOMAG Evib-meter)
Service Training MESX Description of Control Input Codes

008 911 83
14 Input codes for ESX control (only via BEM display module)

14.1 Travel system

Input code Description of display function Display values

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

1001 Travel direction 1000 ) Forward travel detected

Displays the travel direction derived by the control from the 0000 ) Neutral position
"transducer for travel direction". 000I ) Reverse travel detected
Electrics BEM (BOMAG Evib-meter)

1002 Transducer for distance pulses Display value = travel distance in 10 cm

The distances pulses summarized since starting the machine are
displayed. If the machine has travel a longer distance in reverse than
in forward, the value will be negative.
1003 Travel speed Display value = max. speed in km/h

BOMAG
Shows the actual speed.
1010 Parameter "Show distance pulses per 10m" Depending on the selected machine type, e.g. 5896 for
Eeprom Parameter is displayed BW177 BVC
1011 Parameter "Invert travel direction" 0000 ) Direction signal is not inverted
Eeprom Parameter is displayed 000I ) Direction signal is inverted

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14.2 Vibration

Input code Description of display function Display values

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

14.3 Light

Input code Description of display function Display values

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

BOMAG
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Electrics BEM (BOMAG Evib-meter)
Service Training MESX Description of Control Input Codes

008 911 83
14.4 Acceleration transducer

Input code Description of display function Display values

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

14.5 Diesel engine

Input code Description of display function Display values

Electrics BEM (BOMAG Evib-meter)

5000 Input MD+ 0000 ) Engine OFF

Show status of diesel engine. 0001 ) Engine ON

BOMAG
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14.6 Setting the machine type

Input code Description of display function Display values

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

BOMAG
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Electrics BEM (BOMAG Evib-meter)
Service Training MESX Description of Control Input Codes

008 911 83
14.7 Parameter change

Input code Description of display function Display values

7600 Switch on function "Invert travel direction" Display value 7 6 0 0
7601 Inverts the actually adjusted travel direction see adjustment instructions
Electrics BEM (BOMAG Evib-meter)

BOMAG
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Service Training MESX

15 Terminology in connection with ESX

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

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

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

Terminal, cable lug

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

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Service Training MESX

Short circuit to ground

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

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

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

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9.1 Electrics BEM (BOMAG Evib-meter)

Service Training MESX

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

disturbance
variable (z)

input (w) a Output (y)

Controll distance

Closed loop control

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

disturbance
variable (z)

input (w) + e u Output (y)

Controll distance
-

Marking Closed loop control Control

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

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Service Training MESX

Current and voltage measurement

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

Override / emergency operation

In the event of a major fault the control will switch off and the override function will take over.
This has the effect that the machine can still be moved and steered with reduced speed.
Steering and dozer blade movements are only possible with a constant speed.
(see also: page 34, "")

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

PWM – digital output

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

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9.1 Electrics BEM (BOMAG Evib-meter)

228 BOMAG 008 911 83

9.2 Seat contact module

008 911 83 BOMAG 229

9.2 Seat contact module

Seat contact switch

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

The following applies in general:

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

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

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

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

In addition to the seat monitoring system all

monitoring functions are implemented by the

Module UPM2

230 BOMAG 008 911 83

Seat contact module 9.2

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

Stay-Alive LED

Programmierstecker

Spannungs- Status-
versorgung Leuc htdioden
1

4
3

5
2

7
8
9

14
15
6

10

13
12
11

Vibrationstaster
Versorgungsspannung (+UB)

Sitzkontaktschalter
Versorgungsspannung (+UB)

Vibration
Haltewicklung Abstellmagnet

Masseanschluß

Generator / D+ Signal
Anzugswicklung Abstellmagnet
Bremsventil
Warnsummer

Masseanschluß

Öldruck
Fahrhebel

Fig. 1: Module

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

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

PIN Potential with LED on Potential with LED off

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

008 911 83 BOMAG 231

9.2 Seat contact module

Emergency operation

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

Description of function

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

Sw itching on the ignition

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

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

Starting the engine

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

232 BOMAG 008 911 83

Seat contact module 9.2

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

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

Engine has stopped

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

008 911 83 BOMAG 233

9.2 Seat contact module

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

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

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

234 BOMAG 008 911 83

Seat contact module 9.2

0 Hardware description

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

Input Behaviour Comment

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

0.1 Pin assignment of inputs

Signal name Module Signal at input

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

0.2 Pin assignment of outputs

Signal name Module Signal at output

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

008 911 83 BOMAG 235

9.2 Seat contact module

236 BOMAG 008 911 83

10 Speedometer Module

008 911 83 BOMAG 237

10.1 Speedometer module

10.1 Speedometer module

Fig. 1 Speedometer module

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

Manual testing of the speedometer

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

238 BOMAG 008 911 83

Speedometer module 10.1

Pin-no. module Pin name Description

Test E_ANZEIGENTEST Input HIGH active: Activate manual display test

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

OUT - Display - Output: Ground connection for speedometer

OUT + Display + Output: Output voltage for speedometer

GND (2X) Ground Input: Module ground connection

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

Teaching the module

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

Caution
!

BW24RH, BW27RH, C550H and C560H = travel 18

meters.
All other machines = travel 15 meters.

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

The module has now learned the pulses of the

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

008 911 83 BOMAG 239

10.1 Speedometer module

240 BOMAG 008 911 83

11 Service Training

008 911 83 BOMAG 241

242 BOMAG 008 911 83
11.1 Service Training Machine

008 911 83 BOMAG 243

11.1 Service Training Machine

244 BOMAG 008 911 83

Service Training Machine 11.1

Service Training

Single Drum Roller

BW 211 / 213 D- 4
BW 216 / 219 D-4

008 911 83 BOMAG 245

11.1 Service Training Machine

Service Training
Table of contents

Travel system E1
Travel pump E3
Control E7
Charge pressure relief valve E8
High pressure relief valve E9
Pressure override E11
Axle drive motor E14
Drum drive motor E17
Test and adjustment points, travel system E19
Trouble shooting travel system E27

BW 211 / 213 / 216 D-4

246 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Vibration F1
Vibration pump F3
High pressure relief valves F6
Control F7
Vibration motor F8
Drum F11
Test and adjustment points, vibration system F13
Trouble shooting vibration F15

Steering G1
Charge pump G2
Steering pump G3
Steering valve G5
Articulated joint G7
Measuring and adjustment points G9
Trouble shooting steering G10

BW 211 / 213 / 216 D-4

008 911 83 BOMAG 247

248
11.1

Travel circuit
from brake valve

M4 M5

from speed
ø 0.8
range valve
M4 M3 L

BW 216 D-4 / Deutz 1013 EC

2 A

BW 211 / 213 D-4 / Deutz 2012C

ø 0.81
ø 0.6
6

ø 0.6
4 8

BOMAG
T3
25 bar 9
3
1

M2
B

Charge pressure to vibration pump

Charge pressure from hydraulic oil filter

Fig. 1: Hydraulic diagram travel system BW 211 / 213 D-4

1 Travel pump Sauer 90 R 075 4 Multi function valve 7 Speed range valve
2 Servo control 5 Rear axle 8 Flushing valve
3 Charge pressure relief valve 6 Axle drive motor Sauer 51 D 110 9 Drum drive motor Poclain MSE 18 2CX
Service Training

-E1-

008 911 83
Service Training Machine
008 911 83
M4 M3
A
2 M1
Service Training Machine

6 11

BW 216 D-4 / Deutz 1013 EC

BW 211 / 213 D-4 / Deutz 2012C
9
3 12
8
4 T3 T3
25 bar
1 5

B M2

7 10

BOMAG
Fig. 2: Hydraulic diagram travel system BW 216 D-4

1 Travel pump Sauer 90 R 075 5 Rear axle 9 Flushing valve (drum drive motor)
2 Servo control 6 Axle drive motor Sauer 51 D 110 10 Speed range valve (drum drive motor)
3 Charge pressure relief valve 7 Speed range valve 11 Drum drive motor (Sauer 51 C 110)
4 Multi function valve 8 Flushing valve 12 Reduction gear Sauer CR 31
Service Training

-E2-
11.1

249
11.1 Service Training Machine

Service Training
The travel system of the single drum rollers is a closed hydraulic circuit and consists mainly of:

• travel pump with control and safety elements,

• drum drive motor with integrated multi-disc brake (BW 211 and 213 D-4),

• drum drive motor with reduction gear (BW 216 D-4),

• axle drive motor,

• charge pump (also for vibration circuit),

• hydraulic oil filter (in charge circuit),

• hydraulic oil cooler with thermostat

• hydraulic lines.

Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump.

The travel pump is the first pump section, flanged directly to the flywheel side of the diesel engine.

The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to (Δp = 400 bar between low and high
pressure sides).

A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain
oil quantity out of the closed circuit when the machine is driving (Δp between the two sides of the closed
circuit).

Leakage in the individual components of the circuit are replaced by the charge circuit through the boost
check valves in the travel pump.

The charge pumps draw hydraulic oil out of the tank and deliver it through the hydraulic oil filter and the
charge pressure relief valve to the boost check valves in travel and vibration pumps. The machine is
fitted with two charge pumps. One pump is integrated in the vibration pump and the other pump is driven
by the auxiliary output of the engine and serves primarily as steering pump.

The charge circuit provides the oil for the charge system and the control functions in the closed circuits
for travel and vibration drive, as well as to release the parking brakes and to change the travel speed
ranges.

Both travel motors are designed with variable displacement. The operator can choose from four different
travel speed ranges.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC -E3-

250 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Travel pump

The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.

M4 M5

2
A from/to
Travel motor

25 bar 4
3
1

from/to
Travel motor
B
Charge pressure to vibration pump

Charge pressure from hydraulic oil filter

Fig. 3: Hydraulic diagram of travel pump

1 Pump drive 3 Charge pressure relief valve

2 Servo control 4 Multi-function valves

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC -E4-

008 911 83 BOMAG 251

11.1 Service Training Machine

Service Training
The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is
proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing
angle of swash plate) of the pump.

7 1

6
5
Fig. 4: Travel pump

1 Control lever 5 Cylinder block

2 Drive shaft 6 Valve plate
3 Swash plate bearing 7 Control piston
4 Pistons with slipper pads

With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.

When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.

All valves as well as the safety and control elements needed for operation in a closed circuit, are
integrated in the pump.

Note:
These machines are equipped with two charge pumps.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC -E5-

252 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Cross-sectional view of travel pump

2
4
5
1 3

9
10
8
11

Fig. 5: Cross-sectional view of travel pump

1 Retainer for swash plate 7 Swash plate bearing

2 Sliding block 8 Swash plate guide
3 Control piston 9 Swash plate
4 Servo arm 10 Swashing lever
5 Servo valve 11 Charge pump (only in vibration pump)
6 Feedback device

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC -E6-

008 911 83 BOMAG 253

11.1 Service Training Machine

Service Training
View of the rotating group

4 3
5

Fig. 6: Travel pump, view of the rotating group

1 Working pistons
2 Slipper pad
3 Pre-tensioning spring
4 Cylinder block
5 Drive shaft

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC -E7-

254 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Description of function

2 3 4 5 6
1

8 6 7

Fig. 7: Function of travel pump

1 Drive shaft 5 Cylinder block

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

The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).

With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC -E8-

008 911 83 BOMAG 255

11.1 Service Training Machine

Service Training
When moving the swash plate out of neutral position, the working pistons will perform a stroke
movement with every rotation of the cylinder block.

The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.

During a full rotation of the cylinder block each working piston will move through the bottom and top dead
centre back to the initial position. During this movement each piston performs a complete stroke.

During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC -E9-

256 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Tandem pump, connections and adjustment points

32

Thermostat
housing

Fig. 8: Connections and adjustment points

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 10 -

008 911 83 BOMAG 257

11.1 Service Training Machine

Service Training
1 Control solenoid, high frequency (vibration pump)
2 Control solenoid, low frequency (vibration pump)
3 Multi-function valve 400 bar (charging and pressure limitation), travel system
4 Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
5 Multi-function valve 400 bar (charging and pressure limitation), travel system
6 Adjustment screw, mechanical neutral position
7 Port L, leak oil to vibration pump
8 Travel lever
9 Pressure test port, pilot pressure
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 bar
12 Adjustment screw, low frequency
13 Port L2, leak oil to tank
14 Pressure test port MB, high frequency
15 Pressure test port MA, low frequency
16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 End plate with integrated charge pump (only in vibration pump)

19 Port L2
20 Adjustment screw, high frequency
21 Port D, charge pressure to filter
22 Multi-function valve 345 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between hydraulic oil tank and charge pump
24 Multi-function valve 345 bar (charging and pressure limitation), vibration low frequency
25 Charge pressure relief valve, vibration pump (blocked)
26 Port E, charge oil from travel pump
27 Port L1, leak oil port to travel pump
28 Pressure test port MB, high pressure reverse
29 Charge oil from filter
30 Pressure test port MA, high pressure forward
31 High pressure port A, high pressure forward
32 Adjustment screw for mechanical neutral position, vibration

Thermostat housing: 33, 34, 35, 36 Leak oil port

37 cooler inlet

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 11 -

258 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
servo control

The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal
of the pump control lever into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (the displacement of the pump), as well as the
swashing direction (flow direction of the pressure fluid).

The flow quantity delivered by the variable displacement pump is proportional to the value of the
mechanical input signal. A mechanical feedback device ensures the fixed correlation between the
mechanical input signal and the swashing angle of the swash plate (displacement of pump).
Servo cylinder

Control piston

Sliding block

Servo arm

Fig. 9: Control piston

A mechanical safety device (spring) makes sure that a too fast lever movement will not cause any
damage to the servo control.

The pump displacement can be adjusted by actuating the pump control lever via travel lever and travel
control cable. This requires only very little manual forces and only a slight movement of the lever.

Since the control is spring centred, the swash plate will automatically return to neutral position under the
following conditions, thereby interrupting the oil flow and braking the machine:

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 12 -

008 911 83 BOMAG 259

11.1 Service Training Machine

Service Training
• when shutting the engine down,

• if the external control cable comes loose,

• if the pressure in the charge circuit drops below a certain value.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 13 -

260 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Multi-function valves

High pressure limitation

Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override
and a pressure relief valve, one after the other.

1 2

3
A

6 5

B
4

Fig. 10: Multi-function valves

1 to the control 6 Drive shaft

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

If the adjusted pressure is reached, the pressure override will move the swash plate quickly back
towards neutral position, thereby limiting the system pressure. The average response time is less than
90 ms.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 14 -

008 911 83 BOMAG 261

11.1 Service Training Machine

Service Training
In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the
pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override
works as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the
high pressure relief valve is higher than the pressure level of the pressure override. The high pressure
relief valves will only respond if the pressure override is not able to swash the pump back quick enough
in case of sudden pressure peaks.

2 3
4
5
1

6
9 7
8
10
11

Fig. 11: Multi-function valve, details

1 Reducing fitting 7 Check valve

2 Hydraulic by-pass piston 8 Pressure limitation
3 Spring plate 9 Spring
4 Spring 10 By-pass housing
5 High pressure relief valve 10 By-pass sleeve
6 Valve seat

Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.

With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.

Note:
The multi function valves must be tightened with a torque of 89 Nm!

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 15 -

262 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Charge pressure relief valve

The machines are equipped with two charge pumps, one driven by the auxiliary output of the engine
(steering and charge pump) and the other pump is integrated in the vibration pump.

The pressures of both pumps are limited by a charge pressure relief valve.

The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety
elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted
value (26 bar).

The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits
and provides the necessary pressure to control the travel and vibration pumps and to operate the multi-
disc brakes in the travel drives.

Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.

When parking the machine on level ground with the engine running, the pressures in both sides of the
closed circuit are identical (charge pressure).

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 16 -

008 911 83 BOMAG 263

11.1 Service Training Machine

Service Training
Flushing valve

Fig. 12 Cross-section of flushing valve

1 Flushing spool
2 Flushing pressure relief valve

The flushing valves are integrated in the axle drive motor, or on the BW 216 D-4, also in the drum drive
motor. In case of a pressure increase in one of the two sides of the closed circuit the flushing valves
have the function to flush a certain quantity of oil out of the low pressure side.

The valve is operated by the pressure difference between the two sides of the closed circuit (A and B).
If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral
position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows
through a thermostat valve back to the tank. The oil quantity flushed out of the closed circuit is
immediately replaced by oil entering from the charge circuit through the corresponding boost check
valve (part of the multi-function valve).

In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature
household of the hydraulic system is maintained at a permissible level.

Axle drive motor,

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 17 -

264 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
The axle drive motor is a swash plate controlled axial piston motor of series 51 D 110 with variable
displacement.

5 7 8

6
9

11
10
4
2

Fig. 13: Axle drive motor,

1 Control piston 7 Cylinder block

2 Flushing valve 8 Universal joint
3 Control 9 Output shaft
4 Spindle with ball 10 Output shaft bearing
5 Qmin-screw 11 Working piston
6 Valve plate

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 18 -

008 911 83 BOMAG 265

11.1 Service Training Machine

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

With a large angle position the motor works with maximum displacement, slow speed and high torque.

When changing the swash plate position to minimal angle the motor works with minimum displacement,
high speed and low torque.

The displacement is changed by a control piston, which is tightly connected with the valve segment.
Changing of the displacement is accomplished by pressurizing the corresponding control piston side
with pressure oil from the charge circuit via a 4/2-way solenoid valve.

Function

The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.

Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.

The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 19 -

266 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Rear axle

Releasing the axle drive brake manually (on both axle drive designs)

For manual releasing of the brakes on the rear axle you should proceed as follows:

Fig. 14: Manual releasing of rear axle brakes

• Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.

• Turn the brake releasing screw (2) in against the stop.

• To release the brake tighten the screw for max. 1 complete turn.

Attention!

Turn the screws on both sides in uniformly (alternately by 1/4 of a turn)

• Repeat this procedure on the opposite side of the axle.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 20 -

008 911 83 BOMAG 267

11.1 Service Training Machine

Service Training
BW 211 / 213 D-4 Front drum drive motor: Radial piston motor MSE 18
2 CX

On single drum rollers of series BW 211 and 213 D-4 the drum is driven by a hydraulic radial piston
motor.

These drum drive motors consist of three housing parts, the flat distributor, the cylinder block with the
working pistons and the output shaft.

2 3

4
1

43090070

8 7 6 5

Fig. 15: Drum drive motor

1 Drive shaft with output flange

2 Piston with roller
3 Oil distributor
4 Brake piston
5 Multi-disc brake
6 Cylinder block
7 Cam ring
8 Bearing plate

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 21 -

268 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
The housing consists of:

• bearing section (drive shaft bearings),

• torque section (cam race) and

• oil distributor.

Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure
oil presses the working pistons with the rollers against the cam race of the torque section and forces the
rollers to roll along the cam race.

This transforms the axial movement of the pistons to a radial movement of the cylinder block. The
cylinder block transfers this rotation via a splined connection to the output shaft.

The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc
and the rubber elements to the drum.

The function of the radial piston motor is described hereunder. The piston positions described in this
explanation can be seen in the related illustration.

The movement of a piston along the cam race must be examined in several phases during a full rotation:

2
3

Fig. 16: Function of the radial piston motor

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 22 -

008 911 83 BOMAG 269

11.1 Service Training Machine

Service Training
Piston position 1:

The oil enters into the oil distributor under pressure, flows through the distributor and presses against
the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the
roller along the cam and causes a rotation of the cylinder block.

Piston position 2:

At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The
piston continues his travel along the cam race towards the valley between two cams. As the movement
continues the opening cross-section for the oil supply decreases.

Piston position 3:

Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston
is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first
piston out of the dead centre.

Piston position 4:

Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now
connected with the low pressure side and the reverse movement of the piston presses the oil back to
the pump.

Piston position 5:

The pumping movement of the motor back to the pump comes to an end, the connecting bore between
cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre
position. This point is the start of a new working cycle.

Reversing the oil flow reverses also the rotation of the motor.

The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc
and the rubber elements to the drum.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 23 -

270 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Releasing the brake in the radial piston motor manually

For manual releasing of the brake in the Poclain motor (drum drive) you should proceed as follows:

Fig. 17: Manual releasing of the brake in the Poclain motor

• Remove the plug 1 (Fig. 17).

• Lay the U-bar (5) across the brake housing (2) and turn the screw (4) into the tapped bore (3) until it
bottoms.

• Turn the nut (6) down and tighten it for approx. one turn. The drum must turn freely.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 24 -

008 911 83 BOMAG 271

11.1 Service Training Machine

Service Training
BW 216 D-4 Front drum drive motor: Bent axle motor 51 C 110 with
reduction gear CR 31

The drums on the DH216 D-4 versions are driven by a swash plate operated Sauer bent axle motor 51
C 110. This motor is almost identical with the rear axle motor. Another detailed description at this point
is therefore not necessary.

2
3 4
1

10 8
9

Fig. 18: Reduction gear CR 31

1 Travel motor 6 Sun gear

2 Tapered roller bearing 7 Planet carrier
3 Spur wheel 8 Brake discs
4 Hollow wheel 9 Mechanical seal
5 Planet wheel 10 Brake piston

This motor is a fast rotating hydraulic motor. Since the output speed of this motor is much too high to
drive the drum, a reduction gear reduces the output speed to the actually required drum drive speed.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 25 -

272 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Brake control

During operation the closed hydrostatic travel circuit has the function of a service brake. When moving
the travel lever from full forward or reverse position towards neutral, the travel pump will follow towards
zero position relative to the movement of the travel lever. The oil flow is thereby reduced and the
machine is hydraulically braked. When moving the travel lever to neutral position, the pump will also
return to neutral, the supply of oil is interrupted and the hydraulic circuit brakes the machine to standstill.

However, since minor leaks cannot be avoided in any hydraulic circuit and such minor leaks will cause
creeping of the machine when it is parked on a slope with the engine running, the machine is additionally
equipped with multi-disc brakes in drum drive and both wheel drives. When engaging the travel lever in
neutral position the multi-disc brakes will close and the machine can be parked on slopes with the
engine running and without the risk of creeping.

However, these parking brakes can also be operated via a 3/2-way solenoid valve. In de-energized
condition the multi-disc brakes in the travel drives are unloaded. The charge pressure to the brakes is
interrupted and the oil from the brake housings flows as leak oil back into the tank.

If the brake solenoid valve is supplied with current while the engine is running and the brake is open,
the connection of the brake line to the tank is interrupted and oil from the charge circuit is guided to the
brake pistons. The oil pressure works against the spring force of the brake spring and relieves the brake
discs.

Manual releasing of the brake in the drum drive reduction gear

Brake releasing device

in operation position

Brake releasing device in

position “brake manually
released”

Fig. 19 Manual brake releasing device

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 26 -

008 911 83 BOMAG 273

11.1 Service Training Machine

Service Training

Fig. 20: Manual releasing of the brake in the drum drive CR31

• Turn both screws (Fig. 20) for releasing the brake in the drum drive reduction gear evenly in
clockwise direction, until the drum can be turned freely.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 27 -

274 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Travel circuit: BW 211 / 213 D-4 Drum drive with radial piston motor

1
4

6 1

n
ctio 1 Travel pump
i r e
e ld 2 Vibration pump
av 3 Travel lever
Tr 4 Hydraulic oil filter
High pressure 5 Rear axle
Low pressure 6 Axle drive motor
7 Drum drive motor
Charge pressure
8 Hydraulic oil tank
Leak oil (case pressure)

Fig. 21: BW 211 / 213 D-4, travel circuit, routing of hoses

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 28 -

008 911 83 BOMAG 275

11.1 Service Training Machine

Service Training
Travel circuit: BW 216 D-4 Drum drive with travel motor with reduction
gear

2
9

3
8

4
7 5

n
6 ti o
ec 1 Travel pump
l dir 2 Vibration pump
a ve
Tr 3 Hydraulic oil filter
4 Rear axle
High pressure 5 Axle drive motor
6 Reduction gear
Low pressure
7 Drum drive motor
Charge pressure 8 Hydraulic oil tank
Leak oil 9 Travel lever

Fig. 22: Travel circuit with 51 C 110 and CR 31

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 29 -

276 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Brake control: BW 211 / 213 D-4 with radial piston motor

Brake valve

Leak oil from drum drive motor to brake valve

Brake releasing pressure
Charge pressure
Leak oil from brake valve to hydraulic oil tank

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 30 -

008 911 83 BOMAG 277

11.1 Service Training Machine

Service Training
Brake circuit Brake control: BW 216 D-4 Travel motor with reduction gear

Brake valve

Charge pressure
Brake releasing pressure
Leak oil

Fig. 23: Brake circuit

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 31 -

278 BOMAG 008 911 83

Service Training Machine 11.1

Service Training

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 32 -

008 911 83 BOMAG 279

11.1 Service Training Machine

Service Training
Travel drive, components and test points

Travel pump: left hand side

2
1

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

diagram
1 Test port, forward 10, MD max. 426 bar
2 High pressure port, forward 10, A

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 33 -

280 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Travel pump: right hand side

3
1

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

diagram
1 Test port, reverse 10, MC max. 426 bar
2 High pressure port, reverse 10, B
3 Travel control (travel control cable)

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 34 -

008 911 83 BOMAG 281

11.1 Service Training Machine

Service Training
Front travel motor with radial piston motor for BW 211 / 213 D-4

2 1

5
4
6
3

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

diagram
1 High pressure port, forward 12, L
2 High pressure port, reverse 12, R
3 Brake 12 open, 26 bar
pressureless
closed
4 Cross-flushing of travel pump T1 12
5 Cross-flushing outlet to tank 12, 1
6 Travel speed range selector 12, Y Motor Qmax,
depressurized
Motor Qmin,
26 bar

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 35 -

282 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Rear travel motor: Axle motor

1
4
3 2

6
5
7

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

diagram
1 Solenoid for speed range selector Y31 14 Motor Qmax---
valve depressurized,
Motor Qmin---
26 bar
2 Flushing valve 14
3 High pressure port, drum drive 14, A
motor forward
4 High pressure port, drum drive 14, B
motor reverse
5 High pressure from travel pump 14, A
forward
6 High pressure from travel pump 14, B
reverse
7 Qmin- setscrew 14

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 36 -

008 911 83 BOMAG 283

11.1 Service Training Machine

Service Training
BW 216 D-4 Travel motor with reduction gear (drum drive motor)

5
7
6

2 1

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

diagram
1 Pressure travel forward 16 - A
2 Pressure travel reverse 16 - B
3 Flushing valve 16
4 Solenoid for speed range selector Y 30 16 Motor Qmax,
valve depressurized
Motor Qmin,
26 bar
5 Qmin- setscrew 16
6 Leak oil port 16
7 Brake port on gearbox 16

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 37 -

284 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
BW 211 / 213 D-4 Brake and travel speed range selection

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

diagram
1 Speed range selector valve for front Y 31 08, a2 Motor Qmax,
travel motor (Poclain) depressurized
Motor Qmin,
26 bar
2 Brake valve Y 04 08, a1 open, 12V closed,
de-energized

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 38 -

008 911 83 BOMAG 285

11.1 Service Training Machine

Service Training
BW 216 D-4 Brake valve

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

diagram
1 Brake valve Y 04 08, open, 12V closed,
de-energized

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 39 -

286 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Travel lever console with rotary switch for speed range selection

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 40 -

008 911 83 BOMAG 287

11.1 Service Training Machine

Service Training
Travel lever

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

diagram
1 Initiator for backup alarm B14 0 / 12V, normally
closed
2 Initiator for brake B13 Normally closed,
opened in braking
position
0/12V

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 41 -

288 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.

Procedure:

The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.

Machine travels with travel lever in 'Neutral'

Machine does not drive (forw. and reverse)
Machine drives to one direction only

Max. travel speed not reached

TROUBLE SHOOTING TRAVEL

Hydraulic oil overheating

SYSTEM
BW 211 / 213 / 216 D-4
SYMPTOMS

POSSIBLE CAUSES
Brake valve (electric/mechanical/hydraulic) 1
Brake in axle/drum drive motor (mechanical/hydraulic) 2 2 3
Travel speed range switch position /defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/ travel pump high pressure limitation
3 2 3 3
dirty/out of adjustment/defective
Adjustment of travel cable 1 2
Travel pump mechanical neutral 3 3
Travel pump(s) defective 3 3 2
Axle drive motor control valve (electric / mechanical / hydraulic) 1 2
Flushing valve axle drive motor seized 3
Travel motor(s) defective 3 3
Hydraulic oil cooler soiled (internally/externally) 1
Thermostat (hydraulics) soiled/jammed/defective 2
Kupplung Dieselmotor-Pumpe 2
Dieselmotor 1

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 42 -

008 911 83 BOMAG 289

11.1 Service Training Machine

Service Training
Vibration system
The vibration system of the single drum rollers of generation D-4 works with two frequencies and two
amplitudes. This enables perfect adaptation of the machine to various types of soil and different
applications.

The vibration drive is a closed hydraulic circuit. The circuit consists of:

• the vibration pump,

• the vibration motor and

• the pressure resistant connecting hoses

from charge pump via to release the brake

Travel pump
Charge oil
Vibration pump
D M3 E

L2 N

Block

M1

M2

S
B
2
1
M4

M5

Fig. 1: Vibration circuit

1 Vibration pump
2 Vibration motor

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F1-

290 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly
driven by the diesel engine.

When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral
position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to
one of the two control piston sides. The swash plate inside the pump will swash to the corresponding
side and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the
vibrator shaft inside the drum.

When altering the position of the swash plate through the neutral position to the opposite side, the oil
flow will change its direction and the vibration motor will change its sense of rotation.

Since the end stops for the swash plate are set to different swashing angles to both directions, the angle
for the piston stroke is also different to both sides. This angle influences the length of the piston stroke
and thereby the actual displacement of the pump.

• Large angle = high displacement = high vibrator shaft speed (frequency)

• Small angle = low displacement = slow vibrator shaft speed (frequency)

The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending
on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic
weights.

This results in the following constellations:

• Basic weight + change-over weight = high amplitude

• Basic weight - change-over weight = low amplitude

In order to achieve effective compaction results the vibration system is designed in such a way, that high
amplitude is coupled with low frequency and low amplitude with high frequency.

Fig. 2:

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F2-

008 911 83 BOMAG 291

11.1 Service Training Machine

Service Training
Vibration pump

Similar to the travel pump the vibration pump is also a swash plate operated axial piston pump with
variable displacement for operation in a closed circuit.

The displacement of the pump is proportional to the engine speed and the chosen displacement.

When actuating the swash plate out of neutral position the flow quantity to the chosen direction will
increase from ”0” to the maximum value. When altering the position of the swash plate through the
neutral position to the opposite side, the oil flow will change its direction and the vibration motor will
change its sense of rotation. All valves and safety elements for operation in a closed circuit are
integrated in the pump.

from charge pump via Releasing the brake

Travel pump
Charge oil
Vibration pump
D M3 E

1 Vibration pump
L2 N 2 Charge pump
3 High pressure limitation
Block
4 4/3-way solenoid valve
A

M1

M2

S
B

M4

M5

Fig. 3: Hydraulic diagram vibration pump

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F3-

292 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Function

1 2

5 4 3

Fig. 4 Cross-section of vibration pump

1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F4-

008 911 83 BOMAG 293

11.1 Service Training Machine

Service Training

1
2
5

4 3

Fig. 5 Cross-section of vibration pump

1 Control
2 Servo piston
3 Friction free swash plate bearing
4 Attachment plate
5 Spool valve

The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.

The slipper pads rest against the sliding surface of the swash plate and are at the same time held on
the sliding surface by a retaining device.

During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F5-

294 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into
the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he
closed circuit.

Control

The electro-hydraulic displacement control (remote control) converts the electric input signal to a load
controlling output signal. Since the pump is not equipped with a proportional control, but a 12 Volt
solenoid valve, the pump is always actuated to one of the two end stop positions.

Charge pumps

These machines are equipped with two charge pumps.

One of the pumps is an external gear pump, which is directly driven by the auxiliary output of the engine
and serves also as steering pump.

The second pump is an internal gear pump and is located in the end cover of the vibration pump.

The oil flow generated by the charge pumps is joined together with the return flow from the steering
valve before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and
vibration pump.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F6-

008 911 83 BOMAG 295

11.1 Service Training Machine

Service Training
High pressure relief valves

As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.

Fig. 6 Pressure relief valve

1 From the charge pump

2 Closed circuit
3 High pressure relief valve with
integrated boost check valve

Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 371 bar
(pressure difference between high and low pressure side = 345 bar + charge pressure = 26 bar).

The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit. The function of these valves has already been described in the chapter "travel
system".

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F7-

296 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Vibration motor

The vibration motor is a Bosch-Rexroth (Hydromatik) axial piston motor of series A10FM 45 with fixed
displacement in bent axle design. Since the motor can be subjected to pressure from both sides, it is
most suitable for the use in closed hydraulic circuits.

The output speed of the motor depends on the oil quantity supplied by the vibration pump.

2 3
4 5
1

8 7
10 9

Fig. 7 Cross-section of vibration motor

1 Flushing valve block

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

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F8-

008 911 83 BOMAG 297

11.1 Service Training Machine

Service Training
The output torque raises with increasing pressure difference between low and high pressure side in the
closed circuit.

Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.

When switching the vibration on the motor must first start to move the resting vibration shaft. This
resistance causes a hydraulic starting pressure, which is limited to 345 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).

• Hard ground = High operating pressure

• Loose ground = Low operating pressure

A MA

3 1

B MB

Fig. 8 Circuit diagram of vibration motor

1 Vibration motor
2 Flushing valve
3 Flushing pressure relief valve

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F9-

298 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a
pressure difference will appear between the two sides of the closed circuit. The higher pressure moves
the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low
pressure side.

1
A

Fig. 9 Flushing valve

1 Flushing spool
2 Flushing pressure relief valve

The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.

This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC - F 10 -

008 911 83 BOMAG 299

11.1 Service Training Machine

Service Training
Drum

4
14

5 9

7 13
6
10
3 8 11

12

Fig. 10 Cross-section of drum

1 Drum shell 8 Change-over weight

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

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC - F 11 -

300 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Vibration system: Components and test ports

Vibration pump

1
2

5 6 3
4

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

diagram
1 Pressure test port, charge pressure MA 26 bar
2 Differential pressure switch, charge 07 ^p 3.5 bar
pressure
3 High pressure port, low MF
amplitude
4 High pressure port, high ME
amplitude
5 Solenoid valve, low amplitude Y08 12V / 3.33A
6 Solenoid valve, high amplitude Y07 12V / 3.33A

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC - F 12 -

008 911 83 BOMAG 301

11.1 Service Training Machine

Service Training
Vibration pump

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

diagram
1 Pressure test port, vibration MF max. 371 bar
pressure low amplitude
2 Pressure test port, vibration ME max. 371 bar
pressure high amplitude

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC - F 13 -

302 BOMAG 008 911 83

Service Training Machine 11.1

Service Training
Vibration motor

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

diagram
1 High pressure port, low amplitude 16
2 High pressure port, low amplitude 16
3 Leak oil and flushing oil port 16 approx. 10 l/min,
incl. flushing
quantity

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC - F 14 -

008 911 83 BOMAG 303

11.1 Service Training Machine

Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.

Procedure:

The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.

No vibration (charge pressure OK)

Vibration only with one amplitude
Exciter shaft speed too low
TROUBLE SHOOTING
VIBRATION
BW 211 / 213 / 216 D-4
SYMPTOMS

POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1
Vibration push button (on/off) 1
Electrics defective / wiring 2 2
Pump control (electrical / hydraulic) 1 1
Pressure override / high pressure relief valves in vibration pump
2
soiled/out of adjustment/ defective
Charge pump / charge pressure relief valve
2
soiled/ defective
Vibration pump frequency adjustment 2
Vibration pump defective 2 2
Coupling between diesel engine and travel pump defective
Exciter shaft bearings defective 3
Vibration motor coupling defective 2
Vibration motor defective 2 1
Diesel engine 1

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC - F 15 -

304 BOMAG 008 911 83

12 Engine

008 911 83 BOMAG 305

12.1 Diesel engine

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

Fig. 1 Deutz diesel engine TCD 2012 and 2013

306 BOMAG 008 911 83

Engine description TCD 2012 12.2
12.2 Engine description TCD 2012

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

008 911 83 BOMAG 307

12.2 Engine description TCD 2012

Fig. 2 Deutz diesel engine TCD 2012, left hand side

1 Exhaust manifold
2 Exhaust turbo charger
3 Lubrication oil filling neck (optional)
4 Engine mounts
5 Lubrication oil return line from exhaust gas turbo
charger
6 Relay (starter)
7 Ribbed V-belt
8 Coolant inlet
9 Coolant outlet
10 Coolant pump
11 Connection cabin heater ort compensation line

308 BOMAG 008 911 83

Engine description TCD 2013, 4 and 6 cylinder 12.3
12.3 Engine description TCD 2013,
4 and 6 cylinder

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

008 911 83 BOMAG 309

12.3 Engine description TCD 2013, 4 and 6 cylinder

Fig. 2 Deutz diesel engine TCD 2013 L04 V2, left hand side

1 Lubrication oil filling neck (optional)

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

310 BOMAG 008 911 83

Engine description TCD 2013, 4 and 6 cylinder 12.3

Fig. 3 Deutz diesel engine TCD 2013 L06 2V, right hand side 17 Crankcase ventilation valve
18 Injector
1 Combustion air inlet
2 Lubrication oil filling neck
3 Transport device
4 Fan hub
5 Generator
6 Replaceable lubrication oil filter
7 Fuel filter
8 Lubrication oil sump
9 Oil dipstick
10 Lubrication oil drain plug
11 Oil return line crankcase ventilation
12 Engine mounts
13 Transmission connection (SAE)
14 Central plug (for engine control)
15 High pressure pump
16 Rail

008 911 83 BOMAG 311

12.3 Engine description TCD 2013, 4 and 6 cylinder

Fig. 4 Deutz diesel engine TCD 2013 L06 2V, left hand side

1 Exhaust turbo charger

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

312 BOMAG 008 911 83

Lubrication oil circuit TCD 2012 / 2013 12.4
12.4 Lubrication oil circuit TCD
2012 / 2013

25 26 23 22 18 12
12
123 19 20 21 17 15 11
12

8 7 6
5

24

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

008 911 83 BOMAG 313

12.5 Coolant circuit TCD 2012 / 2013

12.5 Coolant circuit TCD 2012 /

2013

Fig. 1 Fuel diagram

1 Coolant outlet on radiator

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

314 BOMAG 008 911 83

Fuel system TCD 2012 / 2013 12.6
12.6 Fuel system TCD 2012 / 2013

Fig. 1 Coolant diagram 12 Fuel return flow on cylinder head

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

008 911 83 BOMAG 315

12.6 Fuel system TCD 2012 / 2013

Fuel pre-filter

Fig. 2 Fuel pre-filter

1 Fuel supply to pump

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

316 BOMAG 008 911 83

Fuel system TCD 2012 / 2013 12.6
TCD 2013 Fuel filter system

5
2
2

11 13
4
4

Fig. 3 TCD 2013 Fuel system

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

008 911 83 BOMAG 317

12.6 Fuel system TCD 2012 / 2013

TCD 2012 Fuel filter system

2
2

2
5
4
1 1
1
4 3 4

Fig. 4 TCD 2012 Fuel system

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

318 BOMAG 008 911 83

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 12.7
12.7 Deutz Common Rail (DCR) in- tion solely controlled by mapping is only possible un-
der this condition. Injection timing and injection
jection system for TCD 2012 / quantity are controlled by the engine electronics. The
2013 electric signals control an electrically operated valve
per cylinder, which is integrated in the injection noz-
The diesel engines type TCD 2012 and 2013 are zle. The short distances between valve and injection
equipped with a "Deutz Common Rail" injection sys- nozzle result in short pressure rise times, which has a
tem, DCR in short. positive effect on the combustion process and its con-
The English term "Common Rail" indicates that the trol. Various types of injection van be realized, e.g.
system is based on a common rail. It describes the pre-injection, main injection and post-injection. These
use of a common high pressure fuel line with corre- are freely controllable, in dependence on the control
sponding branches to supply all cylinders with fuel. unit.
The "Common Rail" injection is an injection system for The electric control is accomplished by the electronic
combustion engines, in which a high pressure pump control unit (EDC16) with EMR3, in dependence on
pressurizes the fuel to a high pressure level. The pres- the operating parameters. The system is capable of
surized fuel fills a piping system, which is permanently providing a wide range of limp-home functions, should
under pressure while the engine is running. any of the sensors fail. This ensures a reliable and
safe completion of travel and work.
The general idea is the total isolation of the pressure
generation from the actual injection process. An injec-

Overview of electronic diesel fuel control

Sensors Control unit (EMR3) Actuators

Injector
Rail

Pump

Fig. 1 TCD 2012 and 2013

008 911 83 BOMAG 319

12.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

10
8

7
5

11
9
4 1

12

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

320 BOMAG 008 911 83

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 12.7
FCU Fuel Control Unit (Y137)

electric connection

Fig. 3 Fuel Control Unit FCU

Two high pressure pumps

High pressure

Low
pressure

High pressu
pumps

Fig. 4 High pressure pump

008 911 83 BOMAG 321

12.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

Injector ( Y148 )

electric connections

Return flow

Armature group

Nozzle

Supply

Fig. 5 Injector

Wiring diagram page 4

Engine control EDC16 - EMR3

FCUFCU

Fig. 6 Excerpt from the wiring diagram

322 BOMAG 008 911 83

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 12.7
TCD 2013

5
7 6

2
4

1 3

Fig. 7 TCD 2013

1 Fuel pre-filter
2 Hand pump
3 Fuel filter
4 FCU Fuel Control Unit (Y137)
5 Rail
6 Fuel low pressure sensor (B145)
7 Connecting plug EMR3

008 911 83 BOMAG 323

12.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

TCD 2012

2 5
6
7
4
2
4
5 1
6

Fig. 8 Diesel engine TCD 2012

1 Rail pressure sensor (B93)

2 Rail pressure PRV
3 Fuel filter
4 FCU Fuel Control Unit (Y137)
5 Rail
6 Fuel low pressure sensor (B145)
7 Connecting plug EMR3

324 BOMAG 008 911 83

Sensors TCD 2012 / 2013 12.8
12.8 Sensors TCD 2012 / 2013

Diagnostics interface
10
Serdia connection

Fig. 1 Sensors TCD 2013

1 Fuel control unit (FCU)

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

008 911 83 BOMAG 325

12.8 Sensors TCD 2012 / 2013

Fig. 2 Sensors TCD 2013

Fig. 3 Wiring loom TCD 2013

326 BOMAG 008 911 83

Sensors TCD 2012 / 2013 12.8
Camshaft speed sensor, B114
l Inductive sensor
l Determination of TDC
l Limp-home function in case of crankshaft sensor
failure

Crankshaft speed sensor, B130

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

Charge pressure sensor, B133

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

Oil pressure sensor, B88

l
Pressure sensor
l
Monitors the oil pressure
l
Engine protection by switching of in case of too low
oil pressure

Charge air temperature sensor, B133

l
Temperature sensor
l
Temperature correction of air mass
l
Optimized injection quantity during cold start

Coolant temperature sensor, B113

l
Temperature sensor
l
Engine protection in case of excessive temperature
by reduction of injection quantity
l
Optimized injection quantity during cold start

Rail pressure sensor, B93

l Pressure sensor
l Monitoring the injection pressure)

Fuel low pressure sensor

l
Pressure sensor
l
Monitoring the inlet pressure approx. 5-7 bar

008 911 83 BOMAG 327

12.8 Sensors TCD 2012 / 2013

TCD 2012 Crankshaft speed sensor (B130)

Fig. 4 Crankshaft speed sensor TCD 2012 Adjustment measurement or sensor gap meas-
urement
1 Toothed disc on crankshaft
2 Speed sensor

Gap measurement C = 0,6mm +/- 0.5mm

Fig. 5 Crankshaft speed sensor

328 BOMAG 008 911 83

Sensors TCD 2012 / 2013 12.8
TCD 2013 Crankshaft speed sensor (B130)

Fig. 6 Crankshaft speed sensor TCD 2013 Adjustment measurement or sensor gap meas-
urement
1 Toothed disc on crankshaft
2 Speed sensor

Gap measurement C = 0,6mm +/- 0,1mm

Fig. 7 Crankshaft speed sensor

008 911 83 BOMAG 329

12.8 Sensors TCD 2012 / 2013

Camshaft speed sensor (B114)

Fig. 8 Camshaft speed sensor TCD 2012/2013 Adjustment measurement or sensor gap meas-
urement
1 Camshaft sprocket
2 Speed sensor

Gap measurement C = 1mm +/- 0.5mm

Fig. 9 Camshaft speed sensor

330 BOMAG 008 911 83

Sensors TCD 2012 / 2013 12.8
Measuring and testing

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

Fig. 11 Speed sensor

008 911 83 BOMAG 331

12.8 Sensors TCD 2012 / 2013

Combination sensor for charge air pressure and

charge air temperature (B133)

Fig. 12 TCD 2012

Fig. 13 TCD 2013

332 BOMAG 008 911 83

Sensors TCD 2012 / 2013 12.8
Measuring and testing

Pin
4 3 2 1

Fig. 14 Charge air pressure and temperature sensor Charge air temperature
Pin 2--- NTC-Temperature
Resistance R=2510 Ohm = 20°C
Resistance R=851 Ohm = 50°C

Charge air pressure

Pin4
0.5 Volt = 0 bar at 5 V feed voltage
4,5 Volt = 4 bar at 5 V feed voltage

Fig. 15 Electric wiring diagram, page 004

008 911 83 BOMAG 333

12.8 Sensors TCD 2012 / 2013

Oil pressure sensor (B88)

Fig. 16 TCD 2012

Fig. 17 TCD 2013

334 BOMAG 008 911 83

Sensors TCD 2012 / 2013 12.8
Measuring and testing

Fig. 18 Electric wiring diagram, page 004 Measurement

Pin 2 = Signal
0.5 Volt = 0 bar at 5 V feed voltage
4,5 Volt = 10 bar at 5 V feed voltage

Fig. 19 Assignment of connections

008 911 83 BOMAG 335

12.8 Sensors TCD 2012 / 2013

Coolant temperature senor (B113)

Fig. 20 TCD 2013 Measurement

Pin 1 = Signal
Resistance R=2500 Ohm = 20 °C
Resistance R=186 Ohm = 100 °C

Fig. 21 Electric wiring diagram, page 004

336 BOMAG 008 911 83

Sensors TCD 2012 / 2013 12.8
Rail pressure senor (B93)

Fig. 22 TCD 2012 Measurement

Pin 2 = Signal
0.5 Volt = 0 bar at 5 V feed voltage
4,5 Volt = 1800 bar at 5 V feed voltage

Fig. 23 Electric wiring diagram, page 004

008 911 83 BOMAG 337

12.8 Sensors TCD 2012 / 2013

Fuel low pressure sensor (B145)

Fig. 24 TCD 2012

Fig. 25 TCD 2013

338 BOMAG 008 911 83

Sensors TCD 2012 / 2013 12.8
Measuring and testing

Fig. 26 Electric wiring diagram, page 004 Measurement

Pin 2 = Signal
0.5 Volt = 0 bar at 5 V feed voltage
4,5 Volt = 7 bar at 5 V feed voltage
Pin 2
Signal

Pin 4
Ground

Pin 1 +

Fig. 27 Connecting plug

008 911 83 BOMAG 339

12.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013

12.9 Engine control EDC16 with l Working range 9-31 V

EMR 3 for TCD 2012 / 2013
l Engine start possible from 6 V

Control unit EDC 16 - EMR 3

l Operating voltage 12 V DC and 24 V DC

Connection Connection
Engine side Vehicle side

Fig. 1 EDC 16 - EMR 3 TCD 2012 and 1013

340 BOMAG 008 911 83

Engine control EDC16 with EMR 3 for TCD 2012 / 2013 12.9
EMR 3 - interface description

Engine side Vehicle side

D 2.1 D 2.2
Pin 1-60 Pin 1-94
in wiring diagram in wiring diagram
Page 004 Page 004
X31:1 to X31:90 X30:1 to X30:94

Fig. 2 EMR 3 - connecting plug TCD 2012 and 2013

16

Engine side Vehicle side

Fig. 3 Connecting plug EMR3

008 911 83 BOMAG 341

12.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013

Interface on engine side X31:

Fig. 4 Electric wiring diagram, page 004

342 BOMAG 008 911 83

Engine control EDC16 with EMR 3 for TCD 2012 / 2013 12.9
Interface on vehicle side X30:

Fig. 5 Electric wiring diagram, page 004

008 911 83 BOMAG 343

12.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013

Engine control EDC16 / EMR3

The EDC16 is located under the operator's stand

Fig. 6 EMR3-position in the machine under the operator's stand

344 BOMAG 008 911 83

Exhaust gas recirculation TCD 2012 / 2013 12.10
12.10Exhaust gas recirculation TCD
2012 / 2013
In order to be able to meet the exhaust gas stand-
ards EC and stage/Tier3, all engines are designed
with exhaust gas recirculation.

On 4-cylinder engines TCD 2012/2013 the exhaust

gas recirculation has been realized internally
through the intake valves, on 6-cylinders through
the exhaust valves. For this purpose the camshaft
has been manufactured with an additional cam for
short-term opening of the intake valve or exhaust
valve respectively.

Fig. 1 Exhaust/intake valve control TCD 2012 / 2013

008 911 83 BOMAG 345

12.11 Engine monitoring, instrument cluster TCD 2012 / 2013

12.11Engine monitoring, instru- speed or shut down engine if necessary,

clean engine oil cooler and radiator, if
ment cluster TCD 2012 / 2013 necessary repair engine.
b red = flashes if engine oil pressure too low, en-
gine is shut down after 10 seconds.
Check engine oil level, repair the engine
if necessary.
c yellow = Engine air filter, lights if air filter cartridge
is soiled, clean or replace if necessary.
d yellow = Charge control light, lights if battery is not
being charged.
Check V-belt, if necessary repair the
generator.
i yellow = Water separator in fuel pre-cleaner.
Lights when the water proportion in the
transparent section of the fuel filter
Fig. 1
reaches the contacts.
Instrument cluster j red = flashes, when the coolant provision (fill-
ing level) is too low, the engine is shut
down after 2 minutes.
i Note
With the ignition switch in position I all gauges and in- n red = Fuel tank filling level
struments are switched on for 3 seconds. When falling below the lowest filling level
the last green LED will light and the red
a red = flashes when the engine overheats, the LED will additionally come on.
warning buzzer sounds, the engine is When the fuel tank is empty only the red
shut down after 2 minutes. LED will flash.
Switch off vibration, run engine with idle

Fig. 1 New instrument cluster

346 BOMAG 008 911 83

Engine monitoring, instrument cluster TCD 2012 / 2013 12.11
New instrument cluster

b j d c a

i
Fig. 2 j red = flashes, when the coolant provision (fill-
a red = flashes when the engine overheats, the ing level) is too low, the engine is shut
warning buzzer sounds, the engine is down after 2 minutes.
shut down after 2 minutes. Middle = Fuel filling level
Switch off vibration, run engine with idle
speed or shut down engine if necessary,
clean engine oil cooler and radiator, if
necessary repair engine.
b red = flashes if engine oil pressure too low, en-
gine is shut down after 10 seconds.
Check engine oil level, repair the engine
if necessary.
c yellow = Engine air filter, lights if air filter cartridge
is soiled, clean or replace if necessary.
d yellow = Charge control light, lights if battery is not
being charged.
Check V-belt, if necessary repair the
generator.
i yellow = Water separator in fuel pre-cleaner.
Lights when the water proportion in the
transparent section of the fuel filter
reaches the contacts.

008 911 83 BOMAG 347

12.12 Fault diagnosis TCD 2012 / 2013

12.12Fault diagnosis TCD 2012 / With flashing control light the engine is shut down. If
the fault indicator for engine oil pressure or coolant
2013 level, coolant temperature light up as well, eliminate
the fault.
When the fault is eliminated the control light will go
out.
The diagnostic button provides the possibility to read
out existing faults in form of flashing codes.
With the ignition switch in position „I“ the control light
lights for about 2 seconds (function check)
permanent light = A fault message is present, the
engine can be started and the
refuse compactor is still operable
with limitations. Inform the service
department.
Fig. 1 the control light flash-
es after 2 seconds= Severe fault, the engine cannot
Control light and diagnostic button for engine be started, inform the service de-
control EMR III partment.
goes out after 2 sec-
i Note onds = the engine function is free of
The diesel engine with EMR III (Electronic Engine faults.
Control) inhibits protective functions for the engine. does not light = Start the engine, press the diag-
nostic push button for 3 seconds.
Depending on the severity of the detected fault the en-
Control light flashes 2x. EMR-con-
gine may continue operation with limitations (limp
trol ok.
home), whereby the control will permanently be on.

Fig. 1 Control light and diagnostics button

348 BOMAG 008 911 83

Fault diagnosis TCD 2012 / 2013 12.12
After output of fault
code = 5 seconds pause, the display by
i Note
flashing and permanent light.)
Depending on the significance of the detected fault
the engine may keep on running, however, with limita-
l If necessary repeat as described above to read out
tions (limp home), whereby the fault lamp will continu- the next fault code.
ally light, or the engine will be shut down and the fault
lamp will flash. If the warning lamps for engine oil
pressure control or coolant level also light up, correct
the fault (e.g. top up oil, let the engine cool down).
Once the fault is eliminated the fault lamp will go out.
The diagnostic button provides the possibility to read
out existing faults in form of flashing codes.

Example fault code 211

Fig. 2
l
Press the diagnose button (Fig. 2) for approx. 1 to 3
seconds, then release the button.

Fig. 3
After 2 seconds = 2 x short flashes of 0.4 seconds of
the first digit (recognition of the
EMR control) (Fig. 3).
after another 2 sec-
onds = 1 x long flash of 0.8 second of the
second digit for the stored fault
after another 2 sec-
onds = 1 x short flash of 0,4 second of the
third digit for the stored fault
l Write down the fault flash code.

008 911 83 BOMAG 349

12.13 EMR3 List of fault codes

12.13EMR3 List of fault codes

350 BOMAG 008 911 83

EMR3 List of fault codes 12.13

008 911 83 BOMAG 351

12.13 EMR3 List of fault codes

352 BOMAG 008 911 83

EMR3 List of fault codes 12.13

008 911 83 BOMAG 353

12.13 EMR3 List of fault codes

354 BOMAG 008 911 83

EMR3 List of fault codes 12.13

008 911 83 BOMAG 355

12.13 EMR3 List of fault codes

356 BOMAG 008 911 83

EMR3 List of fault codes 12.13

008 911 83 BOMAG 357

12.13 EMR3 List of fault codes

358 BOMAG 008 911 83

EMR3 List of fault codes 12.13

008 911 83 BOMAG 359

12.14 SerDia Service-Software TCD 2012 / 2013

12.14SerDia Service-Software TCD

2012 / 2013

EDC16
EMR3

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

360 BOMAG 008 911 83

SerDia Service-Software TCD 2012 / 2013 12.14

SerDia connection

Serdia
connection
socket

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

Replacing the EMR or DCR components

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

008 911 83 BOMAG 361

12.14 SerDia Service-Software TCD 2012 / 2013

SerDia screen shot

Fig. 3 Error log

362 BOMAG 008 911 83

General trouble shooting chart TCD 2012 / 2013 12.15
12.15General trouble shooting
chart TCD 2012 / 2013

Faults Causes Action

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

008 911 83 BOMAG 363

12.15 General trouble shooting chart TCD 2012 / 2013

Faults Causes Action

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

364 BOMAG 008 911 83

Valve adjustment TCD 2012 / 2013 12.16
12.16Valve adjustment TCD 2012 /
2013

Fig. 1 TCD 2012 and 2013 Sense of rotation

General definition Viewed on drive side (flywheel side)
turning ccw: counter-clockwise (see example)
Cylinder arrangement, engine side and sense of rota- Engine sides: Viewed on power take-off side.
tion left = left = exhaust side
right = right = operation side
The cylinders must be successively numbered, start-
ing with 1 at the flywheel .

Fig. 1 TCD 2012 / 2013 Valves Turn the rotation angle disc (3) clockwise, until the
specified angle is reached:
Adjusting the valve clearance (without exhaust
gas recirculation) Engine TCD 2012
Loosen the counter nut (1). IN = intake valve 75°
Attach the rotation angle disc (3) and the spanner EX = exhaust valve 120°
socket (4) to the valve clearance adjustment screw Engine TCD 2013
(2).
IN = intake valve 90°
Fix the magnet (5) of the rotation angle disc (3).
EX = Exhaust valve 150°Hold the rotation angle disc
Turn the rotation angle disc (3) clockwise against the (3) against turning
stop (rocker arm no clearance) and set the scale to ze-
Tighten the counter nut (1).
ro.

008 911 83 BOMAG 365

12.16 Valve adjustment TCD 2012 / 2013

Then adjust the second valve on the rocker arm as de-

scribed above.
Repeat the adjustment procedure on each cylinder.

366 BOMAG 008 911 83

Valve adjustment TCD 2012 / 2013 12.16

Fig. 2 TCD 2012 / 2013 Valves

Adjusting the valve clearance (with exhaust gas

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

Valve clearance adjustment schematic

Overlapping of valves: Exhaust valve not yet closed,
intake valve starts to open.

! Caution
These engines are equipped with an exhaust gas
recirculation system.
During the exhaust cycle the intake valve opens
for a short moment.
This must not be mistaken as overlapping of
valves!

008 911 83 BOMAG 367

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

12.17Ribbed V-belt - fan drive TCD

2012 / 2013

Fig. 1 Ribbed V-belt

i Note
Check the distance between the tongue of the move-
able tensioner arm and the stop on the fixed tensioner
housing.

If the distance "a" is smaller than 3 mm, replace the

belt.

368 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2012 2V) 12.18
12.18Special tools, Deutz engine
(TCD 2012 2V)

TCD 2012 2V Standard tools

8002
Pressure pump
Checking fuel system for leak-tightness

© 35409-2

8005
Compression pressure tester
for diesel engines
10 - 40 bar

© 35410-3

8024
Assembly pliers
Removing valve stem gaskets

© 37509-2

008 911 83 BOMAG 369

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

370 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2012 2V) 12.18

TCD 2012 2V Standard tools

8189
Torx tool set
Case containing:
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E10/E12
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)

© 39432-1

8190
Rotation angle disc
with magnet
Setting valve clearance

© 43528-0

8191
Screwdriver insert
for slotted screw
Valve clearance setting

© 43060-0

008 911 83 BOMAG 371

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

Standard tools TCD 2012 2V

8192
Bowl wrench
Fuel pre-filter (type: Racor)

© 43193-1

8194
Screwdriver insert
with hexagonal socket (size 4 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)

© 43183-0

8196
Open end wrench adapter
Size 13,
for torque wrench
Tightening of lock nut of the valve clearance setting
screw

© 43019-0

372 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2012 2V) 12.18

TCD 2012 2V Standard tools

8198
Pricker
Removing rotary shaft lip seal

© 43206-0

8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)

© 44309-0

9017
Assembly lever
Example: Removing and installing the valves

© 37511-2

008 911 83 BOMAG 373

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

TCD 2012 2V Special tools

100 190
Connection piece
(in conjunction with compression pressure tester 8005)

© 42524-1

100 320
Turning gear
flywheel side

© 35422-1

100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper

© 35423-1

3/12

374 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2012 2V) 12.18

Special tools TCD 2012 2V

100 400
Dial gauge with fixing wheel
Measuring range 0 -10mm / 0.01mm

© 35424-1

100 410
Digital gauge
Measuring range 0 -30 mm / 0.01 mm

© 43205-0

100 750
Measuring apparatus
Measuring bar with two spacing washers
(in conjunction with 100 400 or 100 410)
Checking valve lag dimension
Checking piston projection

© 39402-1

008 911 83 BOMAG 375

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

TCD 2012 2V Special tools

103 050
Socket wrench insert
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)

© 43023-0

103 220
Special pliers
for removing the roller tappet

© 43010-0

110 500
Special wrench
Size 17
Removing and installing high-pressure lines

© 35436-1

376 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2012 2V) 12.18

Special tools TCD 2012 2V

110 700
Socket wrench insert
long
Assembling/disassembling pressure sensors
(rail pressure, oil pressure, fuel pressure)

© 43198-2

110 900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three assembly sleeves
with guide:
- High pressure pump (Ø 36), 110 902
- Injector, 2V motor (Ø 16), 110 903
- Injector, 4V motor (Ø 23), 110 904
Disassembling/assembling O-rings

© 43208-0

120 430
Assembly tool
Removing and installing the heating plugs

© 43020-0

008 911 83 BOMAG 377

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

TCD 2012 2V Special tools

120 900
Support bracket
pivoting
Clamping cylinder head

© 35438-3

120 910
Base plate for support bracket
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)

© 35439-3

121 410
Assembly tool
Assembling valve stem gaskets

© 37614-2

378 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2012 2V) 12.18

Special tools TCD 2012 2V

121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket

© 43210-0

130 300
Universal piston ring pliers
Removing and installing the piston rings

© 43021-0

130 440
Trapezoidal groove wear gauge
for piston diameter 101 mm
Check piston ring groove

© 36461-2

008 911 83 BOMAG 379

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

TCD 2012 2V Special tools

130 450
Trapezoidal groove wear gauge
for piston diameter 98 mm
Check piston ring groove

© 36461-2

130 660
Piston ring tensioning band
Piston diameter 98 mm

© 39408-1

130 670
Piston ring tensioning band
Piston diameter 101 mm

© 39408-1

380 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2012 2V) 12.18

Special tools TCD 2012 2V

142 670
Assembly tool
Assembling crankshaft sealing ring
(opposite side to flywheel)

© 35445-1

142 830
Assembly tool
for crankshaft (flywheel side)

© 35446-1

144 800
Counter support
Torsional vibration damper

© 35453-1

008 911 83 BOMAG 381

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

TCD 2012 2V Special tools

170 050
Special wrench
Unscrew the filter cartridges

© 37629-2

170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

© 43663-0

6066
Assembly block
Engine clamping, double-sided

© 35451-2

382 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2012 2V) 12.18

Special tools TCD 2012 2V

6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided

© 35452-1

008 911 83 BOMAG 383

12.19 Special tools, Deutz engine (TCD 2013 2V)

12.19Special tools, Deutz engine

(TCD 2013 2V)

TCD 2013 2V Standard tools

8002
Pressure pump
Checking cooling system for leak-tightness

© 35409-2

8005
Compression pressure tester
for diesel engines
10 - 40 bar

© 35410-3

8011
Hose clip pliers
e. g. fuel return pipe

© 39426-1

384 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2013 2V) 12.19

Standard tools TCD 2013 2V

8024
Assembly pliers
Removing valve stem gaskets

© 37509-2

8035
Socket wrench insert
reinforced, size 22
removing and installing main bearing

© 37504-2

8113
Socket wrench insert
Torx - E 14

© 43022-0

008 911 83 BOMAG 385

12.19 Special tools, Deutz engine (TCD 2013 2V)

386 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2013 2V) 12.19

Standard tools TCD 2013 2V

8190
Rotation angle disc
with magnet
Setting valve clearance

© 43528-0

8191
Screwdriver insert
for slotted screw
Valve clearance setting

© 43060-0

8192
Bowl wrench
Fuel pre-filter (type: Racor)

© 43193-1

008 911 83 BOMAG 387

12.19 Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V Standard tools

8193
Screwdriver insert
with pressed in hexagonal pin (5 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)

© 43183-0

8194
Screwdriver insert
with hexagon socket (size 4 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)

© 43183-0

8195
Multi-toothed screwdriver set
260 mm long
remove and install air compressor

© 43195-0

388 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2013 2V) 12.19

Standard tools TCD 2013 2V

8196
Open end wrench adapter
Size 13,
for torque wrench
Tightening of lock nut of the valve clearance setting
screw

© 43019-0

8198
Pricker
Removing rotary shaft lip seal

© 43206-0

8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)

© 44309-0

008 911 83 BOMAG 389

12.19 Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V Standard tools

9017
Assembly lever
Example: Removing and installing the valves

© 37511-2

9090
Spring band pliers
320 mm
tighten spring band clamp

© 35420-3

390 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2013 2V) 12.19

TCD 2013 2V Special tools

100 190
Connector
(in conjunction with compression pressure tester 8005)

© 42524-1

100 320
Turning gear
flywheel side

© 35422-1

100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper

© 35423-1

008 911 83 BOMAG 391

12.19 Special tools, Deutz engine (TCD 2013 2V)

Special tools TCD 2013 2V

100 400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm

© 35424-1

100 410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm

© 43205-0

100 750
Measuring device
Measuring bar with two shims
(in conjunction with 100400 and 100410)
Checking valve lag dimension
Checking piston projection

© 39402-1

392 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2013 2V) 12.19

TCD 2013 2V Special tools

103 050
Socket wrench insert
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)

© 43023-0

103 220
Special pliers
for removing the roller tappet

© 43010-0

110 500
Special wrench
Size 17
Removing and installing high-pressure lines

© 35436-1

008 911 83 BOMAG 393

12.19 Special tools, Deutz engine (TCD 2013 2V)

Special tools TCD 2013 2V

110 640
Lever tool
Remove injector

© 43941-0

110 700
Socket wrench insert
long
Installing and removing pressure sensors
(rail pressure, oil pressure, fuel pressure)

© 43198-2

110 900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three
assembly sleeves with guide:
- High pressure pump (Ø 36), 110 902
- Injector, 2V motor (Ø 16), 110 903
- Injector, 4V motor (Ø 23), 110 904
Removing and installing O-rings

© 43208-0

394 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2013 2V) 12.19

TCD 2013 2V Special tools

120 430
Assembly tool
Removing and installing the glow plugs

© 43020-0

120 680
Puller
(in conjunction with slide hammer 150 800)
Removing fixed injector sealing ring

© 35437-1

120 900
Support bracket
pivoting
Clamping cylinder head

© 35438-3

008 911 83 BOMAG 395

12.19 Special tools, Deutz engine (TCD 2013 2V)

Special tools TCD 2013 2V

120 910
Base plate
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)

© 35439-3

121 330
Assembly lever
Removing and installing the valves

© 43185-0

121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket

© 43210-0

396 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2013 2V) 12.19

TCD 2013 2V Special tools

130 300
Universal piston ring pliers
Removing and installing the piston rings

© 43021-0

130 420
Trapezoidal groove wear gauge
Piston diameter 108 mm

© 36461-2

130 640
Piston ring compressor
Piston diameter 108 mm

© 39408-1

008 911 83 BOMAG 397

12.19 Special tools, Deutz engine (TCD 2013 2V)

Special tools TCD 2013 2V

142 810
Assembly tool
Installing crankshaft sealing ring
(flywheel side)

© 35446-1

142 820
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)

© 35445-1

150 170
Puller, universal
Comprising traverse, support and threaded rod
(in conjunction with disc 150 171)
Removing cylinder liner

© 43207-0

398 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2013 2V) 12.19

TCD 2013 2V Special tools

150 171
Plate
(in conjunction with puller 150 170)
for liner diameter: 108 mm
Removing cylinder liner

© 43204-0

150 180
Liner holder
(Set comprises 7 holders)
Turning crankshaft with cylinder head removed

© 43181-0

150 190
Assembly lever
Lever with bolts
(in conjunction with disc 150 191)
Installing cylinder liner

© 43209-2

008 911 83 BOMAG 399

12.19 Special tools, Deutz engine (TCD 2013 2V)

400 BOMAG 008 911 83

Special tools, Deutz engine (TCD 2013 2V) 12.19

TCD 2013 2V Special tools

170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

© 43663-0

6066
Assembly block
Engine clamping, double-sided

© 35451-2

6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided

© 35452-1

008 911 83 BOMAG 401

12.19 Special tools, Deutz engine (TCD 2013 2V)

Special tools TCD 2013 2V

6068
Engine lifting device
Version for commercial vehicles with worm gear, ulti-
mate load (2t), 3-point suspension, spindle clamp,
traverse, chains and hooks

© 43184-0

6692
Slotted nut wrench
Cable plug

© 43199-0

402 BOMAG 008 911 83

13 Air conditioning system

008 911 83 BOMAG 403

13.1 Physical basics

13.1 Physical basics A - heat absorption

In order to understand the working principle of an air B- Heat dissipation

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.

1. gaseous (invisible)

2. vaporous

3. liquid

4. solid

Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.

Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.

404 BOMAG 008 911 83

Physical basics 13.1
Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
l Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
l Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
l Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.

Fig. 4 Pressure - Temperature Diagram

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

008 911 83 BOMAG 405

13.1 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

406 BOMAG 008 911 83

Refrigerant R134a 13.2
13.2 Refrigerant R134a Characteristics of the refrigerant R134a:
Refrigerant R134a is currently available under the fol-
General lowing trade marks.
The evaporation and condensation process is the H-FKW 134a
method commonly used in mobile air conditioning sys- SUVA 134a
tems. The system in this case works with a substance KLEA 134a
that boils at low temperature, a substance referred to
a refrigerant. The refrigerant used is tetrafluoroethane
R134a, which boils at a temperature of -26.5°C and Colour:
under a steam pressure of 1 bar. Refrigerant in form of vapour or liquid is colourless as
Although the refrigerant circuit is a hermetically closed water. The gas is invisible. Only the bordering layer
loop, the system loses approx. 100g of refrigerant between gas and liquid is visible. (Fluid level in rising
over the course of 1 year by diffusion through hoses, pipe of filling cylinder or bubbles in inspection glass).
pipes and seals, even though the system is free of In the inspection glass the liquid refrigerant R134a
leaks. If too much refrigerant is lost the cooling power may appear coloured (milky). This turbidity results
of the system will drop. from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Physical data of the refrigerant R134a

Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous
CH2F-CF3 or CF3-CH2F refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
Chemical designation: sure and is frequently referred to as steam pressure.
Tetrafluoroethane The steam pressure is independent from the temper-
ature.

Boiling point at 1 bar:

- 26.5 °C Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
Solidification point: tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
-101.6 °C
ation oils, e.g. PAG-oils (polyalkylene glycol oils).

Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.

Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the

008 911 83 BOMAG 407

13.3 Compressor oil / refrigeration oil

liquid container has absorbed approx. 8 gr. of water, 13.3 Compressor oil / refrigeration
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle oil
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
Inflammability: until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul- Compressor oil (the oil quantity should be 10 % of the
traviolet light also cracks refrigerant (caused by refrigerant weight) mixes with the refrigerant and cir-
electric welding). This results in toxic fission products, culates permanently through the system.
these must not be inhaled. However, irritation of the In connection with R134a- air conditioning systems
mucous membranes is an early and in-time warning. special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
Filling factor: from this, the materials in the R134a air conditioning
In a container there must be a steam space above the system may be attacked when the mixture is flowing
liquid space. The liquid expands with increasing tem- through the refrigerant circuit under high pressure and
perature. The steam filled space becomes smaller. at high temperatures or if the lubrication film in the
From a certain time on the container will be filled with compressor tears off. The use of non-permitted oils
just liquid. After this only a minor temperature in- can cause damage to the air conditioning system, you
crease is enough to generate very high pressures in should therefore only used the approved oils.
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to Properties of compressor oil / refrigeration oil:
avoid overfilling of a container the pressure gas direc- The most important properties are high solvency in
tive clearly specifies how many kilograms of refriger- connection with refrigerants, good lubrication charac-
ant may be filled into the container per litre volume. teristics, that they are free of acids and their low water
Multiplied with the internal volume this "filling factor" content. For this purpose only certain oils can be
determines the permissible filling capacity For refrig- used. PAG-oils suitable for use with refrigerant R134a
erants used in motor vehicles it is 1.15 kg/l. are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
The contribution of R134a to the greenhouse effect is gressive against metals.
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.

408 BOMAG 008 911 83

Working principle of the air conditioning system 13.4
13.4 Working principle of the air 13.5 Monitoring devices
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en- Pressure switch
vironment. Everybody knows the effect: if a sweating
The pressure switch (8) is used as monitoring feature
body is exposed to wind it will cool down, because
for too high and too low pressures. The switching con-
heat is extracted. For this purpose a refrigerant circu-
tacts (4 and 5) effect the magnetic clutch of the com-
lates in a closed circuit inside the vehicle. This refrig-
pressor via a relay (6).
erant thereby continuously changes its physical state
between liquid and gaseous. If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
Fig. 1 Principle sketch of an air conditioning system
is set to approx. 1.5 bar to avoid icing. The switch on
An engine driven compressor (1) draws in gaseous re- pressure is 0.5 to 2 bar higher than the shut-off pres-
frigerant from the evaporator (5) and compresses it. sure (depending on system, see description of com-
During this process the temperature of the refrigerant ponents.)
increases tremendously.
Thermostat
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front A frost protection thermostat (3) protects the evapora-
of the vehicle radiator, so that a sufficient air flow is as- tor against icing. Similar to the pressure switch, the
sured. In the condenser (2) the gas is cooled down thermostat activates or deactivates the magnetic
and consequently liquefied. clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
In the dryer / liquid container (3) the refrigerant is then
tween the fins of the evaporator or attached to the
collected and freed of moisture and contaminants.
evaporator outlet (suction side). With fixed tempera-
The expansion valve (4) regulates the flow rate from ture controls the control switches the compressor off
the dryer / liquid container (3) back to the evaporator at about 1 °C and back on again at about 2.5°C to 5.5
(5) and the circuit starts again. °C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.

008 911 83 BOMAG 409

13.6 Description of components

Monitoring chain 13.6 Description of components

Compressor

Fig. 2 Monitoring chain consisting of:

l 1 Switch
l 2 Fuse
l 3 Thermostat
l 4 Low pressure switch contact Fig. 1
l 5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
l
6 Relay
the function of the system. Coupling and decoupling is
l
7 Connection for magnetic clutch accomplished by an electromagnetically controlled
l
8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.

Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)

! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil / refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.

Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.

410 BOMAG 008 911 83

Description of components 13.6
Reason of oil loss Amount of oil lost Condenser
Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve

! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1
To avoid excessive oil in the A/C-system and thus The condenser is located in front of the the radiator for
a poor cooling effect, the oil level in the A/C-sys- the machine. It emits heat energy from the system into
tem must be adjusted accordingly. the surrounding air and liquefies the gaseous refriger-
The quantity depends on the amount of oil that ant.
may have been lost in connection with the possi-
ble replacement of other components.
i Note
The compressor oil quantity must be 10% of the The fins must be free of dirt and damage.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re- ! Caution
quires a compressor oil / refrigerant oil filling of
100 gr. When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
Procedure: changing the components, must be replaced with
Drain and measure the compressor oil from the fresh oil.
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.

i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.

008 911 83 BOMAG 411

13.6 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.

412 BOMAG 008 911 83

Description of components 13.6
i Note Expansion valve
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.

! Danger

In case of mechanical damage or corrosion on

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

i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+

008 911 83 BOMAG 413

13.6 Description of components

Evaporator Defroster thermostat

Fig. 1 Fig. 1

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

! Caution
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.

414 BOMAG 008 911 83

Description of components 13.6
Pressure switch Pipes and hoses
Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
Fig. 1
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure Recommended tightening torques for O-ring
side, the pressure switch will switch of the magnetic sealed fittings
clutch of the compressor, thus to avoid destruction of
system components by excessive pressure or draw- Thread Spanner width Torque
ing in external gases and foreign matter as a result of 5/8“ 17 or 19 13,6 - 20,3 Nm
too low pressure. 3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
Working pressure:
1 1/16“ 32 40,7 - 47,5 Nm
Low pressure off: 1,5 ±0,5 bar M30X2 36 105,0 - 115,0
Low pressure on: 3.5 bar Nm
M36X2 41 165,0 - 175,0
Overpressure off: 25,0 ±1,5 bar
Nm
Overpressure on: 18,0 ±1,5 bar
Bending radii for air conditioning hoses

Hose type Nominal width Bending radius

GH 134 NW8 min. 50 mm
GH 134 NW10 min. 65 mm
GH 134 NW12 min. 75 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm

008 911 83 BOMAG 415

13.7 Checking the compressor oil level

13.7 Checking the compressor oil

level

Checking the compressor oil level / refrig-

eration oil level

!Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404).
l Run the compressor for 10 minutes at engine idle
speed.
l In order to avoid any compressor oil losses you
should slowly drain all refrigerant from the air condi- Fig. 2
tioning system. l Turn the nut that hold the armature clockwise with a
socket wrench, until the counterweight is correctly
positioned.

i Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
l Insert the oil dipstick.
l Pull out the dipstick and count the notches covered
by oil.
l Drain off oil or fill up as specified in the table.

Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
Fig. 1
Fastening angle (de- Oil dipstick in incre-
l Measure the fastening angle (Fig. 1) of the com- gree) ments
pressor (oil plug at top) 0 5-7
l
Remove the oil filler plug. 10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
l
Screw the oil filler plug back in.

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

416 BOMAG 008 911 83

Checking the magnetic clutch 13.8
13.8 Checking the magnetic clutch i Note
l Measure the voltage. The gap should be 0.4 to 0.8 mm.
l
Take off the drive V-belt and rotate the V-belt pulley
by hand while the magnetic clutch is disengaged.
i Note
Nominal value = vehicle voltage
l
Check the magnetic coil locking ring for secure fit.
i Note
In case of excessive flatness faults or deviations the
l
Check the current consumption. magnetic clutch needs to be replaced.

Cross-section of magnetic clutch

Fig. 3 shows a cross-section of the magnetic clutch. If
the coil (7) is not supplied with operating voltage,
there is no contact between the front plate of the
clutch (1) and the V-belt pulley (2). A spring presses
the front plate away from the belt pulley. The V-belt
pulley rotates with the bearing (3) in idle speed, the
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is
generated and pulls the front plate of the clutch. Both
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works.

Fig. 1

i Note
Nominal value approx. 3.5 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.

Fig. 3 Cross-section of magnetic clutch

Fig. 2 Measuring the air gap

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

008 911 83 BOMAG 417

13.9 Inspection and maintenance work

13.9 Inspection and maintenance 13.10Checking, replacing the refrig-

work erant compressor V-belt1
l Visual inspection of the complete system for dam-
age. Danger
!
l Check the compressor mounting bracket on the ve- Danger of injury!
hicle engine for tight fit and damage.
Work on the V-belt must only be performed with
l Check the condition, alignment and tightness of the the engine shut down.
V-belt.
Wear safety goggles.
l
Check the routing of refrigerant hoses and cables in
the area of the vehicle engine and transmission, as
Check the V-belt
well as on the chassis for chafing and rectify any de-
tected faults. Ensure sufficient clearance to hot
parts, such as the exhaust; install a protective
shield, if necessary.
l Check the routing of hoses and hoses on the at-
tachment box or in the cabin.
l Check all hose and screw fittings for leaks.
l Check the fastening of the condenser unit.
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. Fig. 4
l
Check the electric control panel. If discolorations on l
Inspect the entire circumference of the V-belt (Fig.
conductors are found, these should be replaced 4) visually for damage and cracks. Replace dam-
and possibly also the corresponding relays. aged or cracked V-belts.
l
Switch on the cooling system and check the refrig- l Check with thumb pressure whether the V-belt can
erant level. be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
l
Filter/dryer and filter/dryer/fluid container combina-
essary.
tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by Tighten the V-belt.
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
l Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
out air temperature - The temperature difference
should be at least 8-10 K.
l
Measuring the pressure in the refrigerant circuit

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

1 Optional equipment

418 BOMAG 008 911 83

Service the air conditioning 13.11
Press the compressor in direction of arrow, until the
13.11Service the air conditioning1
l

correct V-belt tension is reached.

l Retighten all fastening screws.
Cleaning the condenser
Changing the V-belt
! Caution
l Slightly slacken the fastening screws 1, 2 and 3.
A soiled condenser results in a considerable re-
l Press the compressor against the direction of arrow duction of air conditioning power.
completely against the engine.
Under extremely dusty conditions it may be nec-
l Take the old V-belt off. essary to clean the condenser several times per
l Fit the new V-belt to the V-belt pulleys. day.
l Tension the V-belt as previously described. If, during operation of the air conditioning system,
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
Caution
!
In case of formation of foam have the air condi-
Check the V-belt tension after a running time of 30 tioning system inspected by the service depart-
minutes. ment.

Danger
!

Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.

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

Checking the refrigerant level

l
Start the engine.

1 Optional equipment

008 911 83 BOMAG 419

13.11 Service the air conditioning

Fig. 7 Fig. 9
l Switch the air conditioning (Fig. 7) on. l Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
at the top.

i Note
The refrigerant level is correct.

Fig. 8
l Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 8) in the blue section.
l
Open the air outlet nozzles.
l
Check, whether the outflowing air is noticeably cool-
er. Fig. 10
l
If the white float (Fig. 10) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
i Note
the service department.
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on. i Note
l Open the hood. The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.

420 BOMAG 008 911 83

Service the air conditioning 13.11
Checking the moisture level of the drying
agent

Fig. 12
l Check the drier/collector unit (Fig. 12) for mechani-
cal damage or rust.
Fig. 11
l Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
orange = drying agent o.k.
colorless = moisture level of drying agent too high.
l Inform the service department. Replace drier/col-
lector unit, check air conditioning system.

Caution
!

Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.

Checking the condition of the drier/col-

lector unit

!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
with this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.

! Danger

Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.

008 911 83 BOMAG 421

13.12 Drying and evacuation

13.12Drying and evacuation 13.13Emptying in case of repair

Evacuation of air conditioning systems using R-type For repair work the air conditioning systems must very
refrigerants not only has the purpose of emptying the often be emptied of all refrigerant.
system of all air before filling in refrigerant, but also to Especially with expensive refrigerants and larger
verify the leak tightness over a longer lifetime in the amounts of oil it may be necessary to keep the refrig-
achieved vacuum. However, the most important factor erant for later use.
in this work step is the drying of the system.
For later use these refrigerants must be drawn out
Any water residues in the refrigerant circuit will com- with suitable equipment and intermediately stored in
bine with the refrigerant, which will lead to the previ- collecting containers.
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
Environment
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration Contaminated refrigerant must be disposed of en-
system. vironmentally
The refrigerant compressor is not suitable for the pur- Releasing refrigerant into the atmosphere is pro-
pose of evacuation, because it is not able to achieve hibited (see restrictive injunction concerning
a sufficient final vacuum and, apart from this, may be CFC, day of enforcement 01. 08. 1991, § 8)
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
! Danger
It is common practice to evacuate the refrigeration For draining refrigeration systems you should not
system to a final vacuum of 1 Torr, i.e. 1.33 mbar. simply use any delivery containers, but only ap-
An exact time for evacuation and drying cannot be propriate pressure bottles, which must be special-
predicted. It can only be determined by means of a ly marked and should comply with the pressure
vacuum meter. However, if there is no vacuum meter gas directive.
at hand it is generally better to evacuate 1 hour longer
When transferring refrigerant you must make sure
than 1 hour too less.
that the bottle does not contain more than the per-
Function drying: mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced, In order to reduce the evacuation period in case of
water will already evaporate, e.g. under a pressure of short repairs, you may fill the refrigerant circuit with
10 mbar, at an ambient temperature of almost 7°C, approx. 0.5 bar nitrogen when opening. This ensures
but the water will not evaporate all at once. Since it is that nitrogen will flow out of the refrigerant circuit while
very difficult to separate the steam from the vacuum in it is open and no air or moisture can enter. However,
the system, the evacuation process is supported by the necessity for vacuum generation and a dryer
the co-called vacuum breaking (filling the circuit with change remains.
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.

422 BOMAG 008 911 83

Leak test 13.14
13.14Leak test

! Caution
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.

Leak test with electronic leak tester

Fig. 1 Electronic leak tester

Small leaks with only very low amounts of refrigerant
escaping can be detected, e.g. with an electronic leak
tester. Such equipment is able to detect leaks of less
than 5 gr. per year.
The leak tester used must be specially designed for
the refrigerant composition in the air conditioning sys-
tem. For example, leak detectors for refrigerant R12
are not suitable for R134a, because the refrigerant
R134a is free of chlorine atoms, meaning that this leak
detector will not respond.

Leak test with soap bubbles

Fig. 2 Soap bubble test

Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.

008 911 83 BOMAG 423

13.15 Filling instructions

13.15Filling instructions

Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).

! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.

i Note
White frost on the suction line is no measure for as-
sessing the filling.

424 BOMAG 008 911 83

Filling instructions 13.15

Fig. 1 10 Filter dryer

1 High pressure - gaseous 11 Fluid container
2 High pressure - liquid 12 Condenser
3 Low pressure - gaseous 13 Manual shut-off valve (not used)
4 Compressor 14 Pressure switch with high and low pressure con-
5 Compressor pressure switch (not used) tacts
6 not used 15 Defroster thermostat
7 Evaporator 16 Vacuum meter
8 Expansion valve 17 Low pressure gauge
9 Inspection glass 18 High pressure gauge

008 911 83 BOMAG 425

13.15 Filling instructions

19 Pressure reducing valve 16 Switch off the vacuum pump, watch the pressure
20 Vacuum pump gauges to see whether the vacuum is maintained.
21 Nitrogen bottle 17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
22 Refrigerant bottle
gauge bar. Fill refrigerant into the system, until a
23 Pressure gauge bar pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
Filling instructions es).
1 Connect the service adapter with the blue hand 18 Close the red hand wheel.
wheel in the suction side. 19 Perform a leak test with the electronic leak detec-
2 Connect the service adapter with the red hand tor.
wheel in the pressure side (the hand wheels on 20 Start the engine and switch on the system.
the service adapters must be fully backed out - left 21 Open the blue hand wheel and continue filling in
hand stop) refrigerant until the inspection glass is free or air
3 Connect the blue suction hose below the blue bubbles (in fluid container/dryer combinations the
hand wheel on the pressure gauge bar to the blue white pearl should float in the upper third of the in-
service adapter. spection glass). Then close the refrigerant bottle.
4 Connect the red pressure hose below the red 22 Close the blue hand wheel on the pressure gauge
hand wheel on the pressure gauge bar to the red bar.
service adapter. 23 Preparing the test run: -Close windows and doors
5 Connect the yellow hose below the yellow hand -Fan on full speed stage -Mount measuring feel-
wheel on the manometer bar to the 2-stage vacu- ers to air discharge and air intake.
um pump. 24 Run the system for approx. 20 minutes with medi-
6 Connect the last hose below the black hand wheel um engine speed.
on the nitrogen bottle via the pressure reducing 25 The temperature difference between air discharge
valve. and air intake should be (depending on type of air
7 Check on the pressure gauge bar that all hand condition) 8-10°C. The ambient temperature
wheels are closed. thereby is approx. 20°C. (These data are only ref-
8 Turn the hand wheels on both service adapter erence values, which may be influenced by possi-
clockwise. This opens the valves (right hand ble insolation)
stop). 26 Switch off system and engine and check for leaks
9 Open the valve on the nitrogen bottle (only via again.
pressure reducer); pressure approx. 20 bar. 27 Turn out (left hand stop) and remove the hand
10 Open the black and red hand wheels on the pres- wheels on both service adapters.
sure gauge bar and fill nitrogen into the system, 28 Fit all valves with dust caps.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 29 Perform a leak test.
ed on the suction side.
30 Mark the system with the corresponding type
11 Then open the blue hand wheel and raise the plates and information decals, such as type of oil
pressure in the suction side (max. 10 bar). Check and refrigerant.
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.

426 BOMAG 008 911 83

Trouble shooting in refrigerant circuit, basic principles 13.16
13.16Trouble 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 83 BOMAG 427

13.16 Trouble shooting in refrigerant circuit, basic principles

Pressure gauge with saturation temperature scale If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.

Common overheating values

The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
Fig. 3 Absolute pressure gauge is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
Temperature scales on the pressure gauges always
ates within a range between 4 and 12 Kelvin. The in-
refer to the absolute pressures Pabs. Please note that
fluence of the ambient air on the suction line causes
it is not possible to measure a temperature directly
an additional overheating effect.
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper- Overheating is calculated as follows:
ature is assigned to the measured pressure.
Δ to2h = to2h - to
If the refrigerant is fluid, the temperature is below the
saturation temperature. Δ to2h, overheating at evaporator outlet in K
If the refrigerant is gaseous, the temperature is above to2h, temperature at evaporator outlet in °C
the saturation temperature. to, evaporation temperature in °C
Pressure gauges must indicate 0 bar when not con- „h“ represents "overheated"
nected to the system.
Low pressure gauges have a blue, high pressure Supercooling
gauges a red border.

Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause

428 BOMAG 008 911 83

Trouble shooting in refrigerant circuit, basic principles 13.16
a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.

Common supercooling values

In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.

Supercooling is calculated as follows:

Δ tc2u = tc - tc2u
Δ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"

008 911 83 BOMAG 429

13.16 Trouble shooting in refrigerant circuit, basic principles

Fig. 1 Refrigerant circuit with t, h- diagram

1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion

430 BOMAG 008 911 83

Trouble shooting, refrigerant circuit diagram 13.17
13.17Trouble shooting, refrigerant
circuit diagram

Fig. 1 Refrigerant circuit diagram 13 Compressor

1 Cold air 14 Condenser
2 Evaporator 15 Cooling air
3 Thermostat 16 Pressure gauge, low pressure
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air

008 911 83 BOMAG 431

13.18 Trouble shooting procedure

13.18Trouble 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.

432 BOMAG 008 911 83

Trouble shooting procedure 13.18
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 83 BOMAG 433

13.18 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

434 BOMAG 008 911 83

Trouble shooting procedure 13.18
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 83 BOMAG 435

13.18 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

436 BOMAG 008 911 83

Trouble shooting procedure 13.18
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 83 BOMAG 437

13.18 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

438 BOMAG 008 911 83

Trouble shooting procedure 13.18
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 83 BOMAG 439

13.18 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

440 BOMAG 008 911 83

Trouble shooting procedure 13.18
Inspection glass

Faults Possible cause Remedy

Steam bubbles in inspection glass No supercooling before expansion Fill up the system, replace the filter
valve, lack of refrigerant in system, dryer, perform a leak test
pressure loss in system, supercool-
ing caused by excessively soiled fil-
ter dryer
Discolouration of inspection glass Lubricant destroyed by excessive Replace the refrigeration oil, exam-
(black from inside) operating temperatures ine the temperature increase
Moisture indicator changes to pink Moisture level of drying agent too Replace the filter dryer
high
Ball floats at bottom lack of refrigerant Fill the system

Monitoring devices

Faults Possible cause Remedy

The high pressure contact has System pressure exceeded, con- Clean the condenser, replace the
switched off the magnetic clutch denser excessively soiled, condens- expansion valve, check the con-
er fan defective, expansion valve denser fan
defective
The low pressure contact has System pressure fallen short of, re- Clean the evaporator, replace the
switched off the magnetic clutch frigerant level too low, expansion expansion valve, check the evapora-
valve defective, evaporator fan de- tor fan
fective, heat load too low, ambient
temperature below 1.5 °C
The thermostat has switched off the Ambient temperature below 1°C, Check the thermostat switching
magnetic clutch expansion valve defective, thermo- point, replace the expansion valve,
stat defective, air flow volume too clean the evaporator, check the
low evaporator fan

008 911 83 BOMAG 441

13.19 Steam table for R134a

Tempera- Pres- Density spec. volume spec. enthalpy Evapora-

ture sure tion heat
of the fluid of the of the fluid of the of the fluid of the
steam steam steam

442 BOMAG 008 911 83

Steam table for R134a 13.19

008 911 83 BOMAG 443

13.19 Steam table for R134a

444 BOMAG 008 911 83

Steam table for R134a 13.19

008 911 83 BOMAG 445

13.19 Steam table for R134a

446 BOMAG 008 911 83

13.20Heating control / air conditioning control

008 911 83 BOMAG 447

13.20 Heating control / air conditioning control

448 BOMAG 008 911 83

Heating control / air conditioning control 13.20

008 911 83 BOMAG 449

13.20 Heating control / air conditioning control

450 BOMAG 008 911 83

Heating control / air conditioning control 13.20

008 911 83 BOMAG 451

13.20 Heating control / air conditioning control

452 BOMAG 008 911 83

14 Replacing the cab window panes

008 911 83 BOMAG 453

14.1 Assembly of window panes

Fig. 1

1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap

454 BOMAG 008 911 83

Special tools 14.2
14.2 Special tools
1. Locking handle for fastening element

BOMAG part-no.: 055 705 84

Fig. 1
2. Suction lifter

commercial

Fig. 2

008 911 83 BOMAG 455

14.3 Auxiliary materials

14.3 Auxiliary materials

Safety gloves
3. Cutter

Commercial

Fig. 1
4. Window glass bonding agent

BOMAG part-no.: 009 780 34

Fig. 2
5. Activator

BOMAG part-no.: 009 780 33

Fig. 3

456 BOMAG 008 911 83

Auxiliary materials 14.3
6. Silicone sealant

BOMAG part-no.: 009 700 36

Fig. 4

008 911 83 BOMAG 457

14.4 Removing and installing the window pane

14.4 Removing and installing the window

pane
Environment
Environmental damage
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.

! Danger

Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).

Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.

Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).

Fig. 3

458 BOMAG 008 911 83

Removing and installing the window pane 14.4
6. Turn the fixing and spacer washer hand-tight onto
the thread of the fastening element (Fig. 4).

i Note
Do not overtighten the thread.

Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).

i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.

Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.

Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).

i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.

Fig. 7

008 911 83 BOMAG 459

14.4 Removing and installing the window pane

14. Remove the suction lifter (Fig. 8).

Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).

i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.

Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).

Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).

Fig. 11

460 BOMAG 008 911 83

Removing and installing the window pane 14.4
19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).

Fig. 12
20. Treat the inside joint (Fig. 13)

Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.

i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.

Fig. 14

008 911 83 BOMAG 461

14.4 Removing and installing the window pane

462 BOMAG 008 911 83

15 Drum

008 911 83 BOMAG 463

15.1 Special tools, drum, single drum rollers

15.1 Special tools, drum, single drum roll-

ers
1. Disassembly device for side plate

BOMAG part-no.: 007 211 55

Fig. 1
2. Assembly device for side plate

BOMAG part-no.: 971 079 21

Fig. 2
3. Assembly device for coupling hub and flanged
hub

Fig. 3

464 BOMAG 008 911 83

Special tools, drum, single drum rollers 15.1
4. Pressing plate for cylinder roller bearing

Fig. 4
5. Pressing plate for travel bearing

Fig. 5
6. Pressing bushing for radial seal

Fig. 6
7. Lifting device for exciter unit

BOMAG part-no.: 007 215 08

Fig. 7

008 911 83 BOMAG 465

15.2 Repair overview for drum

Fig. 1

466 BOMAG 008 911 83

Repair overview for drum 15.2
1 Rubber buffer 12 Rectangular rubber buffer
2 Vibration bearings 13 Side plate
3 Housing cover, basic weight 14 Travel bearings
4 Flange 15 Oil level inspection plug
5 Flanged housing 16 Oil drain plug
6 Coupling hub 17 Basic weight
7 Mechanical seal 18 Change-over weight
8 Flanged hub 19 Radial seal
9 Vibration motor 20 Vibrator shaft
10 Compensation plates 21 Fan
11 Spacer block 22 Drum shell

008 911 83 BOMAG 467

15.2 Repair overview for drum

Fig. 2

468 BOMAG 008 911 83

Repair overview for drum 15.2

Fig. 3

008 911 83 BOMAG 469

15.2 Repair overview for drum

Fig. 4

470 BOMAG 008 911 83

Repair overview for drum 15.2

Fig. 5

008 911 83 BOMAG 471

15.2 Repair overview for drum

Fig. 6

472 BOMAG 008 911 83

Repair overview for drum 15.2

Fig. 7

008 911 83 BOMAG 473

15.2 Repair overview for drum

Fig. 8

474 BOMAG 008 911 83

Removing and installing the drum 15.3
15.3 Removing and installing the drum

i Note
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (Fig. 1).

Fig. 1

i Note
However, the drum can also be removed without
having to disassemble the side plate, if it is lifted
up and out of the frame (Fig. 2).

Fig. 2

Removing the drum

i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.

Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
8. Mark the hydraulic hoses (Fig. 3)on the travel mo-
tor and disconnect them from the ports.
9. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 3

008 911 83 BOMAG 475

15.3 Removing and installing the drum

10. Mark the hydraulic hoses on the vibration motor

(Fig. 4) and disconnect them from the ports.
11. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 4

! Danger
Danger of squashing! Do not stand or step
under loads being loaded.
Always secure the machine against unintend-
ed rolling!
12. Unscrew bolts 1 (Fig. 5) and nuts and remove the
front scraper (2).
13. Unscrew bolts (3) and nuts and remove the rear
scraper (4).

Fig. 5
14. Support the front cross-member safely with suita-
ble trestles or wooden blocks (Fig. 6).

Fig. 6
15. Support the rear cross-member safely with suita-
ble trestles or wooden blocks (Fig. 7).

Fig. 7

476 BOMAG 008 911 83

Removing and installing the drum 15.3
16. Disassemble bracket 1 (Fig. 8) for the hydraulic
hoses.

Fig. 8
17. Fasten the lifting gear to the side plate on the vi-
bration motor side.
18. Unscrew bolts 1 (Fig. 9) from the spacer blocks
on vibration and travel motors.

Fig. 9

!Danger
Danger of squashing! Do not stand or step
under loads being loaded.
19. Force out plug 1 (Fig. 10) and unscrew the bolts
(2) from the front and rear cross-members.
20. Take off the side plate.

Fig. 10
21. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 11).

!Danger
Danger of squashing! Do not stand or step
under loads being loaded.

Fig. 11

008 911 83 BOMAG 477

15.3 Removing and installing the drum

22. Check all rubber buffers (Fig. 12), replace if nec-

essary (see corresponding chapter).

Fig. 12
23. Check rectangular rubber buffers (Fig. 13), re-
place if necessary.

Fig. 13

Installing the drum

! Danger

Danger of squashing!
Do not stand or step under loads being load-
ed.
1. Place the drum into the frame and align it parallel
to the frame (Fig. 14).

Fig. 14

i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
2. Attach the side plate, insert the bolts 2 (Fig. 15)
into rear and front cross-members and tighten
with 463 Nm.
3. Close the screw holes with plugs (1).

Fig. 15

478 BOMAG 008 911 83

Removing and installing the drum 15.3
4. Fasten the spacer blocks on travel and vibration
motor sides with bolts 1 (Fig. 16) and nuts to the
side plates.

Fig. 16
5. Connect hydraulic hoses to the connections on
travel motor and vibration motor according to the
marking (Fig. 17).

Fig. 17
6. Fasten bracket 1 (Fig. 18) for the hydraulic hoses.

Fig. 18
7. Assemble the front scraper 2 (Fig. 19), fasten
with bolts (1), washers and nuts.
8. Assemble the rear scraper (4), fasten with bolts
(3), washers and nuts.

i Note
Observe the adjustment measurement 30-35 mm

Fig. 19

008 911 83 BOMAG 479

15.3 Removing and installing the drum

! Caution
Before resuming operation of the machine:
Bleed the hydraulic system and check for
function and leaks.
Adjust the pretension of the rubber buffers.
9. On the vibration drive side measure the distance
"X" between spacer block and side plate (Fig. 20).
10. Calculate the thickness of the compensation
plates.

Nominal value:

Fig. 20
Distance "X" + 2 mm

i Note
Compensation plates of 2 and 5 mm thickness
are available.
11. Turn in screws into each welded nut (Fig. 21) and
provide sufficient space to insert the compensa-
tion plates.

Fig. 21
12. Insert the compensation plates (Fig. 22).
13. Turn in the fastening screws.
14. Unscrew the screws from the welded nuts.
15. Tighten the fastening screws.

Fig. 22

480 BOMAG 008 911 83

Repairing the drum 15.4
15.4 Repairing the drum

Removing the travel motor

!Danger
Danger of squashing!
Do not stand or step under suspended loads.
1. Attach the lifting tackle to travel drive 3 (Fig. 3).
2. Unscrew all nuts (1) from the rubber buffers.
3. Take drive disc (2) with travel drive off the rubber
buffers and lay it down.

Fig. 1
4. Unscrew fastening screws 3 (Fig. 4) and take off
support legs (4).
5. Unscrew fastening screws 1 and take off drive
disc (2).

Fig. 2

Disassembling the exciter unit (travel

motor side)
1. Unscrew both socket head cap screws from the
flange (Fig. 3).

Fig. 3

008 911 83 BOMAG 481

15.4 Repairing the drum

2. Mount bracket 1 (Fig. 10) for the lifting device to

the flange.
3. Unscrew screws (2) from the flange.

i Note
Do not unscrew the thin drawn screws.

Fig. 4
4. Slide the lifting device over the bracket.
5. Force the exciter unit off with two forcing screws
(Fig. 5).

Fig. 5

! Danger
Danger of squashing!
Do not stand or step under suspended loads.
6. Pull the exciter unit out of the drum (Fig. 6).
7. Take the coupling element off the coupling half.

Fig. 6

482 BOMAG 008 911 83

Repairing the drum 15.4
Disassembling the exciter unit (travel
motor side)
1. Unscrew fastening screws 1 (Fig. 7) for the fan.
2. Loosen clamping screw (2).
3. Pull the coupling hub off the shaft.

Fig. 7
4. Unscrew all other fastening screws 1 (Fig. 8) from
the flange.
5. Press the flange off the flanged housing with forc-
ing screws (2).

Fig. 8

Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
6. Lift the flange off the flanged housing (Fig. 9).
7. Take the O-ring out of the groove in the flanged
housing.

Fig. 9

008 911 83 BOMAG 483

15.4 Repairing the drum

8. Unclip the circlip from the groove in the flange

(Fig. 10).

Fig. 10
9. Press the cylinder roller bearing with forcing
screws out of the flange (Fig. 11).

Fig. 11
10. Lift the exciter unit out of the flanged housing(Fig.
12).

Fig. 12
11. Knock the radial seal (Fig. 13) out of the flanged
housing.

Fig. 13

484 BOMAG 008 911 83

Repairing the drum 15.4
12. Unclip the circlip from the groove in the flanged
housing (Fig. 14).

Fig. 14
13. Press the cylinder roller bearing with forcing
screws out of the flanged housing (Fig. 15).

Fig. 15
14. Extract inner ring 1 (Fig. 16) for the radial seal
and inner bearing races (2).

! Danger
Danger of burning!
Wear safety gloves.

i Note
If the rings are very tight, heat them up with a
torch.

Fig. 16
15. Unclip the circlip from the basic weight (Fig. 17).

Fig. 17

008 911 83 BOMAG 485

15.4 Repairing the drum

16. To change shaft 1 (Fig. 18) knock out dowel pins

(2 and 3) and press the shaft out of the basic
weight.

i Note
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).

Fig. 18

Disassembling the exciter unit (vibra-

tion motor side)
1. Unscrew fastening screw 1 (Fig. 19).
2. Take rectangular rubber buffer (2) with spacer
block (3) off the side plate.

iNote
Remove both rectangular rubber buffers.

Fig. 19
3. Unscrew fastening screws 1 (Fig. 20).
4. Force cover (2) together with the attached vibra-
tion motor off the side plate with forcing screws.

Fig. 20

486 BOMAG 008 911 83

Repairing the drum 15.4
5. To change the vibration motor loosen clamping
screw 1 (Fig. 21) and pull off coupling half (2).

Fig. 21
6. Unscrew nut 1 (Fig. 22), take off conical socket
(2) and conical disc (3).
7. Take the vibration motor off the cover.

Fig. 22
8. Remove the coupling element (Fig. 23).

Fig. 23
9. Fasten the lifting device.
10. Unscrew fastening screws 1 (Fig. 24).

! Caution
The four short fastening screws (2) must re-
main screwed in (the two others are not visi-
ble).

Fig. 24

008 911 83 BOMAG 487

15.4 Repairing the drum

11. Press the exciter unit out of the drum with forcing
screws (Fig. 25).

i Note
The second forcing screw is covered by the side
plate.

Fig. 25

!Caution
Danger of squashing!
Do not stand or step under suspended loads.
12. Pull the exciter unit out of the drum (Fig. 26).

Fig. 26

Removing, dismantling the side plate

1. Take off V-ring 1 (Fig. 27).
2. Unclip circlip (2).

Fig. 27
3. Attach the disassembly device to the side plate
(Fig. 28) and force off the side plate.

Fig. 28

488 BOMAG 008 911 83

Repairing the drum 15.4
4. Lift the side plate of the flanged hub (Fig. 29).

Fig. 29
5. Knock the grooved roller bearing out of the side
plate (Fig. 30) and take out the spacer ring.

Fig. 30
6. Unclip the circlip from the side plate (Fig. 31).

Fig. 31
7. Take the mechanical seal off the flanged hub
(Fig. 32).

Fig. 32

008 911 83 BOMAG 489

15.4 Repairing the drum

Dismantling the exciter unit (vibration

motor side)
1. Unscrew the fastening from the coupling hub.
2. Pull coupling hub (2) off the shaft using a pulling
device (Fig. 33).

Fig. 33
3. Loosen hose clamp 1 (Fig. 34).
4. Pull coupling hub (2) off the shaft.

Fig. 34
5. Unscrew all other fastening screws 1 (Fig. 35)
and press the flanged hub off the flanged housing
with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged
housing.

Fig. 35

490 BOMAG 008 911 83

Repairing the drum 15.4
8. Unclip the circlip from the groove in the flanged
hub (Fig. 36).

Fig. 36
9. Knock the cylinder roller bearing out of the flang-
ed hub(Fig. 37).

Fig. 37

Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
10. Lift the exciter unit out of the flanged housing(Fig.
38).

Fig. 38
11. Knock the radial seal (Fig. 39) out of the flanged
housing.

Fig. 39

008 911 83 BOMAG 491

15.4 Repairing the drum

12. Unclip the circlip from the groove in the flanged

housing (Fig. 40).

Fig. 40
13. Press the cylinder roller bearing with forcing
screws out of the flanged housing (Fig. 41).

Fig. 41
14. Extract inner rings 1 (Fig. 42) for the radial seals
and inner bearing races (2) from the shaft.

!Danger
Danger of burning!
Wear protective gloves.

i Note
If the rings are very tight, heat them up with a
torch.

Fig. 42
15. Unclip the circlip from the basic weight and re-
move the cover (Fig. 43).

i Note
The shafts cannot be pressed out. If damaged
they must be replaced with basic weight and cov-
er.
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).

Fig. 43

492 BOMAG 008 911 83

Repairing the drum 15.4
Assembling the exciter unit (vibration
motor side)
! Caution
Ensure strict cleanliness.

i Note
If the shafts are damaged they must be inserted
into the basic weight or the cover as follows.

! Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
Fig. 44 nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.

! Caution
Close the bores on the short shaft with a
screw.
1. Cool the shaft down in liquid nitrogen.
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
44).
3. Secure shaft 1 (Fig. 45) with dowel pins (2 and 3).

! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.

i Note
Unscrew the screw from the shaft.

Fig. 45

! Caution
Close the bores on the short shaft with a
screw.
4. Cool the shaft down in liquid nitrogen.
5. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
46).

Fig. 46

008 911 83 BOMAG 493

15.4 Repairing the drum

6. Secure shaft 2 (Fig. 47) with dowel pins (1 and 3).

! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.

i Note
Unscrew the screw from the shaft.

Fig. 47
7. Insert the fitting key into the keyway in the respec-
tive shaft (Fig. 48).

Fig. 48
8. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 49).

Fig. 49

! Danger
Danger of burning!
Wear safety gloves.
9. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 50).

Fig. 50

494 BOMAG 008 911 83

Repairing the drum 15.4
! Danger

Danger of burning!
Wear safety gloves.
10. Heat the inner ring up to approx. 50° C and slide
it onto the short shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 51).

Fig. 51

!Danger
Danger of burning!
Wear safety gloves.
11. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 52).

Fig. 52

!Danger
Danger of burning!
Wear safety gloves.
12. Heat the inner ring up to approx. 50° C and slide
it onto the longer shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 53).

Fig. 53
13. Press cylinder roller bearing 1 (Fig. 54) with
pressing plate (2) into the flanged housing until it
bottoms.

Fig. 54

008 911 83 BOMAG 495

15.4 Repairing the drum

14. Insert the circlip into the groove in the flanged

housing (Fig. 55).

Fig. 55
15. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 56).
16. Fill approx. 1.2 l of oil SAE-15W/40 into the flang-
ed housing.

Fig. 56

!Caution
Danger of squashing!
Do not stand or step under suspended loads.
17. Insert the exciter unit with the longer shaft for-
ward into the flanged housing (Fig. 57).

Fig. 57
18. Press cylinder roller bearing 1 (Fig. 58) with
pressing plate (2) into the flanged hub until it bot-
toms.

Fig. 58

496 BOMAG 008 911 83

Repairing the drum 15.4
19. Insert the circlip into the groove in the flanged hub
(Fig. 59).

Fig. 59
20. Attach the flanged hub to the flanged housing
(Fig. 60).

! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
21. Unscrew eye bolts (1) and replace them with
short screws.
22. Turn short screws (2) into the tapped bores in the
flanged housing (four screws) and tighten them.

Fig. 60
23. Apply some grease to the sealing lip of radial seal
1 (Fig. 61).
24. Insert the radial seal into the flanged hub with the
sealing lip facing down and press it down against
the stop with pressing bushing (2).

Fig. 61

!Danger
Danger of burning!
Wear protective gloves.
25. Heat the coupling hub up to approx. 80 °C and
slide it onto the shaft against the stop (Fig. 62).

Fig. 62

008 911 83 BOMAG 497

15.4 Repairing the drum

26. Apply some grease to the sealing lip of radial seal

1 (Fig. 63).
27. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).

Fig. 63
28. Cover the thread of screw 1 (Fig. 64) with a screw
retention agent (Loctite CVX strong, blue, 582).
29. Slide on the new U-seal ring (2), turn in and tight-
en the screws.

Fig. 64

!Danger
Danger of burning!
Wear safety gloves.
30. Heat coupling hub 1 (Fig. 65) with marking letter
“L“ up to approx. 80° C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).

Fig. 65

498 BOMAG 008 911 83

Repairing the drum 15.4
Assembling and installing the side
plate
1. Fill grooved ball bearing 1 (Fig. 66) on both sides
with grease.
2. Press the grooved ball bearing completely in us-
ing pressing plate (2).

Fig. 66
3. Insert the circlip into the groove in the side plate
(Fig. 67).

Fig. 67
4. Apply a thick coat of grease to the spacer ring on
both sides and insert it into the side plate (Fig.
68).

Fig. 68

008 911 83 BOMAG 499

15.4 Repairing the drum

5. Fill grooved ball bearing 1 (Fig. 69) on one sides

with grease.
6. Insert the grooved ball bearing with the grease
side forward and press it completely in with
pressing plate (2).

i Note
Grease the other side after installing the exciter
unit.

Fig. 69
7. Insert the oiled loop-ring into the mechanical seal
(Fig. 70).
8. Clean the sliding surfaces of the mechanical seal
and cover them with oil.

Fig. 70
9. Lay one half of the radial seal on the flanged hub
with the sliding surface pointing up (Fig. 71).

Fig. 71
10. Lay the second half of the mechanical seal down
with the sliding face pointing down (Fig. 72).

Fig. 72

500 BOMAG 008 911 83

Repairing the drum 15.4
11. Bolt the threaded section of the assembly device
to the flanged hub (Fig. 73).

Fig. 73

! Caution
Danger of squashing! Do not stand or step
under suspended loads.
12. Lay the side plate on the flanged hub (Fig. 74).

Fig. 74
13. Attach bushing 2 (Fig. 75) of the assembly device
and turn on nut (1).

Fig. 75
14. Pull the side plate with the assembly device onto
the flanged hub.

! Caution
During assembly make sure that the mechan-
ical seal slides correctly into the side plate
and the loop rings are not damaged (Fig. 76).

Fig. 76

008 911 83 BOMAG 501

15.4 Repairing the drum

15. Remove the assembly device.

16. Insert the circlip into the groove in the flanged hub
(Fig. 77).

Fig. 77

Assembling the exciter unit (travel

motor side)
!Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.

! Caution
Ensure strict cleanliness.
1. Cool the shaft down in liquid nitrogen.
Fig. 78
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
78).
3. Secure shaft 1 (Fig. 79) with dowel pins (2 and 3).

! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.

Fig. 79

502 BOMAG 008 911 83

Repairing the drum 15.4
4. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 80).

Fig. 80

! Danger
Danger of burning!
Wear safety gloves.
5. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 81).

Fig. 81

! Danger
Danger of burning!
Wear safety gloves.
6. Heat the inner ring up to approx. 50° C and slide
it onto the shaft against the shoulder with the wid-
er chamfer facing towards the outside (Fig. 82).

Fig. 82

! Danger
Danger of burning!
Wear safety gloves.
7. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 83).

Fig. 83

008 911 83 BOMAG 503

15.4 Repairing the drum

8. Press cylinder roller bearing 1 (Fig. 84) with

pressing plate (2) into the flanged housing until it
bottoms.

Fig. 84
9. Insert the circlip into the groove in the flanged
housing (Fig. 85).

Fig. 85
10. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 86).
11. Fill approx. 1.2 l of oil SAE-15W/40 into the flang-
ed housing.

Fig. 86

! Caution
Danger of squashing! Do not stand or step
under suspended loads.
12. Insert the exciter unit into the flanged housing
(Fig. 87).

Fig. 87

504 BOMAG 008 911 83

Repairing the drum 15.4
13. Press cylinder roller bearing 1 (Fig. 88) with
pressing plate (2) into the flange until it bottoms.

Fig. 88
14. Insert the circlip into the groove in the flange (Fig.
89).

Fig. 89
15. Lift the flange onto the flanged housing and align
it the bores (Fig. 90).

! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.

Fig. 90
16. Turn the screws into the tapped bores of the
flanged housing and tighten them (Fig. 91).

Fig. 91

008 911 83 BOMAG 505

15.4 Repairing the drum

17. Apply some grease to the sealing lip of radial seal

1 (Fig. 92).
18. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).

Fig. 92
19. Cover the thread of screw 1 (Fig. 93) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
20. Slide on the new U-seal ring (2), turn in and tight-
en the screws.

Fig. 93
21. Insert the fitting key into the keyway of the shaft
(Fig. 94).

Fig. 94

!Danger
Danger of burning!
Wear safety gloves.
22. Slide the fan with assembly disc over the shaft.
23. Heat coupling hub 1 (Fig. 95) with marking letter
“R“ up t approx. 80° C and slide it over the shaft
against the shoulder.
24. Turn in and tighten clamping screw (2).
25. Assemble the fan to the coupling hub.

Fig. 95

506 BOMAG 008 911 83

Repairing the drum 15.4
Assembling the exciter unit (travel
motor side)
1. Check coupling elements , replace if necessary.
2. Insert the coupling element into the coupling hub
(Fig. 96).

! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
3. Fasten the lifting device to the exciter unit.

Fig. 96 ! Caution
Danger of squashing! Do not stand or step
under suspended loads.
4. Insert the vibrator unit into the drum (Fig. 97).

Fig. 97

i Note
Insert the exciter unit so that oil filler plug 1 (Fig.
98) is in line with bore (2) in the drum.

Fig. 98

008 911 83 BOMAG 507

15.4 Repairing the drum

5. Turn in and tighten screws 2 (Fig. 99).

6. Remove bracket (1) for the lifting device.

Fig. 99
7. Cover the thread of screws (Fig. 100) with a
screw retention agent (e.g. Loctite green 270).
8. Slide on the new U-seal ring, turn in and tighten
the screws.

Fig. 100

Installing the travel motor

1. Assemble drive disc 2 (Fig. 101) and support (4)
with screws (3).

Fig. 101

! Danger
Danger of squashing!
Do not stand or step under suspended loads.
2. Attach the drive disc 2 (Fig. 102) with the assem-
bled travel drive to the rubber buffers. Turn on
and tighten the nuts (1).

Fig. 102

508 BOMAG 008 911 83

Repairing the drum 15.4
Installing the exciter unit (vibration
motor side)

! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.

! Danger
Danger of squashing! Do not stand or step
under suspended loads.
1. Fasten the lifting gear to the exciter unit and insert
it into the drum (Fig. 103).

Fig. 103

! Caution
Ensure correct engagement of coupling and
alignment of shaft (Fig. 104).
If the shafts are not correctly in line determine
the cause, if necessary measure the drum.

Fig. 104
2. Turn in and tighten screws 1 (Fig. 105).
3. Remove the lifting gear.
4. Fit cover (2) to the drum.

Fig. 105

008 911 83 BOMAG 509

15.4 Repairing the drum

5. Check the end float of the exciter shafts (Fig.

106).

Nominal value: 0.6...1.8 mm

Fig. 106
6. Attach disc 1 (Fig. 107), turn in and tighten the
fastening screws (2).

Fig. 107
7. Lay a new V-ring over the journal of the flanged
hub (Fig. 108).
8. Fill the grooved ball bearing with grease.

Fig. 108
9. Check coupling element , replace if necessary.
10. Insert the coupling element into the coupling hub
(Fig. 109).

Fig. 109

510 BOMAG 008 911 83

Repairing the drum 15.4
11. Fasten the vibration motor to the cover so that
sockets 1 (Fig. 110) and ventilation bore (2) are
opposite each other.

Fig. 110
12. Slide on coupling half 2 (Fig. 111) and secure with
clamping screw (1).

Fig. 111
13. Attach the cover with the installed vibration mo-
tor, turn in and tighten the screws (Fig. 112).

Fig. 112
14. Install rectangular rubber buffers 2 (Fig. 113) with
attached spacer block (3) and screws (1) to the
side plate.

i Note
Assemble both rectangular rubber buffers.

Fig. 113

008 911 83 BOMAG 511

15.5 Dismantling, assembling the change-over weights

15.5 Dismantling, assembling the change-

over weights

Dismantling the change-over weight

1. Unscrew all screws (Fig. 3).

Fig. 1
2. Force the cover off the basic weight with forcing
screws (Fig. 4).

Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.

Fig. 2
3. Take the change-over weight out of the basic
weight (Fig. 5).

Fig. 3

512 BOMAG 008 911 83

Dismantling, assembling the change-over weights 15.5
4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.

Fig. 4

Assembling the change-over weights

!Caution
Ensure strict cleanliness.
1. Install new O-rings 1 and 2 (Fig. 5) with grease.

Fig. 5
2. Insert the change-over weight into the basic
weight (Fig. 6).

Fig. 6
3. Fill silicon oil 47 V 1000 cst up to the upper edge
of the change-over weight (approx. 2,5 litres) into
the basic weight (Fig. 12).

Fig. 7

008 911 83 BOMAG 513

15.5 Dismantling, assembling the change-over weights

4. Attach the cover (Fig. 13), so that the raised are-

as are in line.
5. Turn in screws with screw retention agent (e.g.
Loctite blue 243) and tighten with 120 Nm.
6. Check the end float of the shaft.

iNote
There must be play.

Fig. 8

514 BOMAG 008 911 83

Changing the rubber buffers and adjusting the pretension 15.6
15.6 Changing the rubber buffers and ad-
justing the pretension
Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buff-
ers and rectangular buffers are relieved of any
load (Fig. 1).
2. Loosen all fastening screws.

Fig. 1
3. Turn one screw each into the welded nuts (Fig. 2)
on the spacer blocks.

Fig. 2
4. Remove the compensation shims (Fig. 3).

Fig. 3

008 911 83 BOMAG 515

15.6 Changing the rubber buffers and adjusting the pretension

5. Unscrew the screws (Fig. 4) from the welded

nuts.

Fig. 4
Changing the rubber buffers
6. Unscrew nut 1 (Fig. 3) and remove the washer.
7. Unscrew screws (2).
8. Take off rubber buffer (3).
9. Attach the new rubber buffer to the drive disc and
align the bores to the tapped bores in the drum.
10. Turn in and tighten the fastening screws.
11. Assemble the washer, turn on and tighten the nut.

Fig. 5
Adjusting the pre-load
12. Measure distance „X“ between spacer piece and
side plate (Fig. 6).
13. Calculate the thickness of the compensation
plates.

Nominal value:
Distance „X“ + 2 mm

Fig. 6
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 7).

Fig. 7

516 BOMAG 008 911 83

Changing the rubber buffers and adjusting the pretension 15.6
15. Assemble the compensation shims (Fig. 8).

Fig. 8
16. Unscrew the screws (Fig. 9) from the welded
nuts.

Fig. 9
17. Tighten the fastening screws (Fig. 10).
18. Lower the frame again.

Fig. 10

008 911 83 BOMAG 517

15.6 Changing the rubber buffers and adjusting the pretension

518 BOMAG 008 911 83

16 Oscillating articulated joint

008 911 83 BOMAG 519

16.1 Special tools

16.1 Special tools

1. Pressing mandrel for rocker bearings

Fig. 1
2. Pressing sleeve for outer race of rocker bearing

Fig. 2
3. Pressing sleeve for inner race of rocker bearing

Fig. 3
4. Guide journal

Fig. 4

520 BOMAG 008 911 83

Special tools 16.1
5. Clamping device

Fig. 5
6. Disassembly device

Fig. 6

008 911 83 BOMAG 521

16.2 Repair overview oscillating articulated joint

Fig. 1
1 Housing 12 Cover
2 Seal ring 13 Cover
3 Cover 14 Intermediate ring
4 Self-aligning bearing 15 Self-aligning bearing
5 Bolt 16 Intermediate ring
6 Shim/supporting disc 17 Self-aligning bearing
7 Belleville springs 18 Beam
8 Self-aligning bearing 19 Friction bearing
9 Console 20 V-ring
10 Belleville springs 21 Seal ring
11 Shim/supporting disc

522 BOMAG 008 911 83

Repair overview oscillating articulated joint 16.2

Fig. 2

008 911 83 BOMAG 523

16.2 Repair overview oscillating articulated joint

Fig. 3

524 BOMAG 008 911 83

Removing and installing the oscillating articulated joint 16.3
16.3 Removing and installing the oscillat-
ing articulated joint
1. Jack up the frame (Fig. 1) at the back and secure
it with trestles or wooden blocks.

Fig. 1
2. Support the rear frame near the oscillating articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.

Fig. 2
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).

Fig. 3

008 911 83 BOMAG 525

16.3 Removing and installing the oscillating articulated joint

4. Unscrew fastening screws 1 (Fig. 4) and take off

axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).

Fig. 4

!Danger
Danger of accident!
7. Support the oscillating articulated joint in the mid-
dle with a suitable jack or a similar device.
8. Unscrew fastening screws 1 (Fig. 5) and take off
with disc (2).

Fig. 5
9. Unscrew nuts 3 (Fig. 6) and take off the clamping
washers (2).
10. Pull out the fastening screws (1).
11. Slightly raise the front frame and lower the oscil-
lating articulated joint to the ground.
12. Pull out the oscillating articulated joint.

Fig. 6
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).

Fig. 7

526 BOMAG 008 911 83

Dismantling the oscillating articulated joint 16.4
16.4 Dismantling the oscillating articulated
joint
1. Unscrew the nuts from hexagon screw 1 (Fig. 1)
and pull out the hexagon screw.
2. Unscrew the screws (2) for the cover.

Fig. 1
3. Take off the cover with Belleville springs, shim
and backing disc (Fig. 2).
4. Disassemble also the cover from the opposite
side.

i Note
No Belleville springs, shim and backing disc are
under this cover.

Fig. 2
5. Drive the console with a plastic hammer to one
side against the end stop (Fig. 3).

i Note
The outer race of the rocker bearing is thereby
stripped off.

Fig. 3

008 911 83 BOMAG 527

16.4 Dismantling the oscillating articulated joint

6. Force inner race 1 (Fig. 4) of the rocker bearing

off the bolt.
7. Take of supporting disc (2).
8. Drive the console to the opposite side and re-
move the rocker bearing in the same way.

Fig. 4
9. Unscrew fastening screws 1 (Fig. 5).
10. Press bolt (3) out of the console with forcing
screws (2).

i Note
Remove the bolt on the opposite side in the same
way.

Fig. 5
11. Lift console 1 (Fig. 6) off housing (2).

Fig. 6
12. Take the seal rings out of the console (Fig. 7).

Fig. 7

528 BOMAG 008 911 83

Dismantling the oscillating articulated joint 16.4
13. Remove the cover from the housing.
14. Take off shims 1 (Fig. 8), backing disc (2) and
Belleville springs (3).

Fig. 8
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).

Fig. 9
16. Take the intermediate ring out of the housing
(Fig. 10).

Fig. 10
17. Place the plate 1 (Fig. 11) on the beam.
18. Attach the puller (2) to the housing (3) and sepa-
rate the carrier from the rocker bearings.

Fig. 11

008 911 83 BOMAG 529

16.4 Dismantling the oscillating articulated joint

19. Pull the housing off the beam (Fig. 12).

Fig. 12
20. Drive the outer race of the friction bearing out of
the housing (Fig. 13).

Fig. 13
21. Drive the friction bearing out of the housing (Fig.
14).

Fig. 14
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.

Fig. 15

530 BOMAG 008 911 83

Dismantling the oscillating articulated joint 16.4
23. Check rocker bearings, if necessary press out of
the housing (Fig. 16).

Fig. 16

008 911 83 BOMAG 531

16.5 Assembling the oscillating articulated joint

16.5 Assembling the oscillating articulated

joint
1. If previously disassembled, press the rocker
bearing fully into the housing with a pressing
mandrel (Fig. 1).

i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly

! Caution
Do not use any grease.

Fig. 1
2. Slide the new V-ring on the beam against the stop
with the lip facing up (Fig. 2).

Fig. 2
3. Lay the seal ring into the beam (Fig. 3).
4. Fill the space between V-ring and seal ring with
multi-purpose grease.

Fig. 3

532 BOMAG 008 911 83

Assembling the oscillating articulated joint 16.5
5. Press the friction bearing fully into the housing
with the chamfered side pointing towards the out-
side (Fig. 4).

Fig. 4
6. Slide the housing over the beam (Fig. 5).

i Note
The journal on the housing must be centrally in
the recess of the beam.

Fig. 5
7. Press the seal ring carefully towards the inside,
until it sits in the recess of the housing (Fig. 6).

Fig. 6
8. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.

! Caution
Do not use any grease.
9. Press the outer rocker bearing race 1 (Fig. 7) in
until it bottoms with the wider outer rim forward
using pressing sleeve (2).

Fig. 7

008 911 83 BOMAG 533

16.5 Assembling the oscillating articulated joint

10. Press inner rocker bearing race 1 (Fig. 8) in until

it bottoms, using pressing sleeve (2).

Fig. 8
11. Insert the intermediate ring (Fig. 9).

Fig. 9
12. Press inner rocker bearing race 1 (Fig. 10) in until
it bottoms, using pressing sleeve (2).

Fig. 10

i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly

! Caution
Do not use any grease.
13. Press the outer rocker bearing race 1 (Fig. 11) in
until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).

Fig. 11

534 BOMAG 008 911 83

Assembling the oscillating articulated joint 16.5
14. Press in intermediate ring 1 (Fig. 12) until it bot-
toms.
15. Attach cover (2) with the machined edge forward.
16. Turn in screws (3) and tighten crosswise.

Fig. 12
Determining the shim thickness
17. Determine the shim thickness, for this purpose
stand the cross-member on a wooden board with
an ∅ 18 mm bore.

! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
Fig. 13 tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.

i Note
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thick-
ness.

Calculation example:
4,7 mm - 4,0 mm = 0,7 mm
measured value: 4,7 mm
fixed value: 4,0 mm
Shim thickness: 0,7 mm
20. Remove the tensioning device.

008 911 83 BOMAG 535

16.5 Assembling the oscillating articulated joint

21. Insert shim 2 (Fig. 14) of appropriate thickness

and backing disc (1) into the cover.

Fig. 14
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).

Fig. 15
23. Assemble cover 2 (Fig. 16) with Belleville springs,
shim and backing disc.
24. Turn in screws (1) and tighten crosswise.

Fig. 16
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).

Fig. 17

536 BOMAG 008 911 83

Assembling the oscillating articulated joint 16.5
26. Lift console 1 (Fig. 18) over the housing (2).

Fig. 18
27. Turn four guide pins into the housing bores (Fig.
19).

Fig. 19

i Note
Perform the following eight work steps on both
sides.
28. Slide the bolt over the guide pins (Fig. 20) and
drive in until it bottoms.

Fig. 20

! Caution
When driving in the bolt make sure that the
seal ring is not pressed out through the back
of the console (Fig. 21).

Fig. 21

008 911 83 BOMAG 537

16.5 Assembling the oscillating articulated joint

29. Unscrew the guide pins .

30. Turn in the screws and tighten with 75 Nm (Fig.
22).

Fig. 22
31. Slide the backing discs over the bolt (Fig. 23).

Fig. 23
32. Drive the inner rocker bearing race on against the
end stop with the wider outer rim forward (Fig.
24).

Fig. 24
33. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.

! Caution
Do not use any grease.
34. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.

Fig. 25

538 BOMAG 008 911 83

Assembling the oscillating articulated joint 16.5
35. Attach cover 1 (Fig. 26) to the bottom side of the
console.
36. Turn in and tighten screws (2).

Fig. 26
Determining the shim thickness
37. Determine the shim thickness, for this purpose in-
sert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.

! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.

Fig. 27
38. Measure the distance from outer rocker bearing
race to console surface (Fig. 28) and write it
down, e.g. 3.4 mm.

i Note
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thick-
ness.

Calculation example:
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
Fig. 28 fixed value: 2,2 mm
Shim thickness: 1.2 mm
39. Remove the tensioning device.

008 911 83 BOMAG 539

16.5 Assembling the oscillating articulated joint

40. Insert shims 2 (Fig. 29) of appropriate thickness

and backing disc (1) into the cover.

Fig. 29
41. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 30).

Fig. 30
42. Assemble cover 1 (Fig. 31) with Belleville springs,
shims and supporting discs.
43. Turn in screws (2) and tighten crosswise.

Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.

Fig. 32

540 BOMAG 008 911 83

Assembling the oscillating articulated joint 16.5
45. Assemble the washer, turn on and tighten the nut
with 120 Nm (Fig. 33).

Fig. 33

008 911 83 BOMAG 541

16.5 Assembling the oscillating articulated joint

542 BOMAG 008 911 83

17 Suppliers documentation

008 911 83 BOMAG 543

544 BOMAG 008 911 83
17.1 Travel pump series 90R

008 911 83 BOMAG 545

17.1 Travel pump series 90R

546 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90

Axial Piston
Pumps and Motors
Service Manual

008 911 83 BOMAG 547

17.1 Travel pump series 90R

Series 90 Introduction
Introduction

Use of this Manual

This manual includes information for the normal opera- Since dirt and contamination are the greatest enemies of
tion, maintenance, and servicing of the Series 90 family any type of hydraulic equipment, cleanliness require-
of hydrostatic pumps and motors. ments must be strictly adhered to. This is especially
important when changing the system filter and during
The manual also includes the description of the units and adjustment and repair activities.
their individual components, troubleshooting informa-
tion, adjustment instructions, and minor repair proce- For further information refer to Series 90 Technical
dures. Unit warranty obligations should not be affected if Information. For information about fluid requirements
maintenance, adjustment, and minor repairs are per- refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id No.
formed according to the procedures described in this 697581).
manual.
A worldwide network of SAUER-SUNDSTRAND Autho-
Many service and adjustment activities can be performed rized Service Centers is available should repairs be
without removing the unit from the vehicle or machine. needed. Contact any SAUER-SUNDSTRAND Autho-
However, adequate access to the unit must be available, rized Service Center for details. A list of all Service
and the unit must be thoroughly cleaned before beginning Centers can be found in bulletin BLN-2-400527, or in
maintenance, adjustment, or repair activities. brochure SAW (Ident. No. 698266).

Safety Precautions

Observe the following safety precautions when using and servicing hydrostatic products.

Loss of Hydrostatic Braking Ability Fluid under High Pressure

WARNING WARNING
The loss of hydrostatic drive line power in any Use caution when dealing with hydraulic fluid
mode of operation (e.g., forward, reverse, or "neu- under pressure. Escaping hydraulic fluid under
tral" mode) may cause the loss of hydrostatic pressure can have sufficient force to penetrate
braking capacity. A braking system, redundant to your skin causing serious injury. This fluid may
the hydrostatic transmission must, therefore, be also be hot enough to burn. Serious infection or
provided which is adequate to stop and hold the reactions can develop if proper medical treat-
system should the condition develop. ment is not administered immediately.
S000 001E S000 003E

Disable Work Function Flammable Cleaning Solvents

WARNING WARNING
Certain service procedures may require the ve- Some cleaning solvents are flammable. To avoid
hicle/machine to be disabled (wheels raised off possible fire, do not use cleaning solvents in an
the ground, work function disconnected, etc.) area where a source of ignition may be present.
while performing them in order to prevent injury S000 004E

to the technician and bystanders.

S000 005E

Copyright 1987-1998, SAUER-SUNDSTRAND GmbH & Co. S90MVCTCD

S90PVMFCD
All rights reserved. Contents subject to change.

548 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Contents
Contents

Introduction ......................................................................................................................................................................... 2
Use of this Manual ........................................................................................................................................................................................ 2
Safety Precautions ........................................................................................................................................................................................ 2
Functional Description ....................................................................................................................................................... 5
General Description and Cross Sectional Views ......................................................................................................................................... 5
Variable Displacement Pumps ................................................................................................................................................................ 5
Fixed Displacement Motor ..................................................................................................................................................................... 5
Variable Displacement Motor .................................................................................................................................................................. 6
The System Circuit ....................................................................................................................................................................................... 7
The Basic Closed Circuit ........................................................................................................................................................................ 7
Case Drain and Heat Exchanger ........................................................................................................................................................... 7
Common Features of Pumps and Motors .................................................................................................................................................... 8
End Caps and Shafts ............................................................................................................................................................................. 8
Speed Sensors ....................................................................................................................................................................................... 8
Pump Features ............................................................................................................................................................................................. 9
Charge Pump .......................................................................................................................................................................................... 9
Charge Relief Valve ................................................................................................................................................................................. 9
Multi-Function Valves .............................................................................................................................................................................. 9
Pressure Limiter and High Pressure Relief Valves ....................................................................................................................... 10
System Check Valves .................................................................................................................................................................... 10
Bypass Valves ................................................................................................................................................................................ 10
Displacement Limiters .......................................................................................................................................................................... 11
Auxiliary Mounting Pads ....................................................................................................................................................................... 11
Filtration Options ................................................................................................................................................................................... 11
Pressure Override (POR) - 180 Frame Size Only ............................................................................................................................. 12
Pump Control Options .......................................................................................................................................................................... 13
Manual Displacement Control (MDC) ........................................................................................................................................... 13
Hydraulic Displacement Control (HDC) ........................................................................................................................................ 13
Electric Displacement Control (EDC) ............................................................................................................................................ 14
Automotive Control (FBA II B) ....................................................................................................................................................... 14
3-Position (FNR) Electric Control .................................................................................................................................................. 14
Motor Features ........................................................................................................................................................................................... 15
Motor Loop Flushing Valve and Charge Relief Valve ........................................................................................................................... 15
Variable Motor Displacement Limiters .................................................................................................................................................. 15
Variable Motor Controls ........................................................................................................................................................................ 16
Hydraulic 2-Position Control .......................................................................................................................................................... 16
Electric 2-Position Control .............................................................................................................................................................. 16
Technical Specifications .................................................................................................................................................. 17
General Specifications ................................................................................................................................................................................ 17
Circuit Diagrams ......................................................................................................................................................................................... 17
Hydraulic Parameters ................................................................................................................................................................................. 18
Size Specific Data ....................................................................................................................................................................................... 19
Pressure Measurement ................................................................................................................................................... 20
Required Tools ............................................................................................................................................................................................ 20
Port Locations and Pressure Gauge Installation ....................................................................................................................................... 20
Variable Pump ....................................................................................................................................................................................... 20
Fixed Motor ........................................................................................................................................................................................... 23
Variable Motor ....................................................................................................................................................................................... 24
Initial Start-Up Procedure ................................................................................................................................................ 25
Fluid and Filter Maintenance ........................................................................................................................................... 26
Troubleshooting ................................................................................................................................................................ 27
"NEUTRAL" Difficult or Impossible to Find ................................................................................................................................................. 27
System Operating Hot ................................................................................................................................................................................ 27
Transmission Operates Normally in One Direction Only .......................................................................................................................... 28
System Will Not Operate in Either Direction .............................................................................................................................................. 28
Low Motor Output Torque ........................................................................................................................................................................... 29
Improper Motor Output Speed .................................................................................................................................................................... 29
Excessive Noise and/or Vibration .............................................................................................................................................................. 30
System Response is Sluggish .................................................................................................................................................................... 30

008 911 83 BOMAG 549

17.1 Travel pump series 90R

Series 90 Contents
Inspections and Adjustments ......................................................................................................................................... 31
Pump Adjustments ...................................................................................................................................................................................... 31
Charge Pressure Relief Valve Adjustment ........................................................................................................................................... 31
Multi-Function Valve Pressure Adjustment .......................................................................................................................................... 33
Engaging the Bypass Function ............................................................................................................................................................ 35
Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) ....................................................................... 36
Displacement Limiter Adjustment ......................................................................................................................................................... 37
Pump Control Adjustments ......................................................................................................................................................................... 38
Standard Manual Displacement Control (MDC) Adjustment .............................................................................................................. 38
Non-Linear Manual Displacement Control (MDC) .............................................................................................................................. 39
MDC Neutral Start Switch (NSS) Adjustments .................................................................................................................................... 40
Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment ....................................................... 46
Motor Adjustments ...................................................................................................................................................................................... 48
Charge Relief Valve Adjustment ........................................................................................................................................................... 48
Displacement Limiter Adjustment (MV) ................................................................................................................................................ 49
Displacement Control Adjustments ...................................................................................................................................................... 49
Speed Sensor Adjustment .......................................................................................................................................................................... 50
Minor Repair Instructions ................................................................................................................................................ 51
Pump and Motor Minor Repair .................................................................................................................................................................... 53
Pump / Fitting Torques .......................................................................................................................................................................... 53
Shaft Seal and Shaft Replacement ...................................................................................................................................................... 54
Pump Minor Repairs ................................................................................................................................................................................... 56
Multi-Function Valve Cartridges ........................................................................................................................................................... 56
Pressure Override Valve (Option for 180 Frame Size) ....................................................................................................................... 57
Charge Relief Valve ............................................................................................................................................................................... 57
Charge Pump - Remove ...................................................................................................................................................................... 58
Installing the Charge Pump .................................................................................................................................................................. 60
Auxiliary Pad Installation ....................................................................................................................................................................... 62
Auxiliary Pad Conversion ..................................................................................................................................................................... 63
Filtration Options ................................................................................................................................................................................... 64
Pump controls ....................................................................................................................................................................................... 65
Cover Plate ..................................................................................................................................................................................... 65
Manual Displacement Control (MDC) ........................................................................................................................................... 66
Solenoid Override Valve for MDC .................................................................................................................................................. 67
Solenoid Override Valve for MDC with Pressure Released Brake .............................................................................................. 67
Hydraulic and Electric Displacement Controls ............................................................................................................................. 68
Pressure Control Pilot (PCP) for Electric Displacement Control .................................................................................................. 68
3-Position (FNR) Electric Control .................................................................................................................................................. 69
Displacement Control Components ............................................................................................................................................... 69
Minor Repair - Motor ................................................................................................................................................................................... 71
Loop Flushing and Charge Relief Valves ............................................................................................................................................. 71
Variable Motor Displacement Limiters .................................................................................................................................................. 73
Variable Motor Controls ............................................................................................................................................................................... 74
Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND) ..................................................................................................... 74
Hydraulic 2-Position Control (Type PT) ............................................................................................................................................... 74
Control Plugs ........................................................................................................................................................................................ 74
Variable Motor Control Orifices ............................................................................................................................................................ 75
Speed Sensor .............................................................................................................................................................................................. 77
Exploded View Parts Drawings / Parts Lists .................................................................................................................. 78
Variable Pumps ........................................................................................................................................................................................... 78
Minor Repair Parts ................................................................................................................................................................................ 78
Parts List ............................................................................................................................................................................................... 79
Variable Pump Controls ........................................................................................................................................................................ 80
Control Parts List .................................................................................................................................................................................. 81
Filter and Options ................................................................................................................................................................................. 82
Parts List Filter and Options ................................................................................................................................................................. 83
Name Plates ......................................................................................................................................................................................... 83
Fixed Motor ................................................................................................................................................................................................. 84
Minor Repair Parts ................................................................................................................................................................................ 84
Parts List ............................................................................................................................................................................................... 85
Name Plates ......................................................................................................................................................................................... 85
Variable Motor .............................................................................................................................................................................................. 86
Minor Repair Parts ................................................................................................................................................................................ 86
Parts List ............................................................................................................................................................................................... 87
Name Plate ............................................................................................................................................................................................ 87

550 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Functional Description

Functional Description
This section describes the operation of pumps, motors, and their various serviceable features. It is a useful reference for
readers unfamiliar with the functioning of a specific system.

General Description and Cross Sectional Views

Variable Displacement Pumps

The Variable Displacement Pump (PV) is designed to

convert an input torque into hydraulic power. The input
shaft turns the pump cylinder which contains a ring of
pistons. The pistons run against a tilted plate, called the
swashplate. This causes the pistons to compress the
hydraulic fluid which imparts the input energy into the
hydraulic fluid. The high pressure fluid is then ported out
to provide power to a remote function.

The swashplate angle can be varied by the control piston.

Altering the swashplate angle varies the displacement of
fluid in a given revolution of the input shaft.
F000 539
Series 90 Variable Displacement Pump (PV)

Slider Block
Servo Arm
Servo Valve
Cradle Hold Down
Servo Piston

Feed Back

Cradle Bearing

Cradle
Cradle Leveler
Cradle Guide
Charge Pump

P001 413E
Series 90 PV Cross Section

Fixed Displacement Motor

The Fixed Displacement Motor (MF) is designed to

convert an input of hydraulic power into an output torque.
It operates in the reverse manner of the pump. The high
pressure hydraulic fluid enters through the input port. The
fluid pressure builds behind the pistons causing them to
move down the swashplate (the path of least resistance).
As the piston returns up the swashplate again, the fluid is
allowed to exit through the exit port. The spinning pistons
are housed in a cylinder which is connected to the output
shaft. The output torque can be applied to a mechanical
function.
90000347
Series 90 Fixed Displacement Motor (MF)

008 911 83 BOMAG 551

17.1 Travel pump series 90R

Series 90 Functional Description

In the Fixed Displacement Motor the "swashplate" is

Loop Flushing Valve fixed, so any variation in motor speed and torque must be
Valve Plate Piston made by the input mechanism, i.e. the pump.
Roller Bearing

Output Shaft

Fixed Swashplate
End Cap Cylinder Block

90000190E
Series 90 MF Cross Section

Variable Displacement Motor

The Variable Displacement Motor (MV) operates in the

same manner as the fixed motor. However, its swashplate
is not fixed; it can be switched between minimum and
maximum angle to amplify torque or speed like the
Variable Displacement Pump.

90000348
Series 90 Variable Displacement Motor (MV)

Minimum Angle
Valve Plate Piston Control Piston
End Cap
Roller Bearing
Cradle Swashplate
Output Shaft

"A" "A" Partial Section "A-A"

Cradle Swashplate in Full
Displacement Position

Cradle Swashplate

Cylinder Block
Electric 2-Position Control (optional) Maximum Angle
Control Piston

90000234E
Series 90 MV Cross Section

552 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Functional Description

The System Circuit

System loop (low pressure)

Control Handle Displacement Control Valve
Case drain fluid
Heat Exchanger System loop (high pressure)
Bypass Valve

Orificed Reservoir
Control fluid
Check Valve
Vacuum Gauge
Suction line
Heat Exchanger

Charge Pressure Purge Relief Valve

Multi-Function Relief Valve
Servo Control Valve
Variable Cylinder Fixed Displacement
Displacement Motor
Pump

to Pump
Case
Servo Pres.
Relief Valve

Charge Pump
Input
Output Shaft
Shaft
Multi-Function Valve Motor Swashplate
Pump Swashplate Servo Control
Cylinder Loop Flushing Valve

Pump Fixed Motor

90000800E

Circuit Diagram for Series 90 PV and 90 MF

The Basic Closed Circuit

The main ports of the pump are connected by hydraulic

lines to the main ports of the motor. Fluid flows, in either
direction, from the pump to the motor then back to the
pump in this closed circuit. Either of the hydraulic lines
can be under high pressure. In pumping mode the
position of the pump swashplate determines which line is
high pressure as well as the direction of fluid flow.

Case Drain and Heat Exchanger

The pump and motor require case drain lines to remove Reservoir
hot fluid from the system. The motor should be drained
from its topmost drain port to ensure the case remains full Input Output
PV MF
of fluid. The motor case drain can then be connected to
the lower drain port on the pump housing and out the top
most port. A heat exchanger, with a bypass valve, is
required to cool the case drain fluid before it returns to the
reservoir.

Flow (Bi-directional)

Case Drain Line

90000803E
Basic Closed Circuit

008 911 83 BOMAG 553

17.1 Travel pump series 90R

Series 90 Functional Description

Common Features of Pumps and Motors

End Caps and Shafts

Series 90 pumps and motors can be supplied with a

variety of end caps and shafts to allow for almost any
configuration. For pumps, end caps are available with
system ports on either side ("side ports") or both ports on
one side ("twin ports"). Motors have end caps with ports
on the face of the end cap ("axial ports") or both ports on
one side ("twin ports"). See the Series 90 Technical
Information manuals (BLN-10029 and BLN-10030) or the
Series 90 Price Book (BLN-2-40588) for information on
available options.

Removing the end cap will void the warranty on a

Series 90 pump or motor.

Speed Sensors

An optional speed sensor can be installed on Series 90

pumps and motors to provide unit speed information. The
sensor reads a magnetic ring wrapped about the unit's
cylinder. See the corresponding Section to locate, install
and adjust the sensor.

90000810
Speed Sensor

554 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Functional Description

Pump Features

Charge Pump

The charge pump is necessary to supply cool fluid to the

system, to maintain positive pressure in the main system
loop, to provide pressure to operate the control system,
and to make up for internal leakage. Charge pressure
must be at its specified pressure under all conditions of
driving and braking to prevent damage to the transmis-
sion.

The charge pump is a fixed-displacement, gerotor type

pump installed in the variable displacement pump and
driven off the main pump shaft. Charge pressure is limited
by a relief valve.
90000243
The standard charge pump will be satisfactory for most
PV with Charge Pump
applications. However, if the charge pump sizes available
for the given main pump size are not adequate, a gear
pump may be mounted to the auxiliary mounting pad and Case
supply the required additional charge flow. Drain
Charge Relief Valve
Line
System
Charge Relief Valve Check
Valves
The charge relief valve on the pump serves to maintain Input PV PF
charge pressure at a designated level. A direct-acting
poppet valve relieves charge pressure whenever it sur- Charge
Pump
passes a certain level. This level is nominally set refer-
encing case pressure at 1500 rpm. This nominal setting
assumes the pump is in neutral (zero flow); in forward or
reverse charge pressure will be lower. The charge relief
valve setting is specified on the model code of the pump.
Inlet Filter

Tank

90000804E
Pump Charge System

Multi-Function Valves

The multi-function valve incorporates

the system check valve,
the pressure limiter valve,
the high pressure relief valve and
the bypass valve

in a replaceable cartridge.

These functions are described separately. There are two

multi-function valve cartridges in each Series 90 pump to
handle functions in either direction. See corresponding
Sections for adjustments and repairs.

NOTE: Some multi-function valves do not include a 90000243

pressure limiter valve. Multi-Function Valve

008 911 83 BOMAG 555

17.1 Travel pump series 90R

Series 90 Functional Description

Pressure Limiter and High Pressure Relief Valves

Series 90 pumps are designed with a sequenced pres-

Pressure Limiter Housing High Pressure sure limiting system and high pressure relief valves.
Relief / check Check Valve When the preset pressure is reached, the pressure limiter
Pressure Limiter Valve Poppet Poppet
Lock Nut
system acts to rapidly destroke the pump so as to limit the
system pressure. For unusually rapid load application,
the high pressure relief valve acts to immediately limit
Pressure Limiter system pressure by cross-porting system flow to the low
Adjustment Screw
pressure side of the loop. The pressure limiter valve acts
as the pilot for the high pressure relief valve spool. The
high pressure relief valve is sequenced to operate at
Bypass approximately 35 bar (500 psi) above the level that ini-
Actuator Pressure Limiter Bypass tiates the pressure limiter valve.
Valve Poppet
Both the pressure limiter sensing valves and relief valves
are built into the multi-function valves (see above).
90000806E
NOTE: For some applications, such as dual path ve-
Cross Section of Multi-Function Valve
hicles, the pressure limiter function may be de-
feated so that only the high pressure relief valve
function remains.

System Check Valves

The system check valves allow pressurized flow from the

charge pump to enter the low pressure side of the loop
whenever system pressure dips below a certain level.
To Control This is needed as the pump will generally lose system
pressure due to leakage and other factors. Since the
Multi-Function Valve pump can operate in either direction, two system check
valves are used to direct the charge supply into the low
pressure lines. The system check valves are poppet
Servo Piston Bypass
Adjustment
valves located in the multi-function valve assembly.
Port "A"
Bypass Valves
Servo Pres.
Relief Valve
The bypass valves ("tow") can be operated when it is
Port "B"
desired to move the vehicle or mechanical function when
Servo Piston the pump is not running. The valve is opened by manually
Charge Pressure
Relief Valve
resetting the valve position.

Multi-Function Valve The bypass valves are built into the multi-function valves.
90000801E
Circuit Diagram showing Pressure
Control Mechanism

10

556 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Functional Description

Displacement Limiters

All Series 90 pumps are designed for optional mechanical

displacement (stroke) limiters. The maximum displace-
ment of the pump can be limited in either direction.

The setting can be set as low as 0° in either direction.

For instructions on adjustment see corresponding Sec-

tion.

90000244
Auxiliary Mounting Pads PV with Displacement Limiters

Auxiliary mounting pads are available on all Series 90

pumps. SAE A through E mounts are available (availabil-
ity varies by pump size). This pad is used for mounting
auxiliary hydraulic pumps and for mounting additional
Series 90 pumps to make tandem pumps. The pads allow
for full through-torque capability.

90000242
Filtration Options PV with Auxillary Mounting Pad

All Series 90 pumps are available with provisions for

either suction or charge pressure filtration (integral or
remote mounted) to filter the fluid entering the charge
circuit.

Suction Filtration

The suction filter is placed in the circuit between the

reservoir and the inlet to the charge pump. When suction
filtration is used, a reducer fitting is placed in the charge
pressure gauge port (M3). Filtration devices of this type
are provided by the user.
90000243
PV with Suction Filtration
(No filtration device attached)
Charge Pressure Filtration

The pressure filter may be integrally mounted directly on

the pump or a filter may be remotely mounted for ease of
servicing.

A 125 m screen, located in the reservoir or the charge

inlet line, is recommended when using this filtration
option.

90000246 90000247
PV with Integral Charge PV with Remote Charge
Pump Pump

11

008 911 83 BOMAG 557

17.1 Travel pump series 90R

Series 90 Functional Description

Pressure Override (POR) - 180 Frame Size Only
To Control

The pressure override valve (POR) modulates the control

pressure to the displacement control to maintain a pump
Multi-Function Valve
displacement which will produce a system pressure level
less than or equal to the POR setting. For unusually rapid
load application, the high pressure relief valve function of
Pressure
Override Control Valve Bypass the multifunction valves is available to also limit the
Adjustment
pressure level.
Port "A"

Shuttle
The pressure override consists of a three-way normally
Valve open valve which operates in series with the pump
Port "B" displacement control. Control supply pressure is nor-
mally ported through the pressure override valve to the
displacement control valve for controlling the pump's
displacement. If the system demands a pressure above
the override setting, the POR valve will override the
Multi-Function Valve Charge Pressure
Relief Valve control by reducing the control pressure supplied to the
displacement control. As the control pressure reduces,
the internal forces tending to rotate the swashplate
90000802E overcome the force of the servo pistons and allow the
POR-Valve (180 Frame Size only) pump's displacement to decrease.

12

558 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Functional Description

Pump Control Options

Manual Displacement Control (MDC)

The manual displacement control converts a mechanical input signal to a hydraulic signal using a spring- centered four-
way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates
the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement
in one direction to full displacement in the opposite direction.

The MDC is designed so the angular position of the pump swashplate is proportional to the rotation of the control input
shaft.

Non-Linear MDC

The non-linear manual displacement control operates in

the same manner as the regular MDC except that it is
designed so the change in the angular position of the
pump swashplate progressively increases as the control
input shaft is rotated toward its maximum displacement
position.

Solenoid Override Valve for MDC

A solenoid override valve option (not shown here) is

available for MDC. This safety feature will return the 90000237
swashplate to zero displacement position when acti- PV with Manual Displacement Control
vated. The valve may be set in either a normally open or
normally closed mode.

Neutral Start Switch (NSS)

The neutral start switch is an optional feature available

with MDC. When connected properly with the vehicle’s
electrical system, the neutral start switch ensures that the
prime mover can be started only when the control is in a
neutral position.

90000239
PV with Manual Displacement Control and
Hydraulic Displacement Control (HDC) Neutral Start Switch

The hydraulic displacement control uses a hydraulic input

signal to operate a spring-centered four-way servo valve.
This valve ports hydraulic pressure to either side of a
dual-acting servo piston. The servo piston rotates the
cradle swashplate through an angular rotation of ±17°,
thus varying the pump’s displacement from full displace-
ment in one direction to full displacement in the opposite
direction. The HDC is designed so the angular position of
the pump swashplate is proportional to input pressure.

90000240
PV with Hydraulic Displacement Control

13

008 911 83 BOMAG 559

17.1 Travel pump series 90R

Series 90 Functional Description

Electric Displacement Control (EDC)

The electric displacement control is similar to the hydrau-

lic displacement control with the input signal pressure
controlled by a pressure control pilot (PCP) valve. The
PCP valve converts a DC electrical input signal to a
hydraulic signal which operates a spring- centered four-
way servo valve. This valve ports hydraulic pressure to
either side of a dual-acting servo piston. The servo piston
rotates the cradle swashplate through an angular rotation
of ±17°, thus varying the pump’s displacement from full
displacement in one direction to full displacement in the
90000241 opposite direction. The control is designed so the angular
PV with Electric Displacement Control position of the swashplate is proportional to the EDC
input.

Automotive Control (FBA II B)

Automotive Control allows a vehicle to be driven in a

manner similar to an automobile with an automatic trans-
mission.

The Automotive Control includes a three-position electric

control to provide direction control.

3-Position (FNR) Electric Control

This control utilizes a 12 or 24 VDC electrically operated

spool valve to port pressure to either side of the pump
displacement control piston. Energizing one of the sole-
noids will cause the pump to go to its maximum displace-
ment in the corresponding direction.

All functions of the three-position (FNR) electric control

are preset at the factory.

90000354
PV with 3-Position (FNR) Electric Control

14

560 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Functional Description

Motor Features

Motor Loop Flushing Valve and Charge Relief

Valve

All Series 90 motors are designed to accommodate a loop

flushing valve. The loop flushing valve is used in instal-
lations which require additional fluid to be removed from
the main hydraulic circuit because of transmission cool-
ing requirements, or unusual circuits requiring additional
loop flushing to remove excessive contamination in the
high pressure circuit. 90000248
Loop Flushing Valve (MF)
A shuttle valve and charge relief valve are installed in the
motor end cap to provide the loop flushing function. The
shuttle valve provides a circuit between the low pressure
side of the closed loop and the charge relief valve in the
motor end cap.

The motor charge relief valve regulates the charge pres- Top of Motor Charge Relief Valve
sure level only when there is a pressure differential in the
main loop. The shuttle valve is spring centered to the
closed position so that no high pressure fluid is lost from
the circuit when reversing pressures.

For charge relief valve adjustment see corresponding

Section.

Loop Flushing Shuttle Valve End Cap

90000238E

Motor Charge Relief Valve and Loop Flushing

Shuttle Valve

Variable Motor Displacement Limiters

All Series 90 variable motors include mechanical dis-

placement (stroke) limiters. Both the maximum and mini-
mum displacement of the motor can be limited.

The range of the settings is as follows:

055 MV 075 MV

Minimum 19 - 40 cm3 26 - 54 cm3

Displacement 1.2 - 2.4 in3 1.6 - 3.3 in3 90000352
Maximum MV Maximum Displacement Limiter
65 - 100 % 65 - 100 % (Minimum Displacement Limiters on opposite side)
Displacement
T002 251E

15

008 911 83 BOMAG 561

17.1 Travel pump series 90R

Series 90 Functional Description

Variable Motor Controls

Hydraulic 2-Position Control

This control utilizes a hydraulically operated three-way

hydraulic valve to port system pressure to either of the
motor displacement control pistons. The motor is nor-
mally held at its maximum displacement. Supplying pilot
hydraulic pressure to the valve will cause the motor to go
to its minimum displacement.

90000350
MV with Hydraulic 2-Position Control

Electric 2-Position Control

This control utilizes an electric solenoid operated three-

way hydraulic valve to port system pressure to either of
the motor displacement control pistons. The motor is
normally held at its maximum displacement. Energizing
the solenoid will cause the motor to go to its minimum
displacement.

90000351
MV with Electric 2-Position Control

16

562 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Technical Specifications

Technical Specifications

General Specifications

Design Port Connections

(for details see chapter "Pressure Measurement")
Variable Pumps and Motors: Axial piston pump of vari-
able displacement, cradle swashplate design. Main pressure ports: SAE flange, Code 62,
Remaining ports: SAE straight thread O-ring boss.
Fixed Motors: Axial piston motor with fixed displacement,
fixed swashplate design. Direction of Rotation

Type of Mounting (per SAE J744) Clockwise or counterclockwise (motors are bi-directional)

SAE flange, Size "B", 2 bolts, Recommended Installation Position

SAE flange, Size "C and E", 4 bolts.
Pump installation recommended with control position on
Cartridge flange, 2 bolts (for motor only). the top or side. Consult SAUER-SUNDSTRAND for non-
conformance guidelines. The housing must always be
filled with hydraulic fluid.

Circuit Diagrams

L2 M3

A M1

M3
Vg max
X5
A
M1
M5
M4

B M2
L1
M2
B
MV with Electrohydraulic 2-Position
Control
L1 S L2

PV with Charge Pump and Manual

Displacement Control L2 M3

A M1

B M2

L1

90000811
MF 90000812
90000813

17

008 911 83 BOMAG 563

17.1 Travel pump series 90R

Series 90 Technical Specifications

Hydraulic Parameters

Temperature Range1)
System Pressure Range bar psi
°C [°F]
Minimum -40 [-40] intermittent, cold start
Rated Pressure 420 6000
Rated 104 [220]
Maximum 115 [240] intermittent
Maximum Pressure 480 6960
T002 006E
1)
T002 252E At the hottest point, normally the case
drain port.

Charge Pump Inlet Vacuum Viscosity

bar abs in Hg
(on pumps only) mm2/s [SUS]
Minimum Vacuum Minimum 7 [49] intermittent
0.7 10 Recommended
(continuous) 12-60 [70-278]
operating range
Minimum Vacuum during intermittent,
Cold Start 0.2 25 Maximum 1600 [7500]
cold start
(Intermittent) T002 010E

T002 253E

Cleanliness Level and β x-Ratio

Case Pressure bar psi Required fluid cleanliness
ISO 4406 Class 18/13
level
Maximum (Continuous) 3 44 Recommended βx-ratio
for suction filtration β35-45=75 (β10≥2)
Recommended βx-ratio
Maximum during Cold Start β15-20=75 (β10≥10)
5 73 for charge pressure
(Intermittent) filtration
Recommended inlet
T002 254E
screen size for charge 100 m-125 m
pressure filtration
T002 007E

Hydraulic Fluid Cleanliness

Refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id Refer to SAUER-SUNDSTRAND Publications BLN 9887
No. 697581). Also refer to publication ATI-E 9101 for or SDF (NO. 697581) and ATI-E 9201.
information relating to biogradable fluids.

Refer to Series 90 technical information for definitions.

18

564 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Technical Specifications

Size Specific Data

Variable Displacement Pumps

Dimension 030 PV 042 PV 055 PV 075 PV 100 PV 130 PV 180 PV 250 PV

3
Displacement cm 30 42 55 75 100 130 180 250
(maximum) in3 1.83 2.56 3.35 4.57 6.10 7.93 10.98 15.25

Minimum Speed min-1 (rpm) 500 500 500 500 500 500 500 500

Rated Speed min-1 (rpm) 4200 4200 3900 3600 3300 3100 2600 2300

Maximum Speed min-1 (rpm) 4600 4600 4250 3950 3650 3400 2850 2500

Maximum attainable Speed

min-1 (rpm) 5000 5000 4700 4300 4000 3700 3150 2750
at max. Displacement
Theoretical Torque at Nm/bar 0.48 0.67 0.88 1.19 1.59 2.07 2.87 3.97
max. Displacement lbf in/1000 psi 290 380 530 730 870 1260 1750 2433
Weight kg 28 34 40 49 68 88 136 154
(only base unit) lb 62 75 88 108 150 195 300 340
T002 257E

Fixed and Variable Displacement Motors

Einheit 030 MF 042 MF 055 MF 075 MF 100 MF 130 MF 055 MV 075 MV

3
cm 30 42 55 75 100 130 55 75
Displacement (maximum)
in3 1.83 2.56 3.35 4.57 6.10 7.93 3.35 4.57
cm3
Displacement (minimum) -- -- -- -- -- -- 19 26
in3
at maximum
min-1 (rpm) 4200 4200 3900 3600 3300 3100 3900 3600
Rated displacement
speed at minimum
min-1 (rpm) -- -- -- -- -- -- 4600 4250
displacement
at maximum
min-1 (rpm) 4600 4600 4250 3950 3650 3400 4250 3950
Maximum displacement
speed at minimum
min-1 (rpm) -- -- -- -- -- -- 5100 4700
displacement
Max. attainable speed at
min-1 (rpm) 5000 5000 4700 4300 4000 3700 4700 4300
max. displacement
Theoretical torque at max. Nm/bar 0.48 0.67 0.88 1.19 1.59 2.07 0.88 1.19
displacement lbf in/1000 psi 290 380 530 730 970 1260 530 730
Maximum flow ar max. l/min 138 193 234 296 365 442 234 296
displacement gal/min 36.5 51 62 78 96 117 62 78
kW 111 155 187 237 292 354 224 282
Max. corner power
hp 149 208 251 318 392 475 300 378
Weight kg 11 15 22 26 34 45 39 44
SAE-Flange lb 24 34 49 57 74 99 86 98
Weight kg 21 26 33 40 46
-- -- --
Cartridge Motor lb 46 57 72 88 101
T002 258E

Refer to Series 90 technical information for definitions.

19

008 911 83 BOMAG 565

17.1 Travel pump series 90R

Series 90 Pressure Measurement

Pressure Measurement

Required Tools

The service procedures described in this manual for Pressure gauges should be calibrated frequently to en-
Series 90 pumps and motors can be performed using sure accuracy. Snubbers are recommended to protect
common mechanic's tools. Special tools, if required are pressure gauges.
shown.

Port Locations and Pressure Gauge Installation

The following sections list the ports for each type of Outline drawings showing port locations follow the tables
hydraulic unit. The recommended pressure gauge and below.
fitting are also specified.

Variable Pump

Gauge Size Gauge Size

Port Function and Port Function and
Fitting
Fitting
System Pressure 1000 bar or 10 000 psi
M1 L1 Case Pressure
Port "A" 9/16-18 O-ring 10 bar or 100 psi
L2
System Pressure 1000 bar or 10 000 psi
M2 030
Port "B" 9/16-18 O-ring fitting 7/8-14 O-ring
M3 50 bar or 1000 psi 042
Charge Pressure
(M6) 9/16-18 O-ring 055
M4 50 bar or 1000 psi 075 1-1/16-12 O-ring
Servo Pressure 100
M5 9/16-18 O-ring
T002 259E 130 1-5/16-12 O-ring
180
1-5/8-12 O-ring
250
50 bar or 1000 psi
X1 HDC / EDC 7/16-20 O-ring
X2 Control Pressure or
9/16-18 O-ring
External Control 50 bar or 1000 psi
X3
Pressure 9/16-18 O-ring
S Charge Pump Inlet Vacuum Gauge, Tee into
Inlet Line
030
1-1/16-12 O-ring
042
055
1-5/16-12 O-ring
075
100
130 1-5/8-12 O-ring
180
1-1/2 SAE-Split
250 Flange
T002 260E

20

566 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Pressure Measurement

Servo / Displacement
Cylinder Pressure
Gauge Port M4
Case Drain
Port L1

System Pressure
Port B

Servo / Displacement
Cylinder Pressure
Gauge Port M5

Top View

90000814E

System Pressure
Port B External Control Pressure
System Pressure Supply Port X3
Gauge Port M2 Speed Sensor

Charge Inlet Pressure

System Pressure
Gauge Port M1

Carge Pump
Inlet Port S System Pressure Case Drain Port L2 Charge Pressure
Port A Gauge Port M3

Left Side View Right Side View

90000815E
90000816E

PV with Side Port End Cap and Manual Displacement Control

21

008 911 83 BOMAG 567

17.1 Travel pump series 90R

Series 90 Pressure Measurement

Servo / Displacement
Cylinder Pressure
System Pressure Gauge Port M4
Case Drain
Gauge Port M2 Port L1

System Pressure
Port B

Charge Pump Inlet

Port S

System Pressure
Port A
System Pressure Servo / Displacement
Gauge Port M1 Cylinder Pressure
Case Drain Port L2 Gauge Port M5
Top View
Left Side View

90000819E
90000820E

PV with Twin Port End Cap and Manual Displacement Control

Charge Pressure
Gauge Port M6
(before the filter)

Port E
(from filter)
Port D
(to filter)

Charge Pressure
Gauge Port M3
Charge Pressure
(after the filter)
Gauge Port M3
(after the filter)
Rear View Rear View

90000817E
90000818E

PV with Side Port End Cap and Remote Pressure Filtration PV with Side Port End Cap and Integral Pressure Filtration

22

568 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Pressure Measurement

Fixed Motor

Gauge Size Gauge Size

Port Function and Port Function and
Fitting Fitting
System Pressure 1000 bar or 10 000 psi L1 Case Pressure)
M1 10 bar or 500 psi
Port "A" 9/16-18 O-ring L2
System Pressure 1000 bar or 10 000 psi 030
M2
Port "B" 9/16-18 O-ring 042 7/8-14 O-ring
M3 50 bar or 1000 psi 055
Charge Pressure
9/16-18 O-ring 075
T002 261E 100 1-1/16-12 O-ring
130
T002 262E

System Pressure
Gauge Port M1
Charge Pressure System Pressure
Gauge Port M3 Gauge Port M2 Case Drain Port L1

System Pressure Port B

Speed Sensor
System Pressure Port A Case Drain Port L2

Rear View Left Side View

MF with SAE Flange

System Pressure
Gauge Port M1
Charge Pressure System Pressure Case Drain Port L1
Gauge Port M3 Gauge Port M2

Speed Sensor
System Pressure Port B
System Pressure Port A Case Drain Port L2

Rear View Left Side View

90000821E

MF with Cartridge Flange

23

008 911 83 BOMAG 569

17.1 Travel pump series 90R

Series 90 Pressure Measurement

Variable Motor

Gauge Size Gauge Size

Port Function and Port Function and
Fitting Fitting
Systempressure 1000 bar or 10 000 psi Control Cylinbder
M1 1000 bar or 10 000 psi
Port "A" 9/16-18 O-ring M4 Pressure "Minimum
7/16-20 O-ring
Systempressure 1000 bar or 10 000 psi Displacement"
M2
Port "B" 9/16-18 O-ring Control Cylinbder
1000 bar or 10 000 psi
M3 50 bar or 1000 psi M5 Pressure"Maximum
Charge Pressure 7/16-20 O-ring
9/16-18 O-ring Displacement"
T002 263E L1 10 bar or 500 psi
Case Pressure
L2 1-1/16-12 O-ring
T002 264E

Displacement Control
Cylinder Pressure
Gauge Port M4
System Pressure Min. Displacement
Gauge Port M2
Control Pressure Displacement Control
Port X1 Cylinder Pressure
(Hydraulic 2-Position Control) Gauge Port M5
Max. Displacement
(Earlier Production -
Not available as gauge
port with servo orifices)

System Pressure Port B Displacement Control

Cylinder Pressure
Gauge Port M5
Max. Displacement
(Newer Production)
Left Side View

MV with Cartridge Flange and Hydraulic 2-Position Control (SAE Flange Version Similar)

Case Drain Port L1

System Pressure
Gauge Port M1

charge Pressure
Gauge Port M3
(Same position as in MF)

Speed Sensor

System Pressure Port A

Case Drain Port L2

Right Side View

90000823E

MV with SAE Flange (Cartridge Flange Version Similar)

24

570 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Initial Start-Up Procedure

Initial Start-Up Procedure

The following start-up procedure should always be fol- connections for EDC) be disconnected at the pump
lowed when starting-up a new Series 90 installation or control until after initial start-up. This will ensure that the
when restarting an installation in which either the pump or pump remains in its neutral position.
motor had been removed.

WARNING WARNING
The following procedure may require the vehicle/ Do not start prime mover unless pump is in neutral
machine to be disabled (wheels raised off the ground, position (0° swashplate angle). Take precautions to
work function disconnected, etc.) while performing prevent machine movement in case pump is actuated
the procedure in order to prevent injury to the during initial start up.
technician and bystanders. Take necessary safety S000 008E

precautions before moving the vehicle/machine.

S000 007E

“Jog” or slowly rotate prime mover until charge pressure

starts to rise. Start the prime mover and run at the lowest
Prior to installing the pump and/or motor, inspect the units possible RPM until charge pressure has been estab-
for damage incurred during shipping and handling. Make lished. Excess air may be bled from the high pressure
certain all system components (reservoir, hoses, valves, lines through the high pressure system gauge port.
fittings, heat exchanger, etc.) are clean prior to filling with
fluid. Once charge pressure has been established, increase
speed to normal operating RPM. Charge pressure should
Fill the reservoir with recommended hydraulic fluid. This be as indicated in the pump model code. If charge
fluid should be passed through a 10 micron (nominal, no pressure is inadequate, shut down and determine cause
bypass) filter prior to entering the reservoir. The use of for improper pressure. Refer to Troubleshooting.
contaminated fluid will cause damage to the components,
which may result in unexpected vehicle/machine move-
ment. See the publications BLN-9887 and SDF 697581 WARNING
for further related information. Take necessary precautions that the motor shaft
remains stationary during the adjustment
The inlet line leading from the reservoir to the pump must procedure.
be filled prior to start-up. Check inlet line for properly S000 010E
tightened fittings and make sure it is free of restrictions Shut down the prime mover and connect the external
and air leaks. control input signal. Also reconnect the machine function
if disconnected earlier. Start the prime mover, checking
Be certain to fill the pump and/or motor housing with to be certain the pump remains in neutral. With the prime
clean hydraulic fluid prior to start up. mover at normal operating speed, slowly check for for-
ward and reverse machine operation.
Fill the housing by pouring filtered oil into the upper case
drain port. Charge pressure may slightly decrease during forward or
reverse operation. Continue to cycle slowly between
Install a 50 bar (or 1000 psi) pressure gauge in the charge forward and reverse for at least five minutes.
pressure gauge port to monitor the charge pressure
during start-up. Shut down prime mover, remove gauges, and plug ports.
Check reservoir level and add filtered fluid if needed.
It is recommended that the external control input signal
(linkage for MDC, hydraulic lines for HDC, or electrical The transmission is now ready for operation.

25

008 911 83 BOMAG 571

17.1 Travel pump series 90R

Series 90 Fluid and Filter Maintenance

Fluid and Filter Maintenance

To ensure optimum service life of Series 90 products,

regular maintenance of the fluid and filter must be per-
formed. Contaminated fluid is the main cause of unit
Mano- failure. Care should be taken to maintain fluid cleanliness
Vacuummeter while performing any service procedure.

Hydraulic fluid reservoir Check the reservoir daily for proper fluid level, the pres-
ence of water (noted by a cloudy to milky appearance, or
Filter free water in bottom of reservoir), and rancid fluid odor
(indicating excessive heat). If either of these conditions
Charge pump
occur, change the fluid and filter immediately.

It is recommended that the fluid and filter be changed

per the vehicle/machine manufacturer’s recommenda-
Adjustable
Charge pressure relief valve
tions or at the following intervals:
to low
pressure
side and First change
control To pump case

500 operating hours after start up

second and subsequent changes

P000 797E

Suction Filtration Schematic every 2000 operating hours or once a year.

This recommendation applies for the most applications.

High temperatures and pressures will result in acceler-
ated fluid aging and an earlier fluid change may be
required. At lower fluid loads longer change intervalls are
Screen possible. Therefore we suggest to check the fluid with the
manufacturer for suitability. This should be done at latest
half way between fluid changes.
Hydraulic fluid reservoir
Adjustable
Charge pressure It may be necessary to change the fluid more frequently
relief valve than the above intervals if the fluid becomes contami-
nated with foreign matter (dirt, water, grease, etc.) or if
Charge pump
the fluid has been subjected to temperature levels greater
than the recommended maximum. Never reuse fluid.
to low
pressure To pump case The filter should be changed whenever the fluid is changed
side and
control or whenever the filter indicator shows that it is necessary
to change the filter.
Filter

Cleanliness Level and β x-Ratio

Required fluid cleanliness
ISO 4406 Class 18/13
level
P000 798E Recommended βx-ratio
for suction filtration β35-45=75 (β10≥2)
Charge Pressure Filtration Schematic Recommended βx-ratio
(Partial flow) for charge pressure β15-20=75 (β10≥10)
filtration
Recommended inlet
screen size for charge 100 m-125 m
pressure filtration
T002 007E

26

572 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Toubleshooting
Troubleshooting
This section provides general steps to follow if certain undesirable system conditions are observed. Follow the steps in
a section until the problem is solved. Some of the items will be system specific. For areas covered in this manual, a section
is referenced. Always observe the safety precautions listed in the section "Introduction" and related to your
specific equipment.

"NEUTRAL" Difficult or Impossible to Find

Check Description Action

1. Input to pump control. Input to control module is operating Check control input and repair or re-
improperly. place as necessary.

2. Pump displacement control. Control linkages are not secure, control Adjust, repair, or replace control mod-
orifices are blocked, etc. ule as necessary.

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

System Operating Hot

Check Description Action

1. Oil level in reservoir. Insufficient hydraulic fluid will not meet Fill reservoir to proper level.
cooling demands of system.

2. Heat exchanger. Heat exchanger not sufficiently cooling Check air flow and input air tempera-
the system. ture for heat exchanger. Clean, repair
or replace heat exchanger.

3. Charge pressure. Low charge pressure will overwork sys- Measure charge pressure. Inspect and
tem. adjust or replace charge relief valve. Or
repair leaky charge pump.

4. Charge pump inlet vacuum. High inlet vacuum will overwork sys- Check charge inlet vacuum. If high,
tem. A dirty filter will increase the inlet inspect inlet filter and replace as neces-
vacuum. Inadequate line size will re- sary. Check for adequate line size,
strict flow. length or other restrictions.

5. System relief pressure settings. If the system relief settings are too low, Verify settings of pressure limiters and
the relief valves will be overworked. high pressure relief valves and adjust
or replace multi-function valves as nec-
essary.
6. For internal leakage in motor.
Leakage will reduce low side system Monitor motor case flow without loop
pressure and overwork the system. flushing in the circuit (use defeat spool).
If flow is excessive, replace motor.

7. System pressure. High system pressure will overheat Measure system pressure. If pressure
system. is high reduce loads.

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

27

008 911 83 BOMAG 573

17.1 Travel pump series 90R

Series 90 Toubleshooting
Transmission Operates Normally in One Direction Only

Check Description Action

1. Input to pump control. Input to control module is operating Check control input and repair or re-
improperly. place as necessary.

2. Pump displacement control. Control linkages are not secure, control Repair or replace control module as
orifices are blocked, etc. necessary.

3. Interchange system pressure limit- Interchanging the multi-function valves Interchange multi-function valves. If the
ers, high pressure relief valves, and will show if the problem is related to the problem changes direction, repair or
system check valves. valve functions contained in the multi- replace the valve on the side that does
function valves. not operate.

4. Charge pressure. If charge pressure decays in one direc- Measure charge pressure in forward
tion the loop flushing valve may be and reverse. If pressure decays in one
“sticking” in one direction. direction, inspect and repair the motor
loop flushing valve.
If the above actions do not remedy the problem
contact a SAUER-SUNDSTRAND Authorized Service Center.

System Will Not Operate in Either Direction

Check Description Action

1. Oil level in reservoir. Insufficient hydraulic fluid to supply Fill reservoir to proper level.
system loop.

2. Input to pump control. Input to control module is operating Check control input and repair or re-
improperly. place as necessary.

3. Pump displacement control. Control linkages are not secure, control Repair or replace control module as
orifices are blocked, etc. necessary.

4. Ensure bypass valve(s) are closed. If bypass valve(s) is open, the system Close bypass valves. Replace multi-
loop will be depressurized. function valve if defective.

5. Charge pressure with pump in neu- Low charge pressure insufficient to re- Measure charge pressure with the pump
tral. charge system loop. in neutral. If pressure is low, go to step
6; otherwise continue with step 5.

6. Charge pressure with pump in Low charge pressure with the pump in Measure charge pressure with pump in
stroke. stroke indicates a motor charge relief stroke. If pressure is low, adjust or
valve or system pressure relief valve replace motor charge relief valve, oth-
may be improperly set. erwise go to step 9.

7. Pump charge relief valve. A pump charge relief valve that is leaky Adjust or replace pump charge relief
or set too low will depressurize the valve as necessary.
system.

8. Charge pump inlet filter. A clogged filter will undersupply system Inspect filter and replace if necessary.
loop.

9. Charge pump. A malfunctioning charge pump will pro- Repair or replace the charge pump. If
vide insufficient charge flow. OK go to last step.

28

574 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Toubleshooting
10. Pump displacement control. Control linkages are not secure, control Repair or replace control module as
orifices are blocked, etc. necessary.

11. System pressure. Low system pressure will not provide Measure system pressure. Continue
power necessary to move load. with next step.

12. System multi-function valves. Defective multi-function valves will Repair or replace multi-function valve(s).
cause system pressure to be low.

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

Low Motor Output Torque

Check Description Action

1. System pressure at motor. Low system pressure at the motor will Measure system pressure at motor. If
reduce torque. pressure limiter setting is low, increase
setting.

2. Variable motor stuck at minimum Minimum motor displacement yields low Check control supply pressure or re-
displacement. output torque. pair displacement control. Check mo-
tor control orifices.

3. For internal leakage. Internal leakage will reduce system Check for leakage in O-rings, gaskets,
pressure. and other fittings. Repair unit as re-
quired, or replace leaky unit.

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

Improper Motor Output Speed

Check Description Action

1. Oil level in reservoir. Insufficient hydraulic fluid will reduce Fill oil to proper level.
motor speed.

2. Pump output flow. Incorrect outflow will affect output Measure pump output and check for
speed. Incorrect output flow indicates proper pump speed and see that the
the swashplate is out of position. pump is in full stroke.

3. Variable motor displacement con- If variable motor displacement control See if variable motor displacement con-
trol. is not functioning correctly, variable trol is responding. If not, repair or re-
motor swashplate may be in wrong place control.
position.

4. For internal leakage. Internal leakage will reduce system Check for leakage in O-rings, gaskets,
pressure. and other fittings. Repair unit as re-
quired, or replace leaky unit.

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

29

008 911 83 BOMAG 575

17.1 Travel pump series 90R

Series 90 Toubleshooting
Excessive Noise and/or Vibration

Check Description Action

1. Oil in reservoir. Insufficient hydraulic fluid will lead to Fill reservoir to proper level.
cavitation.

2. Air in system. Air bubbles will lead to cavitation. Look for foam in reservoir. Check for
leaks on inlet side of system loop. After-
wards, let reservoir settle until bubbles
are gone. Run system at low speed to
move system fluid to reservoir. Repeat.

3. Pump inlet vacuum. High inlet vacuum will create noise. A Inspect and replace filter as necessary.
dirty filter will increase the inlet vacuum. Check for proper suction line size.

4. Shaft couplings. A loose shaft coupling will cause exces- Replace loose shaft coupling in charge
sive noise. pump or replace pump or motor.

5. Shaft alignment. Unaligned shafts will create excessive Align shafts.

frictional noise.

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

System Response is Sluggish

Check Description Action

1. Oil level in reservoir. Insufficient hydraulic fluid will reduce Fill reservoir to proper level.
output pressure.

2. Multi-function valves’ pressure set- Incorrect pressure settings will affect Adjust or replace multi-function valves.
tings. system reaction time.

3. Pump inlet vacuum. High pump inlet vacuum will reduce Measure charge inlet vacuum. If high
system pressure. replace inlet filter.

4. Prime mover speed. Low engine speed will reduce system Adjust engine speed.
performance.

5. Charge and control pressures. Incorrect charge or control pressures Measure charge and control pressures
will affect system performance. and correct if necessary.

6. System internal leakage. Internal leakage will reduce system Check for leakage in O-rings, gaskets,
pressure. and other fittings.

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

30

576 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Inspections and Adjustments

Inspections and Adjustments
This section offers instruction on how to perform inspections and adjustments on pump and motor components. Read
through the entire related section before beginning a service activity. Refer to the corresponding section for location of
gauge ports and suggested gauge size.

Pump Adjustments
Charge Pressure Relief Valve Adjustment

The following procedure explains how to check and adjust

the charge pressure relief valve.

WARNING
The following procedure may require the vehicle/
machine to be disabled (wheels raised off the ground,
work function disconnected, etc.) while performing
the procedure in order to prevent injury to the
technician and bystanders. Take necessary safety
precautions before moving the vehicle/machine.
S000 007E

90000243
Charge Pressure Gauge Port (Reducer fitting shown - if
filtration device attached)
1. To measure pump charge pressure, install a pres-
sure gauge in the pump charge pressure gauge port
(M3). Also install a gauge to measure case pressure
(tee into L1 or L2 or use servo gauge port). Operate
the system with the pump in “neutral” (zero displace-
ment) when measuring pump charge pressure. Nominal
90L055 EA 1 N Charge Pressure
2. The table shows the acceptable pump charge pres- 6 S 3 C6 C 03
sure range for some nominal charge relief valve HNN 35 35 24
settings (see sample model code at right). These
pressures assume 1500 pump rpm and a reservoir Model Code on Unit Name Plate (“24 bar”)
temperature of 50°C (120°F ), and are referenced to
case pressure (see footnote on next page). Smaller
displacement charge pumps will produce charge
pressure readings in the lower portion of the range, Model Code Measured Charge Pressure *
while larger displacement charge pumps will produce 18.1 bis 21.7 bar
readings in the higher portion of the range. 20
(262 to 315 psi)
22.0 bis 26.9 bar
24
(319 to 390 psi)
25.8 bis 30.7 bar
28
(374 to 445 psi)
T002 266E
* This is the actual charge pressure port gauge reading minus the
case pressure port gauge reading.

Note: These pressures assume a pump speed of

1450 - 1500 rpm. At higher pump input speeds
(with higher charge flows) the charge pressure
will rise over the rated setting.

* This is the actual charge pressure port gauge reading minus

the case pressure port gauge reading.

31

008 911 83 BOMAG 577

17.1 Travel pump series 90R

Series 90 Inspections and Adjustments

3. Earlier production Series 90 pumps are equipped

with a shim adjustable charge pressure relief valve.
Shim kits are available from SAUER-SUNDSTRAND.
Adjustment of charge pressure is accomplished by
removing the plug [1 inch Hex] and changing the shim
thickness behind the spring. The plug for this type of
charge relief valve should be torqued to 68 Nm
(50 lbf ft).

Later production Series 90 pumps are equipped with

90000262 90000264 an external screw adjustable charge pressure relief
Shim Adjustable Charge Screw Adjustable Charge valve. Adjustment of the charge pressure is accom-
Pressure Relief Valve Pressure Relief Valve plished by loosening the lock nut -
(Pump) (Pump)
Frame Size Wrench Size
030 - 100 1-1/16 inch
130 - 250 1-5/8 inch
T002 267E

and turning the adjustment plug with a large screw-

driver or a 1/2 inch hex wrench.

Clockwise rotation of the plug increases the setting,

and counterclockwise rotation decreases the setting
(at a rate of approximately 3.9 bar (50 psi) per turn).
The lock nut for this type of charge relief valve should
be torqued to 52 Nm (39 lbf ft).

4. Once the desired charge pressure setting is achieved,

remove the gauges.

32

578 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Inspections and Adjustments

Multi-Function Valve Pressure Adjustment

Adjustment of the pressure limiter setting and the high

pressure relief valve setting is accomplished simulta-
neously. The latter is automatically set approximately
35 bar (500 psi) above the former.

In order to adjust the pressure limiter setting, the motor

output shaft must be locked so it does not rotate. This
may be accomplished by locking the vehicle’s brakes or
rigidly fixing the work function so it cannot rotate.

WARNING
Take necessary precautions that the motor shaft
remains stationary during the adjustment procedure.
S000 010E
90000258
Multi-Function Valves on PV

1. Install two 1000 bar (or 10 000 psi) pressure gauges

in the high pressure gauge ports (M1 and M2). Install
a 50 bar (or 1000 psi) pressure gauge in the pump
charge pressure gauge port (M3).

2. Start the prime mover and operate at normal speed.

3. Loosen locking nut.

Frame Size Wrench Size

early
10 mm
042 - 100
newer
19 mm
030 - 100
early 130 13 mm
130 - 250 24 mm
T002 268E

4. Insert a internal hex wrench into the pressure adjust-

ing screw.

Frame Size Internal Hex Wrench Size

early 90000259
3 mm
042 - 100 Loosen Pressure Adjusting Screw Lock Nut
newer
5 mm
030 - 100
early 130 4 mm
130 - 250 8 mm
T002 269E

Note: A plastic dust plug is installed in the adjusting

screw on 030 and late 042 through 250 units.

33

008 911 83 BOMAG 579

17.1 Travel pump series 90R

Series 90 Inspections and Adjustments

90L055 EA 1 N 5. The factory preset pressure limiter setting is shown
on the model code as at right. It is referenced to
6 S 3 C6 C 03 charge pressure, so the pressure limiter setting is the
HNN 35 35 24 difference between the high and low pressure sides
of the system loop. Activate or move the control input
so that pressure increases in the high pressure side
Pressure Limiter Setting
of the closed circuit to the pressure limiter pressure
Ports A and B (differential setting. The pressure limiter setting is reached when
pressure in 10s of bars, the pressure stops increasing and remains steady at
e.g. “35” = 350 bar) a given pressure level (as shown on the gauges).

6. Return the pump to its “neutral” (zero flow) position

and adjust the pressure limiter setting by rotating the
pressure adjusting screw with the internal hex wrench.

Clockwise rotation of the pressure adjustment screw

will increase the pressure setting, and counterclock-
wise rotation will decrease the pressure setting. Each
complete rotation of the pressure adjusting screw
changes the pressure as shown in the following table.

Approx Change per Rev of the

Frame Size
Adjusting Screw
early
80 bar (1157 psi) per Rev
042 - 100
newer
90 bar (1300 psi) per Rev
030 - 100
130 - 250 80 bar (1157 psi) per Rev
90000260
T002 270E
Rotate Pressure Adjusting Screw

7. To verify the actual pressure setting, actuate or move

the control input so that the pump again develops
pressure in the high pressure circuit to the newly
adjusted pressure limiter pressure setting, and read
the high pressure gauge. Then allow the pump to
return to its “neutral” position. The pressure in the
high pressure circuit should return to the charge
pressure setting.

8. While holding the pressure adjusting screw station-

ary, tighten the pressure adjusting screw lock.

Frame Size Torque

early
3 Nm (26 lbf in)
042 - 100
newer
20 Nm (15 lbf ft)
030 - 100
130 - 250 40 Nm (30 lbf ft)
T002 271E

Do not overtorque.

90000261 9. Shut down the prime mover, remove the gauges and
Tighten Lock Nut install the gauge port plugs. Replace the plastic dust
plugs (if used).

The same procedure is used for setting the pressure limit

of the other multi-function valve, but the control input
signal must be activated or moved in the opposite direc-
tion so that high pressure develops in the opposite side
of the closed circuit.

34

580 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Inspections and Adjustments

Engaging the Bypass Function

The bypass function is performed by the multi-function

valve cartridges. The prime mover should be shut down
when opening or closing the bypass valves.

The bypass valves on both of the multi-function valves

must be opened to engaged the bypass function.

1. Using a

Frame Size Wrench Size

newer
1-1/16 inch
030 - 100
130 - 250 1-3/8 inch
T002 272E

wrench on the middle sized hex of the multi-function

90000266
valve cartridge, and a
Loosening and Rotating Bypass Hex on Multi-Function
Frame Size Wrench Size Valve
newer
1-1/4 inch Opening Bypass Valve
030 - 100
allows flow to circuit
130 - 250 1-5/8 inch Bypass through Multi-Function Valves
T002 273E Actuator

wrench on the large hex to prevent rotation of the

cartridge assembly, rotate the middle hex three
revolutions counterclockwise to open the bypass
valve. Do not rotate more than 3-1/2 revolutions,
as additional rotation will permit external leak-
age.

2. For units with an MDC-type control, prior to moving 90000827E

the vehicle or otherwise causing the motor shaft to Multi-Function Valve with Bypass Function Engaged
turn, move the control handle of the manual displace-
ment control on the pump to the maximum full
forward position. Hold the handle in this position
during bypass valve operation.

Caution
"Tow" at extremely low speeds and for short
distances only.
S000 011E

3. To close the bypass valve, rotate the middle hex

clockwise until it is seated. Then torque the middle
hex.

Frame Size Torque

newer
41 Nm (30 lbf ft)
030 - 100
130 - 250 100 Nm (75 lbf ft)
T002 274E

35

008 911 83 BOMAG 581

17.1 Travel pump series 90R

Series 90 Inspections and Adjustments

Pressure Override (POR) Valve Pressure
Adjustment (Option for 180 Frame Size)

The Pressure Override Valve is explained in the corre-

sponding section.

1. Install two 1000 bar (or 10 000 psi) pressure gauges

Pressure Override Valve Adjusting Screw in the high pressure gauge ports (M1 and M2). Install
Lock Nut
a 50 bar (or 1000 psi) pressure gauge in the pump
charge pressure gauge port (M3).

2. Start the prime mover and operate at normal speed.

3. With the pump operating at approximately 20% dis-

placement, load the work function and note the
pressure as the POR valve operates (pump displace-
ment reduces to “zero”).

4. Adjustment of the pressure override setting is made

by loosening the lock nut with a 9/16 inch hex wrench
and turning the adjustment screw with a 3/16 inch
internal hex wrench. The POR setting should be at
Right Side View least 50 bar (750 psi) below the high pressure relief
90000828E valve setting of the multi-function valves for proper
Pressure Override Valve for 180 Frame Size operation.

5. Following the adjustment, torque the lock nut to

43 Nm (32 lbf ft).

6. Shut down the prime mover and remove the gauges

and install the gauge port plugs.

36

582 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Inspections and Adjustments

Displacement Limiter Adjustment

The maximum displacement can be limited in either

direction.

1. Loosen the seal lock nut retaining the displacement

limiter adjusting screw.

Frame Size Wrench Size

030 - 100 13 mm
130 17 mm
180 - 250 19 mm
T002 275E

2. Rotate the adjusting screw.

Frame Size Internal Hex Wrench Size

030 - 100 4 mm
90000267
130 5 mm
Loosen Displacement Limiter Lock Nut
180 - 250 6 mm
T002 276E

Rotating the adjusting screw clockwise will decrease

the maximum displacement of the pump while rotat-
ing the adjusting screw counterclockwise will in-
crease the maximum displacement.

Caution
Care should be taken in adjusting displacement
limiters to avoid undesirable flow or speed conditions.
The seal lock nut must be retorqued after every
adjustment to prevent an unexpected change in
operating conditions and to prevent external leakage
during unit operation.
S000 012E
90000268
Rotate Adjusting Screw
3. After establishing the desired maximum displace-
ment setting, tighten the lock nut on the adjusting
screw as follows.

Frame Size Torque

030 - 100 24 Nm (18 lbf ft)
130 48 Nm (35 lbf ft)
180 - 250 125 Nm (92 lbf ft)
T002 278E

4. One turn of the adjusting screw will change the

maximum displacement approximately as follows.

Approx Change in Disp per Rev of

Frame Size
Adjusting Screw 90000269
030 2.8 cm3 / Rev (0.17 in3 / Rev) Tighten Lock Nut
042 3.5 cm3 / Rev (0.21 in3 / Rev)
055 4.2 cm3 / Rev (0.26 in3 / Rev)
075 5.1 cm3 / Rev (0.31 in3 / Rev)
100 6.2 cm3 / Rev (0.38 in3 / Rev)
130 8.8 cm3 / Rev (0.53 in3 / Rev)
180 12.5 cm3 / Rev (0.76 in3 / Rev)
250 17.3 cm3 / Rev (1.06 in3 / Rev)
T002 277E

37

008 911 83 BOMAG 583

17.1 Travel pump series 90R

Series 90 Inspections and Adjustments

Pump Control Adjustments

Standard Manual Displacement Control (MDC)

Adjustment

There are no adjustable elements in the manual dis-

placement control. The control spool is held in its “neutral”
position by centering springs and washers on each end of
the spool. Since there is no centering spring on the control
input shaft, the shaft will automatically assume the appro-
priate position when the control is installed on the pump.

90000237
Variable Displacement Pump with Standard Manual
Displacement Control

38

584 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Inspections and Adjustments

Non-Linear Manual Displacement Control
(MDC)

A centering spring, located on the control input shaft,

locates the control shaft in its “neutral” position. A bias
spring on the control spool maintains a force on the spool
and the control linkage to eliminate looseness (“free-
play”) in the linkage.

The “neutral” adjustment is the only adjustment that can

be made on the nonlinear manual displacement control.
All other functions are preset at the factory.

This adjustment must be made on a test stand or on the

vehicle/machine with the prime mover operating. 90000829
Variable Displacement Pump with Non-Linear Manual
Displacement Control
WARNING
The following procedure may require the vehicle/
machine to be disabled (wheels raised off the ground,
work function disconnected, etc.) while performing
the procedure in order to prevent injury to the
technician and bystanders. Take necessary safety
precautions before moving the vehicle/machine.
S000 007E

1. Install two 50 bar (or 1000 psi) gauges in each of the

displacement control cylinder gauge ports (M4 and
M5). Disconnect the external control linkage from the
control handle and make certain the control shaft is
in its “neutral” position. Start the prime mover and
operate at normal speed.

2. Loosen the lock nut on the neutral adjusting screw 90000357 90000358
with a 13 mm hex wrench. Rotate Neutral Adjusting Tighten Neutral Adjusting
Screw Screw Lock Nut
3. Using a 4 mm internal hex wrench, rotate the neutral
adjusting screw clockwise until the pressure increases
on one of the pressure gauges. Note the angular
position of the wrench.

4. Rotate the adjusting screw counterclockwise until the

pressure increases by an equal amount on the other
gauge. Note the angular position of the wrench.

5. Rotate the adjusting screw clockwise half the dis-

tance between the locations noted above. The gauges
should read the same pressure (case pressure),
indicating that the control is in its “neutral” position.

6. Hold the adjusting screw stationary and tighten the

lock nut to 13.5 Nm (10 lbf ft). Do not overtorque
the nut.

7. Once the neutral position is set, stop the prime

mover, remove the gauges, and install the gauge
port plugs. Reconnect the external control linkage.

39

008 911 83 BOMAG 585

17.1 Travel pump series 90R

Series 90 Inspections and Adjustments

MDC Neutral Start Switch (NSS) Adjustments

The neutral start switch (NSS) provides a means to

A A prevent the system prime mover from starting while the
pump control handle and control input shaft are in a
Control Shaft Switch Cam position which would command the pump to go “in-
stroke” in either the “forward” or “reverse” direction.

Switch Lock Nut When the control input shaft is in its “neutral” position, the
inner end of the switch pin moves into a slot on the
Neutral Start Switch
eccentric cam attached to the control shaft. This allows
Eccentric Plug the spring loaded NSS to close, completing the electrical
Switch Pin starting circuit for the prime mover.
Special Lock Nut
for Eccentric Plug
When the control input shaft is NOT in its “neutral”
MDC with Neutral Start switch position, the eccentric cam moves the switch pin out of
the slot. This forces the NSS to open, breaking the
electrical starting circuit for the prime mover.

The neutral start switch is threaded into the special lock

nut for the eccentric plug.

Turning the NSS clockwise (CW) into the special nut will
move the NSS closer to the switch cam on the control
Orifice Check Valve Seat shaft, and will narrow the NSS deadband. Turning the
Control Spool Assembly
Control Link Assembly
NSS counterclockwise (CCW) out of the special nut will
move the NSS farther from the switch cam on the control
View at Section A-A shaft, and will widen the NSS deadband.

90000830E
The switch pin is located in an eccentric plug which is
Components of the Standard Manual Displacement Control turned to move the center of the NSS deadband.
with Neutral Start Switch
(continued)

40

586 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Inspections and Adjustments

The NSS must be adjusted to meet the following three
requirements:
NSS Deadband Control Shaft
(Switch closed, "ON") ("Free-Play")
i. The distance the control handle can be turned with-
out opening the NSS is called the “NSS Deadband.” Control Deadband
The distance the control handle can be moved with- ("Neutral")
out moving the control spool enough to port hydraulic
fluid to the pump displacement control cylinders is
Total Control
called the “Control Deadband.” These deadbands Shaft Rotation
must be centered in relation to each other.

Since the position of the control deadband cannot be Control Shaft

adjusted, the position of the NSS deadband must be
adjusted to match it.

ii. The NSS deadband must be wide enough so the NSS

will not open within the loose area of control handle
movement caused by normal operating clearances in
the control linkage (control shaft “free-play”).

By setting the NSS to open outside this area, the

control spool springs or control shaft centering spring
can always act to return the handle to “neutral” and
re-close the NSS.

iii. The NSS deadband must be narrow enough so the

NSS will open before the unit builds 7 bar (100 psi)
differential system pressure in either direction.
90000831E

(continued) Neutral Start Switch Adjustment Requirements

41

008 911 83 BOMAG 587

17.1 Travel pump series 90R

Series 90 Inspections and Adjustments

NSS Deadband Adjustment (Conditions ii & iii)

The NSS deadband must be wide enough so the NSS will

not open within the control shaft “free-play” area, and it
must be narrow enough so the NSS will open before the
unit builds 7 bar (100 psi) differential system pressure in
either direction.

1. Install two 1000 bar (10 000 psi) pressure gauges in

the system pressure gauge ports M1 and M2.

2. Using two 1-1/8 inch wrenches, hold the neutral start

switch from turning and loosen the locknut.

3. Disconnect the external control linkage and make

certain the control shaft is in its “neutral” position.

4. Attach a continuity checker to the terminals of the

switch. With the control shaft in its “neutral” position,
turn the switch clockwise (CW) until electrical conti-
90000253
nuity is broken, then turn the switch counterclockwise
Loosening the NSS Lock Nut
(CCW) until electrical continuity is obtained. Turn the
switch counterclockwise (CCW) an additional 1/4
turn (90°) after continuity has been obtained.

5. Hold the switch in place and tighten the locknut to

27 Nm (20 lbf ft) torque.
Control Shaft
6. With the continuity checker attached to the switch,
rotate the control handle (or the control shaft) in each
direction to assure continuity is broken when the
control is not in the “neutral” position.
Switch Lock Nut

Switch Cam 7. If continuity is obtained in “neutral” and satisfactorily

Neutral Start Switch
interrupted in each direction, proceed to check the
switch with the prime mover running. The switch
must open before the unit builds 7 bar (100 psi)
Switch Pin 1-1/8 in. hex wrench differential system pressure in either direction.
Torque: 27 Nm (20 lbf ft)
If the switch opens after the unit builds system
90000832E pressure in either direction, loosen the switch lock
NSS nut and turn the switch clockwise (CW) 1/12 turn
(30°). Tighten the switch lock nut and recheck the
switch operation. Repeat this procedure if neces-
sary.

8. If continuity is not interrupted with an equal move-

ment of the control handle in each direction, turn off
prime mover, remove the pressure gauges, and
continue with the next section.

9. If neutral start switch operation is satisfactory, turn

off the prime mover, remove the pressure gauges,
and reconnect the external control linkage.

90000870
Checking Continuity of NSS (System Pressure Gauges
installed on far side)

42

588 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Inspections and Adjustments

Neutral Start Switch Eccentric Plug Adjustment (Con- 12.7 9.14
dition i) (0.5) (0.36)

The NSS deadband and the control deadband must be

centered in relation to each other.

Since the position of the control deadband cannot be

3.175 1.52
adjusted, the position of the NSS deadband must be
(0.125) (0.06)
adjusted to match it. The switch pin is located in an 25.4+
eccentric plug which is turned to move the center of the (1.0)
NSS deadband.
90000834E
The MDC should be installed on the pump and be in its
Eccentric Plug Adjustment Tool
“neutral” position when adjusting the neutral start switch
eccentric plug.

The accompanying drawing provides dimensions for an

Eccentric Plug Adjustment Tool.

1. Hold the switch and eccentric plug from turning and

use two 1-1/8 inch wrenches to loosen the locknut.
Remove the neutral start switch.

WARNING Switch
Lock Nut
Do not start the prime mover while the neutral start Eccentric Plug
switch is removed from the control. Case pressure X
Switch Pin
will force the pin out of the eccentric plug, causing Special Lock Nut
oil loss. for Eccentric Plug Neutral Start Switch
S000 032E
MDC with Neutral Start Switch

Special Lock Nut

for Eccentric Plug

Control Eccentric Plug

Mounting
Surface
Switch Pin

View in Direction X
(Switch and lock nut removed)

90000833E
NSS with Eccentric Plug

2. Note the slots on the eccentric plug for the adjust-

ment tool. Hold the eccentric plug in place with the
adjustment tool, and loosen the lock nut with a
1-1/8 inch wrench.

(continued)

90000256 90000257
Loosen Eccentric Lock Nut NSS Removed

43

008 911 83 BOMAG 589

17.1 Travel pump series 90R

Series 90 Inspections and Adjustments

3. Position the eccentric plug so the switch pin is offset

Switch Pin
toward the control mounting surface. This will provide
Eccentric Plug
the best contact between the pin and the cam on the
control shaft.

4. Hold the control shaft in its “neutral” position (in the

center of the control shaft “free-play” area). Locate
the switch pin in the slot of the switch cam by turning
the eccentric plug while checking the pin position
90˚ 90˚
(depth) in the plug. When the pin engages the cam
slot, the pin will be at its maximum depth in the plug.
Eccentric Plug
Adjustment Range
Hand tighten the plug lock nut to hold the eccentric
Control Mounting plug in position.
Surface
90000835E 5. Turn the control shaft an equal amount in either
Eccentric Plug Adjustment direction from “neutral.” The switch pin should move
out of the eccentric plug an equal distance when the
control shaft is turned. Turn the eccentric plug to
center the switch pin with the cam slot. Only a small
amount of adjustment in either direction should be
needed to center the pin.

6. While holding the eccentric plug in place, tighten the

eccentric plug lock nut to 27 Nm (20 lbf ft). Reinstall
and adjust the switch as outlined in the previous
section.

Note: The eccentric plug normally requires between

5-1/2 and 6-1/2 turns to install into the control
housing .

90000256
Adjust the Eccentric Plug

Caution
Do not turn the eccentric plug into or out of the
housing beyond specifications.
S000 014E

7. Once the switch is correctly adjusted, hold the switch

in place and tighten the locknut to 27 Nm (20 lbf ft)
torque.

(continued)

44

590 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Inspections and Adjustments

Checking Switch Continuity

Recheck switch continuity to determine whether addi-

tional adjustment of the eccentric plug is necessary.

WARNING
The following procedure may require the vehicle/
machine to be disabled (wheels raised off the ground,
work function disconnected, etc.) while performing
the procedure in order to prevent injury to the
technician and bystanders. Take necessary safety
precautions before moving the vehicle/machine.
S000 007E

1. Install two 50 bar (or 1000 psi) gauges in each of the

displacement control cylinder gauge ports (M4 and
M5). Attach a continuity checker to the terminals of
the neutral start switch.

2. Energize the starter circuit, and start the prime

mover.

3. While operating at normal speed and with the pump

in its “neutral” (zero flow) position, note the pressure
reading on the gauges. This reading should be noted
as the base pressure.

4. Slowly move the control handle in one direction while

observing the pressure gauges and the continuity
checker. Continuity must be broken before the pres-
sure on either gauge increases more than 1 bar
(12 psi) from the base pressure obtained at “neutral.”

5. Slowly move the control handle in the opposite

direction. Again, continuity must be broken before
the gauge pressure increases more than 1 bar (12 psi)
from base pressure.

6. Continuity must again be verified when the control is 90000255

returned to neutral. Checking Continuity of NSS
(Gauges installed in Servo Gauge Ports)
7. If continuity is not broken at base pressure plus 0 to
1 bar (0 to 12 psi) in either direction, stop the prime
mover and readjust the eccentric plug as described
in the previous section. If the pressure difference is
equal in each direction but greater than 1 bar (12 psi),
loosen the switch locknut and turn the switch clock-
wise 1/12 turn (30°) to increase the sensitivity. Re-
tighten the locknut and recheck pressure differences
and continuity.

8. After verifying proper control and switch operation,

stop the prime mover. Remove the continuity checker
and pressure gauges. Reinstall the servo pressure
port plugs and reconnect the electrical leads from the
machine starter circuit to the neutral start switch.
Install and adjust, if necessary, the external control
linkage.

45

008 911 83 BOMAG 591

17.1 Travel pump series 90R

Series 90 Inspections and Adjustments

Hydraulic Displacement Control (HDC) and
Electric Displacement Control (EDC) Adjust-
ment

The “neutral” adjustment is the only adjustment that can

be made on hydraulic and electric displacement controls.
All other functions are preset at the factory.

This adjustment must be made on a test stand or on the

vehicle/machine with the prime mover operating.

The neutral adjustment is performed by adjusting a

neutral adjusting shaft (earlier production EDCs) or a
90000240 neutral adjusting screw (HDCs and current production
PV with Hydraulic Displacement Control EDCs).

WARNING
The following procedure may require the vehicle/
machine to be disabled (wheels raised off the ground,
work function disconnected, etc.) while performing
the procedure in order to prevent injury to the
technician and bystanders. Take necessary safety
precautions before moving the vehicle/machine.
S000 007E

90000241
PV with Electric Displacement Control

1. Install two 50 bar (or 1000 psi) gauges in each of the

two displacement control cylinder gauge ports (M4
and M5). Disconnect the external control input (hy-
draulic or electronic) from the control. Start the prime
mover and operate at normal speed.

2. Loosen the lock nut with a 17 mm hex wrench for the

neutral adjusting shaft or with a 10 mm or 13 mm hex
wrench for the neutral adjusting screw.

90000249
Install Gauges in Displacement Control Cylinder Gauge
Ports

46

592 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Inspections and Adjustments

3. Using a 5 mm internal hex wrench for the neutral

adjusting shaft or a 3 mm or 4 mm internal hex
wrench for the neutral adjusting screw, rotate clock-
wise until the pressure increases in one of the
pressure gauges. Note the angular position of the
wrench. Then rotate the neutral adjusting shaft or
screw counterclockwise until the pressure increases
by an equal amount on the other gauge. Again note
the angular position of the wrench.

4. Rotate the neutral shaft or adjusting screw clockwise 90000250 90000252

half the distance between the locations noted above. Rotate Neutral Adjusting Tighten Neutral Adjusting
Shaft Shaft Lock Nut
The gauges should read the same pressure (case
(Early production) (Early production)
pressure), indicating that the control is in its “neutral”
position.

5. Hold the neutral adjusting shaft or screw stationary.

Tighten the neutral shaft lock nut (early production
controls) to 22 Nm (195 lbf in.). Tighten the neutral
adjusting screw lock nut (later production controls) to
7 Nm (62 lbf in.) for the 6 mm screw or 13.5 Nm
(120 lbf in.) for the 8 mm screw. Do not overtorque
the nut.

6. Once the neutral position is set, stop the prime

mover, remove the gauges, and install the gauge 90000251 90000318
port plugs. Reconnect the external control input. Rotate Neutral Adjusting Tighten Neutral Adjusting
Screw Screw Lock Nut
(Later production) (Later production)

90000355 90000356
Rotate Neutral Adjusting Tighten Neutral Adjusting
Shaft Shaft Lock Nut
(Current production HDC) (Current production HDC)

47

008 911 83 BOMAG 593

17.1 Travel pump series 90R

Series 90 Inspections and Adjustments

Motor Adjustments

Charge Relief Valve Adjustment

1. To measure motor charge pressure, install a 50 bar

(or 1000 psi) pressure gauge in the motor charge
pressure gauge port (M3). Size 30 and 42 don’t have
the M3 gauge port. Install pressure gauge in the
motor system pressure gauge port. For this kind of
measurement add 1 bar (14.5 psi) to the nominal
values shown in the table. Also install a gauge to
measure case pressure. Operate the system with the
pump in stroke (forward or reverse) when measuring
motor charge pressure.

90000248 2. The following table shows acceptable motor charge

Charge Pressure Gauge Port (MF) pressures for some nominal charge relief valve set-
tings (see model code at right). These pressures
90M055 NC 0 N Nominal charge
assume a reservoir temperature of 50°C (120°F).
Pressure Setting
8 N 0 C6 W 00 They are referenced to case pressure and assume a
NNN 00 00 24 one pump/one motor system.

Motor Charge Pressure 3. Earlier production Series 90 motors are equipped

Model Code
(±1.4 bar [±20 psi]) with a shim adjustable charge relief valve. Shim kits
are available as service items. Adjustment of the
10 8.1 bar (117 psi)
charge pressure is accomplished by removing the
plug (7/8 inch hex) and changing the shim thickness
18 16.1 bar (233 psi)
behind the spring. The plug for this type charge relief
port should be torqued to 68 Nm (50 lbf ft).
20 18.1 bar (262 psi)
Later production Series 90 motors are equipped with
24 22.1 bar (320 psi)
an external screw adjustable charge relief valve.
Adjustment of charge pressure is accomplished by
28 26.1 bar (378 psi)
loosening the lock nut,
30 30.0 bar (435 psi) Frame Size Wrench Size
030 - 130 1-1/16 inch
T002 279E
T002 293E
Model Code at the Name Plate (24 bar)
and turning the adjustment plug with a large screw-
driver or a 1/2 inch hex wrench. Clockwise rotation of
the plug increases the setting, and counterclockwise
rotation decreases the setting (at a rate of approxi-
mately 5.4 bar [78 psi] per turn). The lock nut for this
type charge relief valve should be torqued to 52 Nm
(38 lbf ft).

4. Once the desired charge pressure setting is achieved,

remove the gauges.

90000263 90000343
Shim Adjustable Charge Screw Adjustable Charge
Pressure Relief Valve Pressure Relief Valve
(Motor) (Motor)

48

594 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Inspections and Adjustments

Displacement Limiter Adjustment (MV)
Tamper-Resistant Cap
Both the maximum and minimum displacement may be
limited. Seal Lock Nut
Maximum Displacement
1. Remove the tamper resistant cap from the displace- Limiter Screw
ment limiter screw. Loosen the seal lock nut retaining
the displacement limiter adjusting screw with a 19 mm
wrench.

Caution
The displacement limiters act as travel stops for the
swashplate. Do not turn the limiter screws
counterclockwise beyond the point of contact with
the swashplate for either the maximum or minimum
displacement position.
S000 015E

2. All adjustments can only be done when the motor is

running and the pump is in neutral position. Steer the Minimum Displacement
Limiter Screw
respective displacement limiter by the control.
Seal Lock Nut

Rotate the adjusting screw with a 6 mm internal hex Tamper-Resistant Cap

wrench. Rotating the maximum displacement adjust-
SAE Flange Version shown
ing screw clockwise will decrease the maximum
(Cartridge Version similar)
displacement of the motor. Rotating the minimum
displacement adjusting screw clockwise will increase 90000837E

the minimum displacement of the motor. MV Displacement Limiters

Caution
Care should be taken in adjusting displacement
limiters to avoid undesirable flow or speed
conditions. See corresponding section for speed
and pressure limits.

The seal lock nut must be retorqued after every

adjustment to prevent an unexpected change in
operating conditions and to prevent external leakage
during unit operation.
S000 016E 90000359 90000360
Rotate Adjusting Screw for Tighten Lock Nut for
Minimum Displacement Minimum Displacement
3. After establishing the desired displacement setting,
Limiter Limiter
tighten the lock nut on the adjusting screw to 54 Nm
(40 lbf ft). Install a new tamper resistant cap.

4. One turn of the adjusting screw will change the

maximum or minimum displacement according to the
following chart.

Approx Change in Disp per Rev of

Frame Size
Adjusting Screw
055 5.6 cm3 / Rev (0.34 in3 / Rev)
075 7.1 cm3 / Rev (0.43 in3 / Rev)
T002 280E

Displacement Control Adjustments

All variable motor displacement control settings do not 90000352

require adjusting. Maximum Displacement Limiter

49

008 911 83 BOMAG 595

17.1 Travel pump series 90R

Series 90 Inspections and Adjustments

Speed Sensor Adjustment

When installing or adjusting the speed sensor on a pump

or motor, it must be set at a specific distance from the
speed ring on the unit’s cylinder. To locate the position of
Gap the speed sensor on the unit or description see the
corresponding section.

Speed Sensor 1. Loosen the sensor lock nut with an 1-1/16 inch hex
Magnetic Speed Ring wrench.
90000838E
Cross Section View of Speed Sensor in Variable Pump 2. Turn the sensor clockwise (CW) by hand until it
contacts the speed ring.
Gap
3. Turn the sensor counterclockwise (CCW) 1/2 turn
(180°) to establish the nominal gap of 0.71 mm
(0.028 inch).

4. Then turn the sensor clockwise (CW) until the wrench

Magnetic Speed Ring
flats on sensor body are positioned at a 22° angle to
Speed Sensor the pump shaft center line.

90000839E Note: Many adjustable wrenches have a 22° handle

Cross Section View of Speed Sensor in fixed Motor offset.

5. The final sensor position should be between

1/2 (180°) and 1/4 turn (90°) counterclockwise (CCW)
from the point where the sensor contacts the speed
Gap ring.

6. Hold sensor in position with a 1/2 inch hex wrench

Speed Sensor while tightening the lock nut to 13 Nm (10 lbf ft).
Magnetic Speed Ring

90000840E
Cross Section View of Speed Sensor in Variable Motor

Shaft Centerline
1/2 in. Wrench Flats

22˚ 22˚

Speed Sensor with Speed Sensor with

Packard Connector Turck Connector

Shaft Centerline
1/2 in. Wrench Flats

22˚ 22˚

Speed Sensor with Speed Sensor with

Packard Connector Turck Connector

90000841E
Positioning Speed Sensor relative to Pump or Motor Shaft

50

596 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair Instructions

Minor Repair Instructions

Minor repairs may be performed, following the proce- items must be kept free of foreign materials and chemi-
dures in this section, without voiding the unit warranty. cals.
Although specific models are shown, these procedures
apply to all series and types of units in the Series 90 Protect all exposed sealing surfaces and open cavities
Family. from damage and foreign material.

Cleanliness is a primary means of ensuring satisfactory It is recommended that all gaskets and O-rings be
transmission life, on either new or repaired units. Clean- replaced when servicing. All gasket sealing surfaces
ing parts by using a solvent wash and air drying is must be cleaned prior to installing new gaskets. Lightly
adequate, providing clean solvent is used. As with any lubricate all O-rings with clean petroleum jelly prior to
precision equipment, the internal mechanism and related assembly.

51

008 911 83 BOMAG 597

17.1 Travel pump series 90R

Series 90 Minor Repair Instructions

Hydrostatic Unit Outlines for Minor Repair Reference

Charge Pressure
Relief Valve

Control Filtration Options

Control Orifice

Charge Pump Shaft Seal

Main Shaft Speed Sensor

(Auxiliary Pad)

Left Side View Right Side View

90000843E

SAE-Flange PV

Charge Pressure Charge Pressure

Relief Valve Relief Valve

Loop Flushing
Valve
Loop Flushing
Valve

Shaft Shaft
Seal Seal
(Speed Sensor) (Speed Sensor)
Left Side View Left Side View
90000844E
SAE Flange MF Cartridge Flange MF

Control Orifices
Maximum Angle Control Orifices
Charge Pressure Displacement Limiter
Relief Valve Charge Pressure Maximum Angle
Relief Valve Displacement Limiter
Loop Flushing Loop Flushing
Valve Valve
Shaft Shaft
Seal Seal

Control Control

Minimum Angle
Minimum Angle Displacement Limiter
Displacement Limiter

Left Side View Left Side View

90000845E

Cartridge Flange MV SAE Flange MV

52

598 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair Instructions

Pump and Motor Minor Repair

Pump / Fitting Torques

Description Torque

If any plugs or fittings are removed from the pump or 7/16-20 O-ring 20 Nm
motor during servicing, they should be torqued as indi- 9/16 inch Hex Wrench (15 lbf ft)
cated in the accompanying table. 7/16-20 O-ring 12 Nm
3/16 inch Internal Hex Wrench (9 lbf ft)
Always install new O-rings before reinstalling the plugs or 9/16-18 O-ring 37 Nm
fittings. 11/16 inch Hex Wrench (27 lbf ft)
9/16-18 O-ring 23 Nm
1/4 inch Internal Hex Wrench (17 lbf ft)
3/4-16 O-ring 68 Nm
7/8 inch Hex Wrench (50 lbf ft)
3/4-16 O-ring 68 Nm
5/16 inch Internal Hex Wrench (50 lbf ft)
7/8-14 O-ring 95 Nm
Caution 1 inch Hex Wrench (70 lbf ft)
Plugs or fittings installed into aluminum housings 7/8-14 O-ring 68 Nm
should always be torqued to the lower values 3/8 inch Internal Hex Wrench (50 lbf ft)
specified for internal hex plugs of the same size. 1-1/16-12 O-ring 163 Nm
S000 017E 1 1/4 inch Hex Wrench (120 lbf ft)
1-1/16-12 O-ring 115 Nm
9/16 inch Internal Hex Wrench (85 lbf ft)
1-5/16-12 O-ring 190 Nm
1-1/2 inch Hex Wrench (140 lbf ft)
1-5/16-12 O-ring 129 Nm
5/8 inch Internal Hex Wrench (95 lbf ft)
1-5/8-12 O-ring 224 Nm
1-7/8 inch Hex Wrench (165 lbf ft)
T002 281E

53

008 911 83 BOMAG 599

17.1 Travel pump series 90R

Series 90 Minor Repair Instructions

Shaft Seal and Shaft Replacement

Lip type shaft seals are used on Series 90 pumps and

motors. These seals and/or the shafts can be replaced
without major disassembly of the unit. However, replace-
ment usually requires removal of the pump or motor from
the machine.

1. Position the pump with the shaft facing up.

Note: If the unit is positioned horizontally when the

shaft is removed, the cylinder block could move
out of place, making shaft installation difficult.

2. Remove the three or four screws holding the retainer

plate and seal carrier to the housing, using a 10 mm
hex wrench (030 and 042 units), a 5 mm internal hex
wrench (055 through 100 units), or a 6 mm internal
90000270 90000271
Remove Screws Holding Remove Seal Carrier hex wrench (130 through 250 units). Remove the
Retainer Plate and Seal retainer plate.
Carrier
Note: Certain earlier production units use a one piece
retainer plate and seal carrier.

3. After removing the screws, the spring force on the

shaft may move the seal carrier out of its bore by
approximately 5 mm (1/4 inch). If the seal carrier
does not move from its bore after removing the
screws, pry it from its bore as shown and/or lightly tap
the end of the shaft with a soft mallet.

4. Remove the O-ring from the seal carrier.

5. Place seal carrier and seal in an arbor press and

90000272 90000273
press out old seal.
Press Out Old Seal New Seal Installed in Carrier
6. Inspect the seal carrier, the new seal and the O-ring
Screw for any damage or nicks.
Retaining Plate
Seal Carrier 7. Using the arbor press, press the new seal into seal
Seal carrier. Be careful not to damage the seal.
Screw
Seal Carrier
(One Piece) Note: The outside diameter of the seal may be lightly
coated with a sealant (such as Loctite High
Seal
Performance Sealant #59231) prior to installa-
O-ring tion. This aids in preventing leaks caused by
damage to the seal bore in the seal carrier.

90000846E
Series 90 Shaft Seal Components

54

600 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair Instructions

Roller Bearing
8. Inspect the sealing area on the shaft for rust, wear, Assembly Retaining Ring
or contamination. Tapered
Shaft
If the shaft is not being replaced proceed to step Splined OR Roller Bearing
Shaft
12.
OR
9. Remove shaft and roller bearing assembly from
OR
pump or motor. The bearing assembly can be trans- Straight Key
ferred to the new shaft. Shaft

90000866E
10. Remove the retaining ring that secures roller bearing Fixed Motor Shaft Configuration
assembly with a snap ring pliers. Remove the roller
bearing assembly. Roller Bearing
Assembly Retaining Ring

11. Place roller bearing assembly on new shaft and Rollen Bearing
Splined OR
secure with the retaining ring. Shaft
Tapered
12. Wrap spline or key end of shaft with plastic film to Shaft
prevent damage to the sealing lip on the seal during OR
installation.
OR
13. Prior to assembly, lubricate the O-ring on the O.D. of
Straigt Key
the seal carrier and the I.D. of the seal with clean Shaft
petroleum jelly.
90000867E
14. Assemble the seal carrier and seal over the shaft and Variable Pump Shaft Configuration
into the housing bore. Install the retainer plate (if
used).
Roller Bearing
Assembly Retaining
15. Install the screws and torque like the tables. Ring
Splined
Pumps
Shaft
Frame Size Torque Pumps
OR
030 - 042 12 Nm (9 lbf ft) Tapered
055 - 100 16 Nm (12 lbf ft) Shaft
130 - 250 32 Nm (24 lbf ft)
T002 282E 90000868E
Variable Motor Shaft Configuration

Motors

Frame Size Torque Motors

030 - 100 9.5 Nm (7 lbf ft)
130 22.5 Nm (16.6 lbf ft)
T002 283E

Note: Torque the screws in a sequenced pattern then

recheck.

90000274 90000275
Install Seal Carrier Torque Retainer Screw

55

008 911 83 BOMAG 601

17.1 Travel pump series 90R

Series 90 Minor Repair Instructions

Pump Minor Repairs

Multi-Function Valve Cartridges

1. The multi-function valve cartridge is removed with a

hex wrench on the largest hex on the cartridge.

Frame Size Wrench Size

030 - 100 1-1/4 inch
130 - 250 1-5/8 inch
T002 284E

2. Inspect cartridge for damage to parts and O-rings.

90000276 90000277 The multi-function valve cartridge may be disas-

Remove Multi-Function Install and Torque Cartridge sembled for cleaning. However, if the pressure limiter
Valve Cartridge housing assembly is disassembled, the pressure
settings must be readjusted. Usually, if there is
contamination problem, it will be in the valve seat
assembly. If it is not necessary to clean the interior of
the cartridge, proceed to step 7.

Note: Multi-function valve components are not sold

separately as service parts (except O-rings).
90000278
Multi-Function Valve Cartridge Components 3. On early versions of the multi-function valves, the
(Earlier production)
valve seat assembly is held by a retaining ring.
Remove retaining ring with a snap ring pliers.

On late versions, the valve seat section is pressed over

a lip. Place the cartridge in a vise and pry the lower
section off with an appropriate tool. Maintain sufficient
control to prevent the contents from flying loose.
90000279
Multi-Function Valve Cartridge Components
(Later production) 4. Remove pressure limiter lock nut and bypass actuator.

5. Unscrew the pressure limiter adjustment screw from

the bypass actuator. Clean and inspect all disas-
sembled parts.
Pressure Limiter High Pressure
Pressure Limiter Relief/Check
Lock Nut
Valve Spring 6. Reassemble with new, lightly lubricated O-rings by
Valve Poppet
Pressure Limiter
reversing the above procedure. For early versions
Spring Seat assemble with the retaining ring. For late versions,
Housing Check Valve
Poppet
place the cartridge in a vise and press on lower
assembly.

Caution
The pressure settings must be readjusted after
disassembling the pressure limiter housing of the
multi-function valve cartridge.
Valve Seat S000 018E
Pressure Limiter Spring
Pressure Limiter Valve Poppet
Adjustment Screw Pressure Limiter 7. Install cartridge in multi-function valve cavity and torque.
Valve Poppet
Bypass
Frame Size Torque
Actuator
030 - 100 89 Nm (66 lbf ft)
90000869E
Multi-Function Valve Cartridge Sectional View 130 - 250 210 Nm (155 lbf ft)
T002 285E

Do not overtorque the multi-function valve cartridge.

56

602 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair Instructions

Screws
Pressure Override Valve (Option for 180 Frame
Size) Pressure Override
Valve
1. Remove the four screws attaching the pressure
override valve to the pump end cap with a 5 mm O-rings
internal hex wrench. Remove the O-rings.

2. Inspect valve for damage to parts.

3. Install new O-rings. Install the valve onto the pump

end cap and torque the screws to 16 Nm (12 lbf ft).

Charge Relief Valve

The pump charge relief valve may be shim adjustable

(early models) or screw adjustable (late models).

90000870E
1. Remove the shim adjustable charge relief valve plug
Pressure Override Valve Components
with a 1 inch hex wrench.

Before removing the screw adjustable relief valve

plug, mark the plug, lock nut, and housing so as to
approximately maintain the original adjustment when
assembling. Remove the screw adjustable charge
relief valve plug by loosening the lock nut with a
wrench.

Frame Size Wrench Size

030 - 100 1-1/16 inch
130 - 250 1-5/8 inch
T002 286E

Unscrew the plug with a large screwdriver or 1/2 inch

hex wrench. 90000280 90000262
Remove Charge Relief Valve Shim Adjustable Charge
(Shim adjustable) Relief Valve
2. Remove the spring and relief valve poppet.

3. Inspect the poppet and mating seat in the end cap for
damage or foreign material.

When inspecting shim adjustable valves, do not alter

the shims or interchange parts with another valve.

4. Install the poppet and spring. For shim adjustable

valves, install the plug and torque to 68 Nm (50 lbf ft).
For screw adjustable valves, install the plug with its
lock nut, aligning the marks made at disassembly,
and torque the lock nut to 52 Nm (38 lbf ft).
90000264 90000265
Remove Charge Relief Valve Screw Adjustable Charge
Check the charge pressure and adjust, if necessary. (Screw adjustable) Relief Valve

57

008 911 83 BOMAG 603

17.1 Travel pump series 90R

Series 90 Minor Repair Instructions

Charge Pump - Remove

The following procedure shows how to remove and install

a charge pump.

1. For pumps with an auxiliary mounting pad, remove

the four screws holding the pad to the end cap and
remove the pad. Refer to the Auxiliary Mounting Pad
Installation instructions (next section) for details.

Note: At earlier production frame size 75 pumps with

twin ports secure the end cap to the pump
housing with a clamp to avoid gasket damage.

90000281 90000303
Remove Auxiliary Pad Remove Auxiliary Pad
Adapter Screws Adapter
Caution
Do not allow the force of the cylinder block spring
and swashplate leveler springs to separate the end
cap from the pump housing. Gasket damage and
external leakage may result.
S000 019E

2. Remove the six screws holding the charge pump

cover retainer.

Frame Size Wrench Size

90000282 90000284 030 - 100 10 mm
Remove Retainer Screws Remove Charge Pump Cover
130 - 250 13 mm
T002 287E

3. Remove the retainer and the charge pump cover. For

pumps with an auxiliary mounting pad, remove the
auxiliary drive coupling. Note the orientation of the
gerotor.

4. Remove the charge pump shaft and charge pump

drive key.

5. Remove the spacer plate(s), if present (intermediate

production pumps only).
90000297
Remove Drive Coupling Remove the charge pump outer port plate, if present
(early and intermediate production pumps).

Discharge Gerotor Discharge Remove the charge pump gerotor assembly.

Assembly
Alignment Pin
6. Remove the outer eccentric ring and alignment pin.
Inlet Inlet
7. Remove the inner port plate.
Alignment Pin
Gerotor Assembly 8. Inspect all parts for abnormal wear or damage.
Left Hand Rotation Right Hand Rotation
(Outside looking into pump) (Outside looking into pump)

90000871E
Orienting Alignment Pin

58

604 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair Instructions

Note: If a different displacement charge pump is be-
ing installed, the gerotor assembly, gerotor outer Standard End Cap Screws
eccentric ring, and inner port plate (early and Alignment Pin
late production pumps) or outer spacer plate(s) Charge Pump Assembly
(intermediate production pumps) must be re- Thin Port Plate
placed together. If different thickness port plates
Key
are used in an early production charge pump Thick Port Plate
Shaft
assembly, the thicker plate is the inner port Eccentric Ring
O-ring
plate (installed next to the pump end cap). Cover
Gerotor Assembly

Each charge pump assembly includes a different quan- Journal Bearing

tity / types of port plates and spacer plates. Cover Retainer
Retainer Screw
The charge pump kit "No Charge Pump" includes a
spacer.
90000872E
Charge Pump Components (Early Production)

Standard End Cap Screw

Alignment Pin

Thin Port Plate

Charge Pump Assembly

Key Eccentric Ring

Shaft Gerotor Assembly

O-ring Thin Port Plate

Cover Spacer Plate(s)

Journal Bearing

Cover Retainer
Retainer Screw
90000873E
Charge Pump Components (Intermediate Production)

Standard End Cap Screw

Alignment Pin
Charge Pump Assembly

Key
Shaft Port Plate
O-ring Eccentric Ring
Cover Gerotor Assembly

Journal Bearing

Cover Retainer
Retainer Screw
90000874E
Charge Pump Components (Late Production)

Standard End Cap Screw

Spacer

Shaft
O-ring
Cover
Plug
Journal Bearing

Cover Retainer
Retainer Screw
90000875E
"No Charge Pump" Components

59

008 911 83 BOMAG 605

17.1 Travel pump series 90R

Series 90 Minor Repair Instructions

Installing the Charge Pump
Discharge Gerotor Discharge
Assembly
Alignment Pin Be sure to install the charge pump in the proper orienta-
tion. If unsure of charge pump rotation, refer to the model
code.
Inlet Inlet

Alignment Pin Note: The charge pump rotation is determined by the

Gerotor Assembly
orientation of the gerotor assembly outer ec-
centric ring and the location of the alignment pin
Left Hand Rotation Right Hand Rotation in the end cap.
(Outside looking into pump) (Outside looking into pump)

90000871E
Do not mix charge pump piece parts from differ-
Orienting Alignment Pin ent production periods. Always install as a com-
plete assembly.

1. Install the inner port plate and the gerotor assembly

outer ring.

2. Install the alignment pin to properly orient the port

plates and outer eccentric ring for corresponding
pump rotation.

3. Prior to installation, apply a small quantity of petro-

leum jelly to the I.D., O.D., and side faces of the
gerotor assembly to provide initial lubrication.

4. Install the gerotor assembly.

90000285 90000286 5. Install the outer port plate (early production and
Install Inner Port Plate Install Gerotor Assembly intermediate production pumps only).
Outer Ring
6. Install the spacer plate, if present (intermediate
production pumps).

7. Install the charge pump drive key into the charge

pump shaft and retain with petroleum jelly.

90000287 90000288
Install Alignment Pin Install Gerotor Assembly

90000289 90000290
Install Outer Port Plate Install Spacer Plate
(Early and intermediate (Intermediate production
production only) only)

60

606 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair Instructions

Note: Intermediate production 75 cc and 100 cc pumps
use the same charge pump drive shaft. Two
keyways are provided in the drive shaft for the
charge pumps used in these units. The rear
keyway (with identifier groove) is used in 75 cc 100 cc 75 cc
pumps. The front keyway (closest to the inter-
nally splined end of the shaft) is used in 100 cc
pumps.

8. Install the charge pump shaft. The internally splined

end of the shaft must engage the main pump shaft.

Note: The outside diameter of the internally splined

end of some early production charge pump
shafts was chamfered. Early production end
caps may not be machined to accept a non- 90000291 90000292
chamfered shaft. Always use a chamfered Keyways in Charge Pump Install Charge Pump Shaft
Shaft (Intermediate Produc-
charge pump shaft in pumps with the early end
tion 075 and 100)
cap.

9. For pumps with an auxiliary mounting pad, install the

auxiliary drive coupling.

10. Install a new O-ring onto the non-auxiliary pad charge

pump cover. (If an auxiliary pad is installed, an O-ring
is not used on the cover.)

11. Carefully remove the alignment pin from the charge

pump parts. Install the pin in its hole in the charge
pump cover (see previous page for correct orienta-
tion) and retain with petroleum jelly. Install the cover
(with alignment pin) into the end cap and aligned
charge pump parts. (Take care not to damage the
cover O-ring, if used.)

Caution
In order to avoid loss of charge pressure in pumps
with an auxiliary mounting pad, always install the
charge pump cover with the pad drain hole located
on the same side of the end cap as the charge inlet
port. Refer to the section Auxiliary Pad Installation“ 90000293 90000294
for details. Alignment Pin Installed in Install Charge Pump Cover
S000 020E Cover

12. Install the charge pump cover retainer and the six hex
screws and torque the screws.

Frame Size Torque

030 - 100 13.5 Nm (10 lbf ft)
130 - 250 32 Nm (24 lbf ft)
T002 288E

13. For pumps with auxiliary mounting pads, install the

O-ring and auxiliary mounting pad adaptor onto the
end cap. Refer to the corresponding section for 90000283 90000295
Install Cover Retainer Torque Retainer Screws
instructions on auxiliary pad installation.

61

008 911 83 BOMAG 607

17.1 Travel pump series 90R

Series 90 Minor Repair Instructions

Auxiliary Pad Installation

1. Remove the six screws holding the charge pump

cover retainer. Remove the retainer.

Frame Size Wrench Size

030 - 100 10 mm
130 - 250 13 mm
T002 287E

2. Remove the charge pump cover and its O-ring.

Note: The original charge pump cover will not be used

when installing the auxiliary pad.
90000282 90000284
Remove Screws and Remove Charge Pump Cover 3. Remove the four large screws which fasten the end
Retainer
cap to the pump housing.

Frame Size Wrench Sizes

Internal Hex External Hex
030 -
8 mm
early 042
late 042 10 mm
055 19 mm
075 - 100 24 mm
100 - 130 14 mm
180 - 250 17 mm
T002 289E

Note: At earlier production frame size 75 pumps with

90000296
Remove Large End Cap Screws twin ports secure the end cap to the pump
housing with a clamp to avoid gasket damage.

Charge Pump Parts

Cover Caution
Assembly
Coupling Do not allow the force of the cylinder block spring
Special Washer (Typical) and swashplate leveler springs to separate the end
Journal Bearing
End Cap cap from the pump housing. Gasket damage and
Screw O-ring external leakage may result.
S000 019E
auxiliary Pad
(Typical)
O-ring Cover Retainer
Retainer Screw
Auxiliary Pad Kit
Pad Cover 4. Take care to assure the surfaces are clean and free
Screw
of any foreign material or paint prior to installing the
auxiliary pad.
90000876E
Auxiliary Pad Components (Typical) 5. Install the auxiliary drive coupling onto the pump
drive shaft spline (auxiliary drive spline must be
toward the rear of the pump).

62

608 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair Instructions

6. Carefully remove the alignment pin from the charge
pump parts. Install the pin in its hole in the new
charge pump cover (with hole for the auxiliary cou-
pling) and retain with petroleum jelly. Install the new
charge pump cover with alignment pin into the end
cap and the aligned charge pump parts.

Caution
In order to avoid loss of charge pressure in pumps
with an auxiliary mounting pad, always install the
charge pump cover with the pad drain hole lo-
cated on the same side of the end cap as the
charge inlet port. Refer to the section "Auxiliary
Pad Installation" for details.
S000 020E 90000297 90000298
Install Drive Coupling Install Alignment Pin in
Cover (CCW rotation shown)
7. Install the charge pump cover retainer and the six hex
screws and torque the screws.

Frame Size Torque

030 - 100 13.5 Nm (10 lbf ft)
130 - 250 32 Nm (24 lbf ft)
T002 288E

8. Install O-ring on end cap pilot.

9. Install the auxiliary mounting pad adapter on external

pilot on rear of end cap.
90000299 90000300
10. Install four new large screws and washers through Install New Charge Pump Install Screws and Cover
the mounting pad and end cap into the housing. Cover Retainer
Torque per the accompanying table.

Frame Size Torque

030 -
58 Nm (43 lbf ft)
early 042
late 042 122 Nm (90 lbf ft)
055 122 Nm (90 lbf ft)
075 - 100 256 Nm (189 lbf ft)
100 - 130 298 Nm (220 lbf ft)
180 - 250 580 Nm (429 lbf ft)
T002 290E
90000302 90000303
Install O-ring on End Cap Install Auxiliary Pad Adapter
11. Install the O-ring and flange cover or auxiliary pump.
Pilot

Auxiliary Pad Conversion

To convert an auxiliary mounting pad to a different size

mounting pad, use the above procedure with the following
additions:

After removing the charge pump cover (step 2), remove

the old auxiliary drive coupling.

After removing the four end cap retaining screws, remove

the old auxiliary mounting pad adapter.
90000281 90000305
Install Auxiliary Pad Adapter Torque Pad Adapter Screws
Screws

63

008 911 83 BOMAG 609

17.1 Travel pump series 90R

Series 90 Minor Repair

Filtration Options

Suction Filtration Installation

1. Install the hydraulic fitting to connect the external

suction filter to the charge pump inlet port.

2. The reducer fitting (placed on the charge pressure

gauge port) is installed as follows.

Frame Size Wrench Size Torque

030 - 042 1-1/4 inch 70 Nm (52 lbf ft)
055 - 130 1-1/2 inch 122 Nm (90 lbf ft)
180 - 250 1-1/2 inch 156 Nm (115 lbf ft)
T002 291E
90000310 90000243
Charge Pump Inlet Reducer Fitting and
The gauge port plug takes a 1/4 inch internal hex
Gauge Port Plug wrench and is torqued to 27 Nm (20 lbf ft).

Remote Charge Pressure Filtration or Integral Charge

Pressure Filtration

Install either of these two filtration devices as follows.

1. Remove the reducer fitting, located at charge pres-

sure gauge port, from pump end cap (this part will not
be used).

2. Install the filter manifold or filter head into the port.

The hydraulic tube should enter its mating bore in the
90000311 90000314
remote Pressure Filter Integral Pressure Filter Head pump end cap with a low force.
Manifold
3. After rotating the filter manifold or filter head clock-
wise so that the threads engage with the threads in
the end cap, continue to rotate it clockwise between
6 and 7 revolutions. Face manifold or head to the
desired position.

Caution
Failure to install the filter manifold or filter head to a
sufficient depth in the end cap will result in insufficient
engagement of the tube in the end cap bore. This may
allow unfiltered oil to bypass the filter and enter the
90000312 90000315 charge system.
Install Remote Pressure Install Integral Pressure S000 021E
Filter Manifold Filter Head

4. While holding the filter manifold or filter head in the

desired position, tighten the swivel lock nut.

Frame Size Wrench Size Torque

030 - 042 1-3/8 inch 70 Nm (52 lbf ft)
055 - 130 1-5/8 inch 122 Nm (90 lbf ft)
180 - 250 1-5/8 inch 156 Nm (115 lbf ft)
T002 292E

90000313 90000316
Tighten Remote Pressure Tighten Integral Pressure 5. After installing the integral pressure filter head as-
Filter Manifold Lock Nut Filter Head Lock Nut sembly, install the filter canister per the instructions
on the filter canister.

64

610 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair

Pump controls

Cover Plate

1. Thoroughly clean external surfaces prior to removal

of cover plate.

2. Using a 5 mm internal hex wrench, remove the eight

cover plate mounting screws. Remove the cover
plate and gasket from housing.

Caution
Protect exposed surfaces and cavities from damage
and foreign material.
S000 022E 90000361
Pump with Cover Plate

3. In preparation for installing the cover plate, place a

new gasket on the housing. Place the cover plate into
position and install the screws. Torque the screws to
16 Nm (12 lbf ft).

NOTE
A sealing washer must be installed under the head of
any mounting screws that are installed into "thru"
holes in the housing.
S000 023E

65

008 911 83 BOMAG 611

17.1 Travel pump series 90R

Series 90 Minor Repair

Manual Displacement Control (MDC)

1. Thoroughly clean external surfaces prior to removal

of control.

2. Using a 5 mm internal hex wrench, remove the eight

control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket
from housing.

Caution
Protect exposed surfaces and cavities from damage
and foreign material.
S000 022E

90000319 90000320
Remove Mounting Screws Remove Control 3. In preparation for installing the control, place a new
gasket on the housing. Inspect to assure that the
control orifice check valve and spring are in their
proper position in the control.

4. While setting the control into position, engage the pin

on the control linkage into the mating hole in the link
attached to the swashplate.

5. With the control in position, move control lever both

directions to check proper engagement of control
linkage pin. Proper engagement will be indicated by
centering torque as the lever is moved from center.
90000321 90000322 Non-engagement of control linkage pin is indicated
Inner Face of Control Assemble Control to Linkage by lack of centering torque as the lever is moved. In
case of non-engagement remove the control and
repeat the above procedure.

6. Align the control gasket and install the screws. Torque

the screws to 16 Nm (12 lbf ft).

NOTE
A sealing washer must be installed under the head of
any mounting screws that are installed into "thru"
holes in the housing.
S000 023E

90000323 90000324 7. If the control is equipped with a neutral start switch,

Assemble Control to Torque Mounting Screws refer to the "MDC Neutral Start Switch Adjustment"
Pump
instructions.

WARNING
The neutral start switch "neutral" must be read-
justed after reassembling the MDC module.
S000 024E

66

612 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair

Solenoid Override Valve for MDC

1. Thoroughly clean external surfaces prior to removal

of valve.

2. Using a 5 mm internal hex wrench, remove the two

screws and remove solenoid manifold from housing.
Remove the old gasket.

3. The solenoid may be removed from the valve by

removing the nut with a 3/4 inch hex wrench. The
solenoid valve may be removed from the manifold
with a 7/8 inch hex wrench.

4. When installing the solenoid valve into the manifold,

the valve should be torqued to 24 ± 2.4 Nm (17.7 ± 1.8 90000363
lbf ft). When installing the solenoid onto the valve, Components of Solenoid Override for MDC
torque the nut to 6 Nm (53 ± 12 lbf in).

5. In preparation for installing the solenoid manifold,

place a new gasket on the control housing. Install the
manifold onto the control housing, align the gasket,
and install the screws. Torque the screws to
13.5 Nm (10 lbf ft).

Solenoid Override Valve for MDC with Pressure

Released Brake

1. Thoroughly clean external surfaces prior to removal

of valve.

2. Using a 4 mm internal hex wrench, remove the four

solenoid valve mounting screws. Remove the sole-
noid valve (with O-rings) from the adapter plate.

3. Using a 4 mm internal hex wrench, remove the four

adapter plate mounting screws. Remove the adapter
plate and O-rings from the control housing.

4. Remove the check valve seat and O-ring from the

control side of the adapter plate. Remove the check
ball and spring.

5. Install a new O-ring on the check valve seat and

reassemble the check valve spring, ball, and seat
into the adapter plate.

6. Install new O-rings on the adapter plate. Place the 90000364

adapter plate into position and install the screws. Components of Solenoid Override with Brake Pressure
Torque the screws to 5.4 Nm (48 lbf in). Defeat for MDC

7. Install new O-rings onto the solenoid valve assembly

and install the solenoid valve onto the adapter plate.
Install the screws and torque to 5.4 Nm (48 lbf in).

67

008 911 83 BOMAG 613

17.1 Travel pump series 90R

Series 90 Minor Repair

Hydraulic and Electric Displacement Controls

1. Thoroughly clean external surfaces prior to removal

of control.

2. Using a 5 mm internal hex wrench, remove the eight

control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket
from housing.

Caution
Protect exposed surfaces and cavities from damage
and foreign material.
S000 022E

3. In preparation for installing the control, place a new

90000325 90000326
Remove Mounting Screws Remove Control gasket on the housing. Inspect to ensure that the
control orifice check valve and spring are in their
proper position in the control.

4. While setting the control into position, engage the pin

on the control linkage into the mating hole in the link
attached to the swashplate.

5. With the control in position, move control assembly

left and right to check engagement of pin in the link.
Proper engagement will be indicated by an increas-
ing resistance as the control is moved away from
center position. Non-engagement of pin will be indi-
90000327 90000328
cated by lack of spring force. In case of non-engage-
Inner Face of Control Assemble Control to Linkage ment, remove control and repeat the above proce-
dure.

6. Align the control gasket and install the screws. Torque

the screws to 16 Nm (12 lbf ft).
Caution
A sealing washer must be installed under the
head of any mounting screws that are installed
into "thru" holes in the housing.
S000 023E

Pressure Control Pilot (PCP) for Electric Displace-

ment Control
90000329 90000330
Install Mounting Screws Torque Mounting Screws
1. Thoroughly clean external surfaces of control.

2. Using a 4 mm internal hex wrench, remove the four

screws and remove the PCP.

3. Check surfaces for nicks or damage. Clean internal

screens.

4. Install new O-rings in PCP Housing. Place PCP

against EDC housing and install the screws. Torque
to 5.4 Nm (48 lbf in).

Note: Do not remove black plastic cover from the

90000332 90000334
PCP Components Torque PCP Valve Screws aluminum plate. This is not a serviceable item
and will void the product warranty.

68

614 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair

3-Position (FNR) Electric Control

1. Thoroughly clean external surfaces prior to removal

of control.

2. Using a 4 mm internal hex wrench, remove the four

solenoid valve mounting screws. Remove the sole-
noid valve (with O-rings and orifice) from the adapter
plate.

3. Using a 5 mm internal hex wrench, remove the eight

adapter plate mounting screws. Remove the adapter
plate and gasket from housing.

Caution 90000362
Protect exposed surfaces and cavities from damage 3-Position Electric Control Components
and foreign material.
S000 022E

4. Inspect the orifice installed between the valve and

adapter plate. This orifice MUST be installed in the
case drain passage for proper pressure limiter op-
eration.

5. In preparation for installing the adapter plate, place a

new gasket on the housing. Place the adapter plate
into position and install the screws. Torque the
screws to 16 Nm (12 lbf ft).

NOTE
A sealing washer must be installed under the head of
any mounting screws that are installed into thru“
holes in the housing.
S000 023E

6. Install new O-rings and the orifice onto the solenoid

valve assembly and install the solenoid valve onto
the adapter plate. Install the screws and torque to
5.4 Nm (48 lbf in).
Displacement Control Components

Displacement Control Orifices

A
1. Remove the control assembly as described in the
B
instructions for the specific displacement control.
TA P
TB
2. Orifice plugs may be located in the control assembly,
at the pump housing face surface. Remove the
orifice plugs with a 4 mm internal hex wrench. Note
the location of each plug, do not interchange plugs.
Torque the orifice plugs to 3 Nm (26 lbf in).

3. Assemble the control onto the pump. Refer to the Orifice Plugs
instructions for the specific control.
Orifice Check Valve
90000849E
Underside of an HDC/EDC Module Showing Orifice
Locations

69

008 911 83 BOMAG 615

17.1 Travel pump series 90R

Series 90 Minor Repair

Displacement Control Orifice Check Valve

1. Remove the control assembly as described in the

instructions for the specific displacement control.

2. The orifice check valve is located in the control

assembly, at the surface of the pump housing face.
TA A B TB Remove the spring retainer and spring from the
orifice check valve cavity and then remove the orifice
P
check valve.

3. Install the desired orifice check valve in the cavity and

then install the spring and spring retainer to hold the
orifice check valve in position.
Orifice Plugs
4. Assemble the control onto the pump. Refer to the
instructions for the specific control.
Orifice check Valve
90000848E
Underside of an MDC Module Showing Orifice Locations

Displacement Control Adapter Plate (Early produc-

tion 130 Pumps only)

The screws fastening the control adapter plate to the

housing have retaining compound on the threads. They
are removed with a 6 mm internal hex wrench.

When installing the adapter plate, ensure the O-rings are

in the proper position and torque the screws to 32 Nm
(24 lbf ft).

Displacement Control Filter Screens

If the pump is equipped with control filter screens in the

pump housing (late production), they should be pressed
into position (with the rounded edge of the filter screens
facing the control until they are flush to 2.0 mm (0.08 inch)
below the surface of the housing.

90000847
Displacement Control Adapter Plate (Early production
130cc Pumps only)

70

616 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair

Minor Repair - Motor

Loop Flushing and Charge Relief Valves

Loop Flushing Valve

1. Using an 1-1/16 inch wrench, remove the hex plugs

and O-rings from both sides of the valve. Remove the
springs, shoulder washers, and flushing valve shuttle
spool. Note orientation of the washers. Remove the
flushing valve spool.

2. Inspect parts for damage or foreign material.

Note: Early production motors used a small diameter 90000338 90000339

shuttle valve spool. Late production motors use Remove Plugs Springs Remove Flushing Shuttle
a larger diameter spool. Spool

3. Install flushing valve spool in end cap, then install the

shoulder washers (with shoulders facing “out”) and
springs on each end of the spool. Install the hex plugs
with O-rings, and torque to 41 Nm (30 lbf ft) on 030
through 100 motors or 68 Nm (50 lbf ft) on 130
motors.

Motor Charge Relief Valve

1. Remove the shim adjustable charge relief valve plug

with a 7/8 inch hex wrench. 90000340 90000341
Install Flushing Shuttle Torque Plugs
Before removing the screw adjustable relief valve Spool
plug, mark the plug, lock nut, and housing so as to be
able to maintain the original adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock nut with a 1-1/16 inch
hex wrench for 030 through 100 units, or a 1-5/8 inch
hex wrench for 130 units, and unscrewing the plug
with a large screwdriver or 1/2 inch hex wrench.

2. Remove the spring and valve poppet.

3. Inspect the poppet and mating seat in the end cap for
damage or foreign material. When inspecting shim 90000342 90000343
adjustable valves, do not alter the shims or inter- Remove Shim Charge Relief Remove Screw Charge Relief
change parts with another valve. Valve Valve

71

008 911 83 BOMAG 617

17.1 Travel pump series 90R

Series 90 Minor Repair

4. Install the poppet and spring. For shim adjustable

valves, install the plug and torque to 68 Nm (50 lbf ft).
For screw adjustable valves, install the plug with its
lock nut, aligning the marks made at disassembly,
and torque the lock nut to 52 Nm (38 lbf ft).

5. Check and adjust the charge pressure.

90000344 90000345
Shim Adjustable Charge Screw Adjustable Charge
Relief Valve Relief Valve

Defeating the Loop Flushing Valve

Lock Nut
Plug
Plug 1. Remove loop flushing valve components (these parts
O-ring
O-ring
will not be used).
Shims
Spring Spring
2. Install defeating spool into spool bore in end cap.
Poppet Poppet
Plug with O-ring
(defeat) 3. Install hex plugs provided and torque to 41 Nm
(30 lbf ft).

4. Remove charge relief valve components (these parts

Plug with O-ring are not necessary).
(defeat)

5. Replace with the hex plug provided and torque to

Plug
41 Nm (30 lbf ft).
O-ring Spool (defeat)

Spring
Plug with O-ring
(defeat)
Shoulder Washer

Note orientation of washers!

Shoulder OUT (toward spring). Spool

Shoulder Washer

Spring

O-ring

Plug

90000850E
Motor charge Relief Valve and Loop Flushing Valve Parts

72

618 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair

Variable Motor Displacement Limiters

1. Remove the tamper-resistant cap from the displace-

ment limiter. Measure and note the length of the
adjustment screw up to the seal lock nut. Using a
19 mm hex wrench, loosen the seal lock nut and
remove the nut. Remove the limiter screw from the Tamper-Resistant Cap
motor housing with a 6 mm internal hex wrench. Seal Lock Nut
Maximum Displacement
Limiter Screw
2. Install the limiter screw with the noted length between
adjustment screw and the seal lock nut. Do not install
a new tamper-resistant cap until the limiter has been
adjusted.

3. Final adjustment of the displacement limiters should

be performed on a test stand.

Do not turn the limiter screws counterclockwise

beyond their initial adjustment positions.

Minimum Displacement
Caution Limiter Screw
Care should be taken in adjusting displacement Seal Lock Nut
limiters to avoid undesirable speed conditions. The
Tamper-Resistant Cap
seal lock nut must be retorqued after every
adjustment to prevent an unexpected change in SAE Flange Version shown
(cartridge Version similar)
operating conditions and to prevent external leakage
during unit operation.
S000 026E

90000851E
One full turn of the displacement limiter adjustment MV Displacement Limiters
screw will change the displacement as follows:

Approx Change in Disp per Rev of

Frame Size
Adjusting Screw
055 5.6 cm3 / Rev (0.34 in3 / Rev)
075 7.1 cm3 / Rev (0.43 in3 / Rev)
T002 295E

4. Following the final adjustment, install new tamper

resistant caps.

73

008 911 83 BOMAG 619

17.1 Travel pump series 90R

Series 90 Minor Repair

Variable Motor Controls

Electrohydraulic 2-Position Control (Types

NA, NB, NC, and ND)

1. Thoroughly clean external surfaces prior to removal

of the control.

2. Disconnect the external electrical signal connection.

Note: Remove BEFORE removing control.
Install AFTER installing control. 3. Remove the hex nut and solenoid from the control
Refer to "Control Orifices" Section
valve.

4. Remove the orifice check valve for the maximum

angle control cylinder, if equipped.
Hydraulic 2-Position
Control Valve
5. Remove the control valve from the motor housing.

6. Remove O-rings from the valve.

7. Install new O-rings on the control valve.

Electric 2-Position
Control Valve
8. Install the valve into the motor housing and torque to
47 Nm (35 lbf ft). Do not overtorque the control
valve. Over-torquing may result in the valve spool
sticking.

9. Install the solenoid onto the valve and torque the hex
90000852E nut to 5 Nm (44 lbf in). Do not overtorque the nut.
MV Control components
10. If previously removed, reinstall the orifice check
valve. Reconnect the external signal connection.

Hydraulic 2-Position Control (Type PT)

Follow the steps above, except that in step 2 a hydraulic

signal line will be disconnected, and steps 3 and 9 are not
applicable.
1/8 in. int. hex wrench
Torque: 5.4 Nm (48 lbf in)

Control Plugs

Remove the control plugs from the housings of earlier

9/16 in. hex wrench
Torque: 34 Nm (25 lbf ft) production motors, if necessary. Install new O-rings,
reinstall, and torque.
7/8 in. hex wrench
Torque: 68 Nm (50 lbf ft)

90000853E
MV Control Plugs

74

620 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair

Variable Motor Control Orifices
Control Suply Orifice
Control Supply Orifice
Screen (pressed in)
1. Remove the control supply orifice from the motor
O-ring
housing with an 1-1/16 inch hex wrench.
Backup Washer

2. Remove the O-rings and the backup washers. Check O-ring

that the filter screen is secure in the orifice body and Backup Washer
that the screen and the orifice are not plugged.

3. Install new backup washers and O-rings onto the

orifice body. Install the orifice into the motor housing O-ring

and torque to 37 Nm (27 lbf ft). Backup Washer Backup Washer

Caution
Screen
Do not interchange the control supply orifice with the (pressed in)
minimum displacement orifice (next section).
S000 027E Orifice Body
O-ring
Cross-section View of
Control Supply Orifice Assembly

90000854E
MV Control Supply Orifice

Minimum Displacement Cylinder Orifice or Orifice

Check Valve
Orifice Orifice / Check Valve
Assembly
1. Remove the minimum displacement cylinder drain
orifice or the orifice check valve from the motor
O-ring
housing with an 1-1/16 inch hex wrench.
Backup Washer

2. Remove the O-rings and the backup washers. Check O-ring

that the orifice is not plugged. Check that the check Backup Washer
valve seat is secure in the body and that the check
ball is free.

3. Install new backup washers and O-rings onto the

orifice body. Install the orifice into the motor housing
and torque to 37 Nm (27 lbf ft).

O-ring O-ring

Orifice Body Orifice Body

Caution
Do not interchange the control supply orifice (previous Backup Washer
Spring Pin
Backup Washer
section) with the minimum displacement orifice. O-ring O-ring
S000 028E Kugel
Backup Washer Backup Washer

Orifice Seat
(Spot welded)
Cross-Section View of Cross-Section View of
Orifice Assembly Orifice / Check Valve
Assembly

90000855E
MV Minimum Displacement Orifice

75

008 911 83 BOMAG 621

17.1 Travel pump series 90R

Series 90 Minor Repair

Maximum Displacement Cylinder Orifice Check Valve

1. Remove the seal lock nut with a 3/4 inch hex wrench.
Housing Plug Remove the maximum displacement cylinder orifice
check valve from the motor housing with a 1/4 inch
Seal Lock Nut
(seal toward housing) end wrench. Remove the O-ring. The check ball in
the valve must be free.
O-ring
2. Reinstall the check valve and torque to 15 Nm
Orifice / Check Valve Assembly
(11 lbf ft). Install a new O-ring. Install the seal lock
nut with the seal toward the motor housing.
Seal Lock Nut
(seal toward housing)
Hold the check valve from turning while torquing
the seal lock nut to 34 Nm (25 lbf•ft).
O-ring
3. If no orifice check valve is installed, the housing plug
Orifice Body may be removed with a 9/16 inch hex wrench. Always
install a new O-ring. Reinstall the plug and torque to
Check Ball
20 Nm (15 lbf ft).
Spring Pin

Cross-Section View of
Orifice / Check Valve
Assembly

90000856E
MV Maximum Displacement Orifice

76

622 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Minor Repair

Speed Sensor

1. Remove the speed sensor by disconnecting the

electrical connector, loosening the lock nut, and Housing Plug
Speed Sensor 1/4 in. int. hex wrench
unscrewing the speed sensor from the pump or or Torque: 23 Nm (17 lbf ft)
motor housing.

2. Always install a new O-ring before installing the 1-1/16 in. hex wrench
Torque: 13 Nm (10 lbf ft)
sensor. After adjustment!

3. Reinstall the speed sensor (with lock nut and O-ring)

into the housing. Adjust the gap between the sensor
and the magnetic speed ring as instructed in Section
"Speed Sensor Adjustment" and torque the sensor
lock nut.

4. If a speed sensor is not installed, the housing plug

should be torqued as indicated in the accompanying 90000857E
figure. Typical Location of Speed Sensor - PV

1-1/16 in. hex wrench

Torque: 13 Nm (10 lbf ft)
After adjustment!

or

Housing Plug Speed Sensor

1/4 in. int. hex wrench
Torque: 23 Nm (17 lbf ft)

90000858E
Typical Location of Speed Sensor - MF

1-1/16 in. hex wrench

Torque: 13 Nm (10 lbf ft)
After adjustment!

or
Speed Sensor
Housing Plug
1-1/16 in. hex wrench
Torque: 37 Nm (27 lbf ft)

90000859E

Typical Location of Speed Sensor - MV

77

008 911 83 BOMAG 623

17.1 Travel pump series 90R

Series 90 Exploded View Parts Drawings / Parts Lists

Exploded View Parts Drawings / Parts Lists

Variable Pumps

Minor Repair Parts

K90 L35
B70 K10 K018 (Early Production
bis 075 Frame Size) (L70)
B83 G532 K50 K042
OR G536 K70
B83 (L40) L60 L70
G542 K80
G546 (B80)
L40
B82 (B90) L30
P2B_
(B70)
B90
P30 P06
P13
L50

P30
B71

P2A_ P06
P13 G512
G516
G502
G506
G172
G522 G176
G526
B80
(G502
G506) (G502
G506)

(G63)
G63
(CODE 61 OPTION)
(G64)
G64
(CODE 61 OPTION) (K018
BOTH SIDES THRU
K042)

G531
G501
G538
G508
G511
G518
OR

G541
G548

G63
(CODE 61 OPTION)

G521
G528
(G63)
(G501
G508) (G64)
G64
(G501
(CODE 61 OPTION)
G508)

90000860E

78

624 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Exploded View Parts Drawings / Parts Lists

Parts List

Item Description Qty Item Description Qty

B70 ............... Plug ......................................................... 2 G532 ............ Plug ......................................................... 1

B71 ............... Plug ......................................................... 1 G536 ............ O-ring ...................................................... 1
B80 ............... Plug ......................................................... 1 G538 ............ O-ring ...................................................... 1
B82 ............... Plug ......................................................... 1 G541 ............ Plug ......................................................... 1
B90 ............... Filter screen ............................................ 3 G542 ............ Plug ......................................................... 1
G546 ............ O-ring ...................................................... 1
G63 .............. Split flange clamp .................................... 4 G548 ............ O-ring ...................................................... 1
G64 .............. Plug ......................................................... 4
G172 ............ Plug ......................................................... 1 K10 ............... Plug assembly ......................................... 1
G176 ............ O-ring ...................................................... 1 K50 ............... O-ring ...................................................... 1
G501 ............ Plug ......................................................... 3 K70 ............... Spring ...................................................... 1
G502 ............ Plug ......................................................... 3 K80 ............... Poppet ..................................................... 1
G506 ............ O-ring ...................................................... 3 K90 ............... Nut ........................................................... 1
G508 ............ O-ring ...................................................... 3
G511 ............ Plug ......................................................... 1 L30 ............... Seal carrier .............................................. 1
G512 ............ Plug ......................................................... 1 L35 ............... Seal carrier .............................................. 1
G516 ............ O-ring ...................................................... 1 L40 ............... Lip seal .................................................... 1
G518 ............ O-ring ...................................................... 1 L50 ............... O-ring ...................................................... 1
G521 ............ Plug ......................................................... 1 L60 ............... Retainer ................................................... 1
G522 ............ Plug ......................................................... 1 L70 ............... Screw ...................................................... 3
G526 ............ O-ring ...................................................... 1
G528 ............ O-ring ...................................................... 1 L8 ................. Key .......................................................... 1
G531 ............ Plug ......................................................... 1 L9 ................. Slotted nut ............................................... 1

79

008 911 83 BOMAG 625

17.1 Travel pump series 90R

Series 90 Exploded View Parts Drawings / Parts Lists

Variable Pump Controls

M0DC
M90D M1DC M0DD
M1DD
OR

M11D

M0MA M0ME
M0MB M0MF
M0MC M0MG
M0MD M0M9 M0CA
M9ME M76M M74M M90C
M78M M1CA M87C
M92M M11C

M97M M77M
M95M M98M M75M
M96M S40
M72M
M90M
M71M
M1MA M880 OR
M1MB M7MA
T201
M1MC M7MB
THRU
T001 M1MD M7MC
T209, M0EA
THRU M1ME M7MD
T222 M0EF M91E
T009, M1MF M7ME
T250 M0EP
T022 M1MG M7MF
T050 T301 M7MG
THRU T401
M87M M11M M9EA M98E
T309, THRU
M9EP
T322 T409, M90E M95E
T422 M97E
T350
T450 M1EA M880
M1EF
M870
M1EP M96E
M860
M11E
M850

M840 M87E
M840 M810
REF
M830 M840
M820
REF

(Early Production
130 cc Frame Size)
OR

M1HA, M1HC
OR
M1HF, M1HG
M90H
M1HH, M1HJ
M880
M1HK, M1HL M87H
M1HM, M1HN

M11H M0HA, M0HC

M0HF, M0HG
M0HH, M0HJ
M0HK, M0HL
M0HM, M0HN

90000861E

80

626 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Exploded View Parts Drawings / Parts Lists

Control Parts List

Item Description Qty Item Description Qty

M0CA ........... Cover plate kit ......................................... 1 M71M ........... Washer .................................................... 1
M1CA ........... Cover plate .............................................. 1 M72M ........... Nut ........................................................... 1
M11C ........... Control gasket ......................................... 1 M80 .............. Control gasket ......................................... 1
M11D ........... Control gasket ......................................... 1 M87M ........... Washer, seal (042) ................................. 1
M87C ........... Washer, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6
M90C ........... Screw ...................................................... 6 S40 ............... Neutral start switch kit ............................. 1

M0DC ........... Control kit, 3-position FNR 12V .............. 1 M0MC .......... Control MDC w/ sol. valve ...................... 1
M0DD ........... Control kit, 3-position FNR 24V .............. 1 M7M ............. Control handle ......................................... 1
M1DC ........... Control, 3-position FNR 12V ................... 1 M71M ........... Washer .................................................... 1
M1DD ........... Control, 3-position FNR 24V ................... 1 M72M ........... Nut ........................................................... 1
M80 .............. Control gasket ......................................... 1 M74M ........... Solenoid valve ......................................... 1
M87D ........... Washer, seal (042) ................................. 1 M75M ........... Control manifold ...................................... 1
M90D ........... Screw ...................................................... 6 M77M ........... Manifold gasket ....................................... 1
M78M ........... Screw ...................................................... 2
M0EA ........... Control kit, EDC with M80 .............. Control gasket ......................................... 1
MS connector .......................................... 1 M87M ........... Washer, seal (042) ................................. 1
M0EP ........... Control kit, EDC with M90M ........... Screw ...................................................... 6
Packard connector .................................. 1
M1EA ........... Control, EDC with M0MD .......... Control MDC w/ sol. valve and
MS-connector .......................................... 1 neutral start switch .................................. 1
M1EP ........... Control, EDC with M7M ............. Control handle ......................................... 1
Packard-connector .................................. 1 M71M ........... Washer .................................................... 1
M9EA ........... PCP type 3 oil filled (MS) ........................ 1 M72M ........... Nut ........................................................... 1
M9EA ........... PCP type 3 oil filled (Packard) ................ 1 M75M ........... Control manifold ...................................... 1
M80 .............. Control gasket ......................................... 1 M76M ........... Solenoid valve ......................................... 1
M87E ............ Washer, seal (042) ................................. 1 M77M ........... Manifold gasket ....................................... 1
M90E ............ Screw ...................................................... 6 M78M ........... Screw ...................................................... 2
M91E ............ Plastic cap (MS) ...................................... 1 M80 .............. Control gasket ......................................... 1
M95E ............ O-ring ...................................................... 2 M87M ........... Washer, seal (042) ................................. 1
M96E ............ O-ring ...................................................... 1 M90M ........... Screw ...................................................... 6
M97E ............ O-ring ...................................................... 1 S40 ............... Neutral start switch ................................. 1
M98E ............ Screw ...................................................... 4
M1MA ........... Servovalve kit .......................................... 1 M810 ............ Adapter plate - Control (130 cc) ............. 1
M820 ............ O-ring (130 cc) ........................................ 1
M0HA ........... Control kit, hydraulic, HDC ..................... 1 M830 ............ O-ring (130 cc) ........................................ 1
M0HC ........... Control kit, hydraulic, HDC ..................... 1 M840 ............ O-ring (130 cc) ........................................ 2
M1HA ........... Control, hydraulic, HDC .......................... 1 M850 ............ Plug (130 cc) ........................................... 1
M1HC ........... Control, hydraulic, HDC .......................... 1 M860 ............ Screw (130 cc) ........................................ 6
M11H ........... Control gasket ......................................... 1 M870 ............ Plug (130 cc) ........................................... 1
M80 .............. Control gasket ......................................... 1
M87H ........... Washer, seal (042) ................................. 1 M9ME ........... 4/2 Way valve ......................................... 1
M90H ........... Screw ...................................................... 6 M92M ........... Screw ...................................................... 4
M95M ........... O-ring ...................................................... 1
M0MA ........... Control MDC M96M ........... O-ring ...................................................... 1
w/o neutral start switch ........................... 1 M97M ........... O-ring ...................................................... 1
M7M ............. Control handle ......................................... 1 M98M ........... Screw ...................................................... 4
M71M ........... Washer .................................................... 1
M72M ........... Nut ........................................................... 1 T001-9 .......... Control orifice kit ..................................... 1
M80 .............. Control gasket ......................................... 1 T201-9 .......... Orificed check valve ................................ 1
M87M ........... Washer, seal (042) ................................. 1 T301-9 .......... Spring ...................................................... 1
M90M ........... Screw ...................................................... 6 T401-9 .......... Spring retainer ......................................... 1

M0MB ........... Control MDC

w/ neutral start switch ............................. 1
M7M ............. Control handle ......................................... 1
81

008 911 83 BOMAG 627

17.1 Travel pump series 90R

Series 90 Exploded View Parts Drawings / Parts Lists

Filter and Options

N40P
N40L

N00M
N00S
N35M
REF N35S
N10M
N10S
N30R N35M N25M Or
N00R
N20M
N10R N15M
N31R

N20R OR
N15R
N35R N25R

90000862E

H50L

H50

H40

OR H05

H30
H60
H50
H40
H30
OR H05
(H30)

J80N
H40
H60 H05
H50 OR
H60
H50

H90L

J40N
J15N
H70 J15_

J30 J10_

J30

H80 J70_
H70
OR
J80_ J50_

J60_

J90_ H80
J00_

J92_

J95_

90000863E

82

628 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Exploded View Parts Drawings / Parts Lists

Parts List Filter and Options

Item Description Qty Item Description Qty

H05B-H ........ Kit - Charge pump ................................... 1 J80A-V ......... Screw ...................................................... 4
H50L ............ Spacer (No charge pump) ...................... 1 J80N ............. Screw ...................................................... 4
H30 .............. Port plate ................................................. 2 J90A-V ......... O-ring ...................................................... 1
H40 .............. Pin ........................................................... 1 J92A-V ......... Cover plate .............................................. 1
H50 .............. Charge pump shaft ................................. 1 J95A-V ......... Screw ................................................... 2/4
H60 .............. Key .......................................................... 1
H70 .............. Retaining plate ........................................ 1 N00M ........... Filtration manifold kit (Int) ....................... 1
H80 .............. Screw ...................................................... 6 N10M ........... Manifold ................................................... 1
H90L ............ Plug ......................................................... 1 N15M ........... O-ring ...................................................... 2
N20M ........... Nut ........................................................... 1
J00A ............. Aux. mtg. SAE A flange .......................... 1 N25M ........... Tube ........................................................ 1
J00B ............. Aux. mtg. SAE B flange .......................... 1 N35M ........... Plug ......................................................... 2
J00C ............. Aux. mtg. SAE C flange .......................... 1 N40L ............ Filter ........................................................ 1
J00D ............. Aux. mtg. SAE D flange .......................... 1 N40P ............ Filter ........................................................ 1
J00T ............. Aux. mtg. SAE A flange (11 T) ............... 1
J00V ............. Aux. mtg. SAE B-B flange ....................... 1 N00R ............ Filtration manifold kit (Rmt) ..................... 1
J00N ............. Aux. mtg. flange - none .......................... 1 N10R ............ Manifold ................................................... 1
J10A-V ......... Coupling .................................................. 1 N15R ............ O-ring ...................................................... 1
J15 ............... Charge pump cover assembly ................ 1 N20R ............ Nut ........................................................... 1
J15N ............. Charge pump cover assembly ................ 1 N25R ............ Tube ........................................................ 1
J30 ............... Bushing ................................................... 1 N30R ............ Plastic plug .............................................. 2
J50A-V ......... O-ring ...................................................... 1 N35R ............ Plug ......................................................... 1
J60A/T .......... Flange adaptor SAE A ............................ 1
J60B/V ......... Flange adaptor SAE B ............................ 1 N00S ............ Filtration kit (Suction Flt) ......................... 1
J60C ............. Flange adaptor SAE C ............................ 1 N10S ............ Reducer fitting (Suction Flt) .................... 1
J60D ............. Flange adaptor SAE D ............................ 1 N35S ............ Plug ......................................................... 1
J70A-V ......... Washer .................................................... 4

Name Plates

Ames, Iowa, U.S.A. Neumünster, Germany Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ Model Code Typ

90L055 EA 1 N 90L055 EA 1 N
Model Model
6 S 3 C6 C 03 6 S 3 C6 C 03 Code
Code
Model No. Ident Nr Model No. Ident Nr
Model Number Model Number 687459
94 – 2029
Serial Number Serial Number
Serial No. Fabr Nr Serial No. Fabr Nr
MADE IN U.S.A. MADE IN GERMANY

Place of Manufacture Place of Manufacture

Name Plate (U.S.A. Production) Name Plate (German Production)

83

008 911 83 BOMAG 629

17.1 Travel pump series 90R

Series 90 Exploded View Parts Drawings / Parts Lists

Fixed Motor

Minor Repair Parts

H68W

H60W L35
(Early Production
H62W 075 Frame Size) (L70)
H64W
(L40) L60 L70
H66W
H60N L30
L40
(H50N) (B80)

(G50)
(H50W) (H30W)
L50
(H40W)
(H20W)

G50
G70
H10N (B80)
H50N
H20W
(G63)
B80 H10W H40W
G63
H30W
(CODE 61 OPTION)
H50W
(G64) G64
(CODE 61 OPTION)

B83 B83 OR

B80
G63
(CODE 61 OPTION)

(G63)
G64
(CODE 61 OPTION) (B83)
(G64) (B83)

90000864E

84

630 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Exploded View Parts Drawings / Parts Lists

Parts List

Item Description Qty Item Description Qty

B80 ............... Plug ......................................................... 2 H50W ........... Plug ......................................................... 2

B83 ............... Plug ......................................................... 1 H60W ........... Charge relief valve plug .......................... 1
B83 ............... Speed sensor .......................................... 1 H62W ........... O-ring ...................................................... 1
H64W ........... Spring ...................................................... 1
G50 .............. Plug ......................................................... 2 H66W ........... Charge relief poppet ............................... 1
G70 .............. Plug ......................................................... 1 H68W ........... Lock nut ................................................... 1
G63 .............. Split flange screw .................................... 4
G64 .............. Screw - Shipping Cover .......................... 4 L30 ............... Seal carrier .............................................. 1
L35 ............... Seal carrier .............................................. 1
H10N ............ Loop flushing spool - defeat .................... 1 L40 ............... Lip seal .................................................... 1
H50N ............ Plug ......................................................... 2 L50 ............... O-ring ...................................................... 1
L60 ............... Retainer ................................................... 1
H10W ........... Shuttle valve spool .................................. 1 L70 ............... Screw ...................................................... 3
H20W ........... Spring guide ............................................ 2
H30W ........... Spring ...................................................... 2 L8 ................. Key .......................................................... 1
H40W ........... O-ring ...................................................... 2 L9 ................. Slotted nut ............................................... 1

Name Plates

Ames, Iowa, U.S.A. Neumünster, Germany Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ Model Code Typ

90M055 NC 0 N 90M055 NC 0 N
8 N 0 C6 W 00 Model Model
8 N 0 C6 W 00
Code Code
NNN 00 00 24 NNN 00 00 24
Model No. Ident Nr Model No. Ident Nr
Model Number 94 – 2029 Model Number 312918
Serial Number A – 91 – 26 – 67890 Serial Number N – 91 – 26 – 67890
Serial No. Fabr Nr Serial No. Fabr Nr
MADE IN U.S.A. MADE IN GERMANY

Place of Manufacture Place of Manufacture

Name Plate (U.S.A. Production) Name Plate (German Production)

85

008 911 83 BOMAG 631

17.1 Travel pump series 90R

Series 90 Exploded View Parts Drawings / Parts Lists

Variable Motor

Minor Repair Parts

Y100 Y102
Y101

L35
Y40 (Early Production
075 Frame Size) (L70)
Y50
Y60 L70
E15 L60
E35 E26 (Y50) (L40)
L30

L40
B83
(B74)
B80
B83 L50
B76

H68W T100
T101
T30
H60W T40
(B74) T50
H62W T60
H64W (T50)

H66W M1PT Y80 Y71

H60N B74 Y72
Y70
M1NA, M1NB P700
(G50) M1NC, M1ND P702
(P400)
(H50N) G50 (B80)
(P401)
(H50W) (P402)
E25 P601 (P403)
(H40W) (B74)
P603
E35
(H30W) H10N
(H20W) (P400) P600
E15
(P401) P602
G70 H50N (P402)
(P403)

H10W
H20W
H30W
(G63) H40W H50W

G63
(G64) (CODE 61 OPTION)
P800
G64
(CODE 61 OPTION)

90000865E

86

632 BOMAG 008 911 83

Travel pump series 90R 17.1

Series 90 Exploded View Parts Drawings / Parts Lists

Parts List

Item Description Qty Item Description Qty

B74 ............... Plug ......................................................... 4 L30 ............... Seal carrier .............................................. 1

B76 ............... Plug ......................................................... 1 L35 ............... Seal carrier .............................................. 1
B80 ............... Plug ......................................................... 2 L40 ............... Lip seal .................................................... 1
B83 ............... Plug ......................................................... 1 L50 ............... O-ring ...................................................... 1
B83 ............... Speed sensor .......................................... 1 L60 ............... Retainer ................................................... 1
L70 ............... Screw ...................................................... 3
E15 ............... Cap .......................................................... 1
E25 ............... Set screw ................................................ 1 M1N ............. Control valve - electric ............................ 1
E35 ............... Nut - Seal Lock ....................................... 1 M1P .............. Control valve - hydraulic ......................... 1

G50 .............. Plug ......................................................... 2 P400 ............. Plug ......................................................... 2

G63 .............. Split flange clamp .................................... 4 P600 ............. Plug ......................................................... 1
G64 .............. Shipping cover screw .............................. 4 P601 ............. PCOR-Valve ............................................ 1
P700 ............. Special plug ............................................. 1
G70 .............. Plug ......................................................... 1 P800 ............. O-ring ...................................................... 1

H10N ............ Loop flushing spool - defeat .................... 1 T30 ............... Filter screen ............................................ 1
H50N ............ Plug ......................................................... 2 T40 ............... O-ring ...................................................... 1
H60N ............ Plug ......................................................... 1 T50 ............... Backup ring ............................................. 2
T60 ............... O-ring ...................................................... 1
H10W ........... Shuttle valve spool .................................. 1 T100 ............. Orifice plug .............................................. 1
H20W ........... Spring guide ............................................ 2
H30W ........... Spring ...................................................... 2 Y40 ............... O-ring ...................................................... 1
H40W ........... O-ring ...................................................... 2 Y50 ............... Backup ring ............................................. 2
H50W ........... Plug ......................................................... 2 Y60 ............... O-ring ...................................................... 1
H60W ........... Charge relief valve plug .......................... 1 Y70 ............... Orifice check valve .................................. 1
H62W ........... O-ring ...................................................... 1 Y71 ............... Nut - Seal Lock ....................................... 1
H64W ........... Spring ...................................................... 1 Y72 ............... O-ring ...................................................... 1
H66W ........... Charge relief poppet ............................... 1 Y80 ............... Plug ......................................................... 1
H68W ........... Lock nut ................................................... 1 Y100 ............. Orifice plug .............................................. 1
Y102 ............. Orifice check valve .................................. 1
L8 ................. Key .......................................................... 1
L9 ................. Slotted nut ............................................... 1

Name Plate

Ames, Iowa, U.S.A. Neumünster, Germany

Model Code Typ

90S055 NB 2 0
8 N 4 S1 W 01 Model Code
NNN 01 00 24
Model No. Ident Nr
Model Number 94 – 4002
Serial Number A – 91 – 26 – 67890
Serial No. Fabr Nr
MADE IN U.S.A.

Place of Manufacture
Name Plate (U.S.A. Production)

87

008 911 83 BOMAG 633

17.1 Travel pump series 90R

Hydraulic Power Systems

SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide
SAUER-SUNDSTRAND is a world leader in the design SAUER-SUNDSTRAND specializes in integrating a full
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SAUER-SUNDSTRAND COMPANY SAUER-SUNDSTRAND GMBH & CO.

2800 East 13th Street Postfach 2460 D-24531 Neumünster
Ames IA 50010 U.S.A. Krokamp 35 D-24539 Neumünster Germany
Phone: (515) 239-6000 Fax: (515) 239-6618 Phone: (04321) 871-0 Fax: (04321) 871 122

SM-SPV/SMF/SMV90-E • 10/98 • 300047G

634 BOMAG 008 911 83

17.2 Travel drive series 51

008 911 83 BOMAG 635

17.2 Travel drive series 51

636 BOMAG 008 911 83

Travel drive series 51 17.2

saue
Series 51

Bent Axis
Variable Motors
Service Manual

008 911 83 BOMAG 637

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
General Description
Series 51 Variable Displacement Motors are bent Motors equipped with controls normally start at maxi-
axis design units, incorporating spherical pistons. mum displacement. This provides maximum starting
torque (high acceleration).
These motors are designed primarily to be combined
with other products in closed circuit systems to trans- The controls may utilize externally or internally sup-
fer and control hydraulic power. plied servo pressure. They may be overridden by a
pressure compensator which functions when the
Series 51 Motors have a large maximum / minimum motor is operating in motor and pump modes. A
displacement ratio (5 to 1) and high output speed defeat option is available to disable the pressure
capabilities. SAE flange and cartridge motor configu- compensator override when the motor is running in
rations are available. pump mode.

The pressure compensator option features a low

pressure rise (short ramp) to provide optimal power
A complete family of controls and regulators is avai-
utilization throughout the entire displacement range
lable to fulfill the requirements of a wide range of
of the motor. The pressure compensator is also
applications.
available as a stand-alone regulator.

● The Series 51 - Advanced Technology Today

● The Most Technically Advanced Hydraulic Units in the Industry

● SAE Flange and Cartridge Motors

● Cartridge Motors designed for Direct Installation in Compact

Planetary Drives

● Large Displacement Ratio (5:1)

● Complete Family of Control Systems

● Proven Reliability and Performance

● Optimum Product Configurations

● Compact, Lightweight

Front page: Option - hydraulic two-position control

Copyright 1992-1997, Sauer-Sundstrand Company.
All rights reserved. Contents subject to change. Printed in U.S.A. 0992H
2

638 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Contents

Introduction ......................................................................................................................................................4
Basic Hydraulic Circuits ...................................................................................................................................4
General Description of the Series 51 Variable Displacement Motors ..............................................................5
Functional Description ......................................................................................................................................6
Technical Specifications and Data - Variable Displacement Motors .............................................................. 20
Safety Precautions .........................................................................................................................................21
Gauge Installation ..........................................................................................................................................23
Start-Up Procedure and Maintenance ............................................................................................................25
Component Inspection and Adjustment .........................................................................................................27
Troubleshooting ............................................................................................................................................. 37
Exploded View of the Series 51 Variable Motor .............................................................................................41
Minor Repair and Replacement - Variable Motor ........................................................................................... 51
General .....................................................................................................................................................51
Shaft Seal (SAE Flange Configuration) ....................................................................................................52
Shaft Seal (Cartridge Configuration) .........................................................................................................53
Loop Flushing Shuttle Valve (Option)........................................................................................................54
Charge Pressure Relief Valve ...................................................................................................................55
Minimum Angle Servo Cover .................................................................................................................... 55
Hydraulic 2-Position Control (Type N2) .....................................................................................................56
Electrohydraulic 2-Position Controls (Types E1•E2 and F1•F2) ...............................................................57
Electric 2-Position Controls (Type S1) ......................................................................................................58
Hydraulic Proportional Control (Type HZ) .................................................................................................59
Hydraulic Proportional Control (Type HS) .................................................................................................60
Hydraulic Proportional Control with Maximum Angle Over-ride (Types H1•H2 or K1•K2) ........................61
Two Connection Hydraulic Proportional Control (Type HP) ......................................................................62
Two Connection Hydraulic Proportional Control for “Dual Path” Vehicles (Type HC) ...............................64
Electrohydraulic Proportional Control (Types EP and EQ)........................................................................68
Pressure Control Pilot (PCP) Valve for Electrohydraulic Proportional Control (Types EP and EQ) .......... 70
Multi-function Block ...................................................................................................................................71
Pressure Compensator Regulator (Type PC) ........................................................................................... 76
Control Orifices .........................................................................................................................................77
Plug / Fitting Torques ................................................................................................................................77

0-1 3

008 911 83 BOMAG 639

17.2 Travel drive series 51

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Bent Axis Variable Displacement Motors Series 51
Introduction
The purpose of this manual is to provide information Dirt or contamination is the greatest enemy of any
necessary for the normal servicing of the Series 51 type of hydraulic equipment. The greatest possible
family of variable displacement hydrostatic motors. cleanliness is necessary when starting up the sys-
tem, changing filters, or performing any other service
This manual includes unit and component descrip- procedure.
tion, troubleshooting, adjustments, and minor repair
procedures. By following the procedures in this For Technical Information on Series 51 motors, refer
manual, inspections and minor repairs may be per- to publication BLN-10042 or 368753.
formed without affecting the unit warranty.
For Fluid Quality Requirements, refer to publication
A Series 51 motor does occasionally require servic- BLN-9987 or 697581.
ing, and these units are designed to meet this require-
ment. Sauer-Sundstrand provides a complete repair serv-
ice for its products. Contact any Sauer-Sundstrand
Many repairs or adjustments can be completed with- Authorized Service Center for details. Sauer-Sund-
out removing the unit from the vehicle or machine, strand Authorized Service Center locations are listed
provided the unit is accessible and can be thoroughly in publication BLN-2-40527 or 698266.
cleaned before beginning any procedures.

Basic Hydraulic Circuits

CASE Closed Circuit
DRAIN
LINE The main ports of the pump are connected by hydrau-
lic lines to the main ports of the motor. Fluid flows in
either direction from the pump to the motor then back
to the pump in this closed circuit. Either of the hydrau-
INPUT PV MV OUTPUT lic lines can be under high pressure. The direction
and speed of fluid flow (and the motor output shaft
rotation) depends on the position of the pump swash-
plate. The system pressure is determined by the
machine load.

FLOW (BI-DIRECTIONAL) Open Circuit

RESERVOIR The outlet port of the pump is connected by a hydrau-
51000001 lic line to a directional control valve. The working ports
Fig. 0-1 - Basic Closed Circuit of this valve are connected to the main ports of the
motor. When the valve is actuated, fluid flows first
FLOW FLOW from the pump to the valve. The valve then directs the
(UNI-DIRECTIONAL) (BI-DIRECTIONAL) fluid to the motor in either direction. The direction of
fluid flow (and motor output shaft rotation) depends
CONTROL VALVE

on the direction the control valve is shifted. The speed

INPUT PUMP of fluid flow (and motor output shaft speed) depends
MV OUTPUT on pump output volume and the distance the control
valve is shifted. The system pressure is determined
by the machine load.
CASE Fluid returning from the motor is routed through the
DRAIN
RESERVOIR LINE
control valve to the reservoir. Additional components
may be necessary to provide dynamic braking and to
51000002 deal with over-running loads.
Fig. 0-2 - Basic Open Circuit

4 0-2

640 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
General Description of the Series 51 Variable Displacement Motors
The Series 51 variable displacement hydraulic mo- Various hydraulic and electrohydraulic controls may
tors use spherical pistons and piston rings. The angle be mounted on the motor end cap to control the servo
between the cylinder block and the output shaft can piston and the motor displacement. Servo pressure
be set between 32° and 6°, providing a 5 to 1 oil may either be supplied internally from the motor, or
maximum to minimum displacement ratio. externally.

At maximum displacement, the motor will provide a For all controls except the N2 and PC, servo pressure
certain maximum output shaft torque and minimum oil is supplied to a four (4) way spool valve in the motor
speed corresponding to the pressure and flow sup- end cap. When a combination of pilot pressure (or
plied to the motor. Under the same input conditions force) from an external control assembly and internal
but at minimum displacement, the shaft speed will be spring force shifts this valve, servo pressure is routed
approximately five (5) times faster while the available to move the servo piston and change the motor’s
output torque will decrease to approximately one-fifth displacement.
(1/5) the full displacement value. The displacement
is changed by a servo piston which is connected to A synchronizing shaft, with spherical rollers, synchro-
the valve segment. nizes the rotation of the output shaft and the cylinder
block. The ball end of each piston runs in a socket
bushing, pressed into the output shaft. There are no
other parts used to connect the pistons to the shaft.
Two tapered roller bearings support the output shaft.
Minimum
Displacement Limiter
Hydraulic Pressure Compensator
Proportional Override
Control Valve Segment
Control
Pressure Bearing Plate
Port

Tapered Roller Bearings

Synchronizing
Piston Shaft

Servo Piston
Cylinder

Charge Pressure
Relief Valve
P001 196
Fig. 10-1 - Sectional view of Series 51 variable displacement motor (SAE Flange
Configuration) with Hydraulic Proportional Control

10 - 1 5

008 911 83 BOMAG 641

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Functional Description
Loop Flushing
Series 51 motors used in closed circuit applications
incorporate an integral loop flushing valve as stan-
dard equipment. Installations that require additional
fluid to be removed from the main hydraulic circuit
because of fluid cooling requirements, or circuits
requiring the removal of excessive contamination
from the high pressure circuit, can benefit from loop
flushing. Series 51 motors used in open circuit appli-
51000003 51000004
cations may have the optional loop flushing defeat
Fig. 10-2 - Loop Fig. 10-3 - Loop
components installed.
Flushing Flushing Defeat
Components Components Series 51 motors equipped with an integral loop
flushing valve also include a charge pressure relief
valve. The setting of the motor charge relief valve
affects the function of the flushing circuit. Higher
motor charge relief settings reduce the loop flushing
flow and increase the flow over the pump charge
pressure relief valve when the circuit is operating.
Lower motor charge relief settings increase the loop
flushing flow and may increase the motor case pres-
sure when the circuit is operating.

An appropriate combination of pump and motor charge

pressure settings should be maintained to insure the
proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all condi-
tions of operation to maintain pump control perfor-
mance in closed loop systems.

NOTE: An optional orifice may be installed between

the motor charge relief and the motor case to
limit the maximum flushing oil flow.

6 10 - 2

642 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Displacement Limiters
All Series 51 motors incorporate mechanical dis-
placement limiters. The minimum displacement of
the motor can be limited within the standard range by
a set screw in the motor housing. The maximum
displacement can be limited with spacers installed on
the servo piston.

51000005
Fig. 10-4 - Minimum Displacement Limiter
with Tamper Resistant Cap (Cartridge
Motor Configuration Shown)

51000006
Fig. 10-5 - Maximum Displacement Limiter
Screw

Controls - General
A wide range of control options is available for the
Series 51 motors. These include pilot operated
Electrohydraulic 2-Position Controls, Hydraulic Pro-
portional Controls (single or two [2] connection), and
Electrohydraulic Proportional Controls. A directly op-
erated Hydraulic 2-Position Control and a Pressure
Compensator regulator are also available.

The Series 51 variable motor servo piston (except 5100007

when equipped with N2 control or the PC regulator) Fig. 10-6 - Internal Servo Pressure Supply
may be operated either by servo pressure oil supplied Screen with Multi-function Block and/or
internally from the main ports of the motor, or by servo Control Removed (Plug for External
pressure oil supplied from an external source. (The Supply)
N2 control uses servo pressure supplied by an exter-
nal control valve. The PC regulator obtains servo
pressure from the main ports of the motor.)

Orifice plugs are installed in the control spool sleeve

in the end cap to regulate the flow of oil from the servo
piston to the motor housing. Orifice plugs may be
installed in the end cap to regulate the flow of servo
pressure supply oil to the control valve, and to regu-
late the flow of oil from the control valve to the servo
piston. 51000008
Fig. 10-7 - External Servo Pressure Supply
Fitting (Plug for Internal Supply)
10 - 3 7

008 911 83 BOMAG 643

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Hydraulic 2-Position Control (Type N2)
This is a two (2) position (maximum - minimum
displacement) control, consisting of a cover plate
mounted on the end cap. An external control valve
supplies servo pressure from an external source
directly to the servo piston. PCOR is not available
with the N2 control.

When servo pressure is supplied to port “Y1,” the

51000009 setting piston moves to the maximum motor displace-
Fig. 10-8 - Series 51 Motor with N2 Control ment position. When servo pressure is supplied to
port “Y2,” the setting piston moves to the minimum
motor displacement position.

Orifices may be installed in the external control valve

or its connections to regulate the speed of servo
piston movement.

51000010
Fig. 10-9 - N2 Control Components

L2 M6 (M4) Y1 Y2 (M3)

A
M1

max.
disp.

U4 (opt.)

M2
B

L1
51000011
Fig. 10-10 - N2 Control Schematic

8 10 - 4

644 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Electrohydraulic 2-Position Control (Types
E1•E2 and F1•F2)
A 12 or 24 VDC solenoid valve, mounted on the multi-
function block, connects the end of the control valve
spool in the end cap with pilot pressure (provided by
the shuttle spool in the multi-function block) or with
the motor case. The control valve in the end cap is
biased by a threshold spring, and controls oil flow to
the ends of the servo piston. Servo pressure may be
51000012
supplied from an external source or internally by the Fig. 10-11 - Series 51 Motor with E1•E2 or
shuttle spool in the multi-function block. PCOR is
F1•F2 Control
available with these controls.

With the E1 and E2 controls, energizing the solenoid

will cause the motor to shift to minimum displace-
ment. When the solenoid is not energized, the motor
is held at maximum displacement.

With the F1 and F2 controls, energizing the solenoid

causes the motor to shift to maximum displacement.
When the solenoid is not energized, the motor is held
at minimum displacement.
51000013
Fig. 10-12 - E1•E2 and F1•F2 Control
Components

L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
E1•E2
B1
U5
(plug for T7,
ext. servo T8 M9
T1
press.) X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1

M8 M7
F1•F2

51000014
Fig. 10-13 - E1•E2 and F1•F2 Control
Schematic

10 - 5 9

008 911 83 BOMAG 645

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Electric 2-Position Control (Type S1)
A 12 VDC solenoid valve, mounted on the multi-
function block, directly operates the control valve
spool in the end cap. The control valve in the end cap
is biased by a threshold spring, and controls oil flow
to the ends of the servo piston. Servo pressure may
be supplied from an external source or internally by
the shuttle spool in the multi-function block. PCOR is
available with this control.
51000162
Fig. 10-14 - Series 51 Motor with S1 Control With the S1 control, energizing the solenoid causes
the motor to shift to maximum displacement. When
the solenoid is not energized, the motor is held at
minimum displacement.

51000163
Fig. 10-15 - S1 Control Components

L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
S1
B1
U5
(plug for T7,
ext. servo T8 M9
T1
press.) X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1
51000085
Fig. 10-16 - S1 Control Schematic

10 10 - 6

646 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Hydraulic Proportional Control (Type HZ)
The HZ control consists of a cover plate mounted
directly on the end cap. A ball type shuttle valve
provides internal servo pressure supply to the control
valve in the end cap. PCOR is not available with the
HZ control.

Feedback springs (single spring for 060, 080 and

110) and a threshold spring are installed in the end
cap. The feedback springs and threshold spring 51000015

provide a force on the end of the control spool. The Fig. 10-17 - Series 51 Motor with HZ
force of the threshold spring is externally adjustable Control
with an adjusting screw. The feedback spring is
positioned between the control spool and a feedback
lug attached to the servo piston. The force of the
feedback spring increases as the motor’s displace-
ment decreases.

Pilot oil pressure from an external source is applied to

the end of the control spool opposite the feedback
and threshold springs. An increase in pilot pressure
(above the threshold pressure and within the modu-
lating pressure range) will result in a decrease in
51000016
motor displacement, while a decrease in pilot pres- Fig. 10-18 - HZ Control Components
sure will result in an increase in motor displacement.

L2 M6 M4 M3

A
M1

max.
disp.

U4 (opt.) T3

T2

T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
B
Servo
Pressure
internal L1

X1 M7
51000017
Fig. 10-19 - HZ Control Schematic

10 - 7 11

008 911 83 BOMAG 647

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Hydraulic Proportional Control (Type HS)
The HS control consists of a cover plate (with a
hydraulic port) mounted on the multi-function block.
Servo pressure may be supplied from an external
source or internally by the shuttle spool in the multi-
function block. PCOR is available with this control.

The function of the HS control is identical to the

function of the HZ control.
51000018
Fig. 10-20 - Series 51 Motor with HS
Control

51000019
Fig. 10-21 - HS Control Components
L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
B1
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1

M7 X1 HS

H1•H2
M7 X1

K1•K2
M7 X1
51000022
Fig. 10-22 - HS, H1•H2, and K1•K2 Control
Schematic

12 10 - 8

648 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Hydraulic Proportional Control with
Electric Override (Types H1•H2 and K1•K2)
The function of the H1•H2 and K1•K2 controls is
similar to the function of the HS control. A 12 or 24
VDC solenoid valve is installed between the external
pilot pressure source and the control spool.

With the H1•H2 controls, energizing the solenoid

allows the control to function as an HS control. When
the solenoid is not energized, pilot pressure is blocked 51000020

and the end of the control spool is drained to the motor Fig. 10-23 - Series 51 Motor with H1•H2
case, causing the motor to shift to maximum displace- Control
ment.

With the K1•K2 controls, energizing the solenoid

blocks pilot pressure and drains the end of the control
spool to the motor case, causing the motor to shift to
maximum displacement. When the solenoid is not
energized, the control functions as an HS control.

51000167
Fig. 10-24 - Series 51 Motor with K1•K2
Control

51000021
Fig. 10-25 - H1•H2 and K1•K2 Control
Components

10 - 9 13

008 911 83 BOMAG 649

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)

Two Line Hydraulic Proportional Control
(Type HP)
This control consists of a valve block with two (2)
hydraulic ports mounted on the multi-function block.
The valve block incorporates a shuttle spool and a
pilot piston with centering springs. A pin transmits
force from the pilot piston to the control spool in the
end cap. Feedback springs (single spring for 060,
51000023
080, and 110) and a threshold spring are installed in
Fig. 10-26 - Series 51 Motor with HP the end cap. These springs function similar to the HS
control. Servo pressure may be supplied from an
Control
external source or internally by the shuttle spool in the
multi-function block. PCOR is available with this
control.

Two pilot pressures are provided to the control. The

shuttle spool directs the higher pilot pressure to the
end of the pilot piston opposite the feedback spring,
and the lower pressure to the opposite side of the pilot
piston. The rod transmits a force, proportional to the
difference of the pilot pressures, to the control spool.

51000024
An increase in the difference between the pilot pres-
Fig. 10-27 - HP Control Components sures will result in a decrease in motor displacement,
while a decrease will result in an increase in displace-
ment.
L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
B1
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
Servo B
Press,
internal
L1

X2 X1
51000025
Fig. 10-28 - HP Control Schematic

14 10 - 10

650 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Two Line Hydraulic Proportional Control
for “Dual-Path” Vehicles (Type HC)
The HC control operates in a similar manner to the HP
control, however the HC control is optimized for use
in “dual-path” drive vehicles. This control consists of
a valve block with two (2) hydraulic ports mounted on
the end cap. The valve block incorporates a shuttle
spool and a pilot piston with centering springs. A pin
transmits force from the pilot piston to the control
51000158
spool in the end cap. Fig. 10-29 - Series 51 Motor with HC
A bleed valve is provided to eliminate any air which Control
might become trapped in the pilot piston oil passages.

Feedback springs are installed in the end cap. Servo

pressure is supplied internally by a ball type shuttle
valve in the control housing. PCOR is not available
with this control.

Two pilot pressures are provided to the control. The

shuttle spool directs the higher pilot pressure to the
end of the pilot piston opposite the feedback springs,
and the lower pressure to the opposite side of the pilot
piston. The pin transmits a force, proportional to the
difference of the pilot pressures, to the control spool.

An increase in the difference between the pilot pres- 51000111

sures will result in a decrease in motor displacement, Fig. 10-30 - HC Control Components
while a decrease will result in an increase in displace-
ment. The feedback springs in the end cap have L2 M6 M4 M3
differing spring rates and operate in parallel (060,
A
080, and 110) or series (160 or 250) to provide a linear M1
relationship between motor displacement and pilot
pressure differential. max.
disp.

U4 (opt.) T3

T2

T7,
T8 M9
T1
M5

M2
B

L1

X2 X1
51000160
Fig. 10-31 - HC Control Schematic

10 - 11 15

008 911 83 BOMAG 651

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Electrohydraulic Proportional Control
(Types EP and EQ)
This control consists of a valve block and PCP (Pres-
sure Control Pilot) valve mounted on the multi-func-
tion block. The valve block incorporates a pilot piston
with centering springs. A pin transmits force from the
pilot piston to the control spool in the end cap.
Feedback springs (single spring for 060, 080, and
110) and a threshold spring are installed in the end
51000026
cap. These springs function similar to the HS control.
Fig. 10-32 - Series 51 Motor with EP Control
Servo pressure may be supplied from an external
(EQ Similar) source or internally by the shuttle spool in the multi-
function block. PCOR is available with this control.

An external pilot pressure source is connected to the

inlet of the PCP valve, which produces differential
pilot pressures proportional to the current through it.
These pressures are applied to the pilot piston. The
operation of this control is similar to that of the HP
Control, with the motor displacement being propor-
tional to the current through the PCP valve.

An increase in current (above the threshold current)

will result in a decrease in motor displacement, while
a decrease will result in an increase in displacement.
51000027
Fig. 10-33- EQ Control Components (EP
Similar)

L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
B1
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1

M7 X1 M8
51000028
Fig. 10-34 - EP and EQ Control Schematic

16 10 - 12

652 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Multi-function Block Components
The Multi-function Valve Block includes a shuttle
valve which provides internally supplied servo pres-
sure, and an optional Pressure Compensator Over-
Ride (PCOR) function with optional brake pressure
defeat.

51000029
Fig. 10-35 - Multi-function Block (Without
Control)

Servo Pressure Supply

For internal supply, the multi-function block incorpo-

rates a shuttle spool with internal check ball valve that
routes oil from the main circuit ports of the motor to the
control valve in the end cap. “High side” pressure is
provided to the servo control valve in the end cap.

For external supply, the connection between the

shuttle spool and the servo control valve is blocked in
51000030
the end cap. The external pressure supply to the Fig. 10-36 - Multi-function Block with Servo
servo control valve connects to a port (“M5”) on the
Pressure Supply Shuttle Spool
end cap.

Pressure Compensator Over-Ride (PCOR)

The Pressure Compensator Over-Ride (PCOR) sys-

tem includes a spool valve located in the PCOR block
which is attached to the multi-function block. This
system increases the motor displacement at system
pressures above the PCOR valve setting. (Pressure
Compensator Over-Ride is not available with the N2
and HZ controls, or the PC regulator.)

For bi-directional PCOR operation, the shuttle valve

in the multi-function block routes system high pres-
sure to the PCOR spool valve. For single direction
51000031
PCOR operation, the PCOR spool valve is connected Fig. 10-37 - Multi-function Block with PCOR
to one (1) side of the closed loop through passages in Block and Spool Valve (K1•K2 Control
the multi-function block
Shown)
When system pressure exceeds the PCOR setting,
the spool valve moves to connect the displacement
reducing end of the servo piston to the motor case,
and the displacement increasing end of the servo
piston to system pressure. This increases the motor
displacement, which reduces the motor output speed.
When the PCOR valve closes, control of the servo
piston returns to the control spool in the motor end
cap.

10 - 13 17

008 911 83 BOMAG 653

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
An optional “brake pressure defeat” spool may be
installed in the multi-function block. When used with
the PCOR, this spool assures that the PCOR does
not cause the motor displacement to increase during
deceleration (which could cause pump overspeed).
Pressure from a source such as the pump servos or
an external valve, shifts the defeat spool to block the
high pressure supply to the PCOR valve from the
“deceleration” side of the closed loop. Either bi-
51000032 directional or single direction PCOR operation can be
Fig. 10-38 - Multi-function Block with PCOR specified when PCOR defeat is installed.
Defeat Spool Components

Shuttle Valve Shuttle Valve PCOR Brake Pressure Defeat Operation

A1 T4 A1
Rotation High pressure Control pressure
Defeat
Spool
port on port

CW A XB
T5
CCW B XA
U7 U7

U6 U6
B1 T6
B1

PCOR PCOR
Valve Valve

XA XB

Standard with Defeat

Pressure Compensator Override
51000033
Fig. 10-39 - PCOR and PCOR with Defeat
Schematic

18 10 - 14

654 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Pressure Compensator Regulator (Type
PC)
In this regulator, the Pressure Compensator system
in the multi-function block assembly controls the
motor displacement. At system pressures below the
compensator setting, the servo piston is maintained
in the minimum motor displacement position. When
system pressure exceeds the POR setting, hydraulic
pressure acts on the servo piston to increase the
motor displacement.

With the Pressure Compensator regulator, an in- 51000034

crease in system pressure (above the setting pres- Fig. 10-40 - Series 51 Motor with PC
sure) will result in an increase in motor displacement Regulator
and output torque, and a decrease in motor shaft
speed.

51000035
Fig. 10-41 - PC Regulator Components

L2 M6 M4 M3

A
M1

max.
disp.
T5
U7

U4 (opt.)

U6 T7

T1
M9
M5

M2
B

L1
51000036
Fig. 10-42 - PC Regulator Schematic

10 - 15 19

008 911 83 BOMAG 655

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Technical Specifications and Data - Variable Displacement Motors
Design Hydraulic Fluid
Piston motor with variable displacement, bent axis Refer to Sauer-Sundstrand publication BLN-9887 or
construction. 697581.
Type of Mounting Temperature 1)

SAE four (4) bolt flange – SAE Flange Configuration. ϑ min = -40°C (-40°F), intermittent, cold start
Two (2) bolt flange – Cartridge Motor Configuration. ϑ nominal = 104°C (220°F), continuous
ϑ max = 115°C (240°F), intermittent
Pipe Connections
1)
at the hottest point, normally the case drain line.
Main pressure ports: SAE flange
Hydraulic fluid viscosity must be as shown below.
Remaining ports: SAE O-ring thread
Fluid Viscosity Limits
Direction of Rotation
ν min = 5 mm2/s (42 SUS) intermittent
Clockwise and counter-clockwise.
ν min = 6.4 mm2/s (47 SUS) min. continuous
Installation Position ν min = 13 mm2/s (70 SUS) optimum
ν max = 110 mm2/s (510 SUS) max. continuous
Installation position discretionary. The housing must ν max = 1600 mm2/s (7400 SUS) intermittent, cold start
always be filled with hydraulic fluid.
Filtration
System Pressure Range, Input
Acceptable contamination level: ISO Code 18/13 or
Max: 480 bar (6960 psi) better. Refer to Sauer-Sundstrand publication BLN-9887
Min: 10 bar (145 psi) or 697581.
Case Pressure
Max. Continuous: 3 bar (44 psi)
Intermittent (Cold start): 5 bar (73 psi)

Frame Size
Dimension 060 080 110 160 250
Displacement maximum cm3 60.0 80.7 109.9 160.9 250.0
in3 3.66 4.92 6.71 9.82 15.26
minimum cm3 12.0 16.1 22.0 32.2 50.0
in3 0.73 0.98 1.34 1.96 3.05
Continuous speed at max disp min-1 (rpm) 3600 3100 2800 2500 2200
at min disp min-1 (rpm) 5600 5000 4500 4000 3400
Max. speed at max disp min-1 (rpm) 4400 4000 3600 3200 2700
at min disp min-1 (rpm) 7000 6250 5600 5000 4250
Theoretical at max disp Nm / bar 0.95 1.28 1.75 2.56 3.98
torque lbf•in / 1000 psi 583 784 1067 1563 2428
at min disp Nm / bar 0.19 0.26 0.35 0.51 0.80
lbf•in / 1000 psi 117 156 214 313 486
Max. continuous Q max L / min 216 250 308 402 550
flow gal / min 57 66 81 106 145
Max. corner power Pcorner max kW 336 403 492 644 850
hp 450 540 660 864 1140
Mass moment J kg • m2 0.0046 0.0071 0.0128 0.0234 0.0480
of inertia lbf • ft2 0.1092 0.1685 0.3037 0.5553 1.1580
Weight m kg 28 32 44 56 86
(with control N2) lb 62 71 97 123 190

20 10 - 16

656 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Safety Precautions

● When Series 51 units are used in vehicular ● Use caution when dealing with hydraulic
hydrostatic drive systems, the loss of hy- fluid under pressure. Escaping hydraulic
drostatic drive line power in any mode of fluid under pressure can have sufficient
operation may cause a loss of hydrostatic force to penetrate your skin causing seri-
braking capacity. A braking system, redun- ous injury. This fluid may also be hot enough
dant to the hydrostatic transmission must, to burn. Serious infection or reactions can
therefore, be provided which is adequate to develop if proper medical treatment is not
stop and hold the system should the condi- administered immediately.
tion develop.
● Some cleaning solvents are flammable. To
● Certain service procedures may require the avoid possible fire, do not use cleaning
vehicle/machine to be disabled (wheels solvents in an area where a source of igni-
raised off the ground, work function discon- tion may be present.
nected, etc.) while performing them in order
to prevent injury to the technician and by-
standers.

20 - 1 21

008 911 83 BOMAG 657

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Notes

22 20 - 2

658 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Gauge Installation
Various pressure gauge readings can be a great Snubbers are recommended to protect pressure
asset in troubleshooting problems with the Series 51 gauges. Frequent gauge calibration is necessary to
motor or support system. insure accuracy.

Fig. 30-1 - Gauge Ports, Motor with N2 Control

Port "L1" Port Y2:
Servo press., external
(N2 Control Only) Gauge port M6:
Charge pressure
"X" Gauge port M3; 9/16 — 18 UNF-2B
Servo pressure
min. displacement Gauge port M2:
Port "B" system
pressure
A B
Gauge port M1:
Port "A" system M1
pressure Port Y1:
M2
Servo press., external
(N2 Control Only)
Port "L2"
Gauge port M4:
Servo pressure
max. displacement
Side Port End Cap Axial Port End Cap
Right Side View View in Direction "X"
51000037

Fig. 30-2- Gauge Ports, Motor with E1•E2, F1•F2, H1•H2, and K1•K2 Controls
Port X3:
servo press., external
Gauge port M5:
servo press., internal Control • E1/E2 • F1/F2
XA
Control • E1/E2•F1/F2 Control • H1/H2 • K1/K2
Gauge port M8 Gauge port M7
Control • H1/H2 control pressure
Control pressure port X1 View"T"
Control • K1/K2
Control pressure port X1
XA
XB XB

"T" 51000038

Fig. 30-3 - Gauge Ports, Motor with HS and HZ Controls

Port X3:
servo press., ext.
Gauge port M5: Gauge port M7:
servo press., int. Control pressure
XA
Gauge port M7:
Control pressure
View"U" View"U"
(HS) (HZ)

XA XB
Control pressure Control pressure
XB
port X1 port X1
"U" 51000039

30 - 1 23

008 911 83 BOMAG 659

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Gauge Installation (Continued)
Fig. 30-4 - Gauge Ports, Motor with HP Control

Port X3:
servo press., ext.
Gauge port M5:
servo press., int. XA

View"V"

XA XB

XB X1 X2 Ports X1, X2:

Control pressure
9/16 — 18 UNF-2B
"V" 51000040

Fig. 30-5 - Gauge Ports, Motor with EP•EQ Control

Port X3:
servo press., ext.
Gauge port M5:
servo press., int. XA

View"W"

XA XB

XB
MS-Connector (MS3102C) Packard
7/8 — 20 UNEF Connector
Manual override
Port X1:
External PCP
"W" supply pressure 51000041

Gauge Information
System 600 bar or 10,000 psi Gauge Motor 60 bar or 1000 psi Gauge
M1 Pressure M6 Charge
Port “A” 9/16 — 18 O-Ring Fitting Pressure 9/16 — 18 O-Ring Fitting
System 600 bar or 10,000 psi Gauge M7 Control 60 bar or 1000 psi Gauge
M2 Pressure M8 Test Port 9/16 — 18 O-Ring Fitting
Port “B” 9/16 — 18 O-Ring Fitting L1 Case 60 bar or 1000 psi Gauge
Servo 600 bar or 10,000 psi Gauge L2 Pressure 060, 080, 110:
M3 Pressure 1-1/16 — 12 O-Ring Fitting
(Min. Angle) 9/16 — 18 O-Ring Fitting 160, 250:
Servo 600 bar or 10,000 psi Gauge 1-5/16 — 12 O-Ring Fitting
M4 Pressure X1 Control 60 bar or 1000 psi Gauge
(Max. Angle) 9/16 — 18 O-Ring Fitting X2 Pressure 9/16 — 18 O-Ring Fitting
Servo 600 bar or 10,000 psi Gauge X3
M5 Supply 9/16 — 18 O-Ring Fitting or XA Defeat 60 bar or 1000 psi Gauge
(M9) Pressure Tee into Control Pressure Line XB Pressure Tee into Defeat Pressure
Line(s)

24 30 - 2

660 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Start-Up Procedure and Maintenance
Start-Up Precautions Fill the reservoir with recommended hydraulic fluid,
which should be passed through a 10 micron (nomi-
Cleanliness
nal, no bypass) filter prior to entering the reservoir.
Ensure that all system components, including fittings, The use of contaminated fluid will cause damage to
pipes, and hoses, are completely clean. If cloths are the components, which may result in unexpected
used for cleaning components, they must be made of vehicle/machine movement.
lint-free materials.
The inlet line leading from the reservoir to the pump
Follow the guidelines presented in Sauer-Sundstrand must be filled prior to start up. Check inlet line for
publication BLN-9887 or 697581 for required fluid properly tightened fittings and make sure it is free of
cleanliness levels at machine start-up. restrictions and air leaks.
Reservoir and Fluid Level Be certain to fill the pump and motor housing with
clean hydraulic fluid prior to start up. Fill the
The reservoir should be designed to accommodate
housing by pouring filtered oil into the upper case
maximum volume changes during all system operat-
drain port.
ing modes, and to promote de-aeration of the fluid as
it passes through the tank. The reservoir outlet (charge Install a 0 to 60 bar or 0 to 1000 psi pressure gauge
pump inlet) and the reservoir inlet (fluid return) must in the charge pressure gauge port to monitor the
always be below the normal fluid level. A sight glass charge pressure during start-up.
is the preferred method for checking fluid level.
The external control input signal should be discon-
The reservoir inlet (fluid return) should be positioned nected at the pump control during initial start-up. This
so that flow to the reservoir is directed into the interior will allow the pump to remain in its neutral position.
of the reservoir for maximum dwell and efficient de-
“Jog” or slowly rotate prime mover until charge pres-
aeration. A baffle (or baffles) between the reservoir
sure starts to rise. Start the prime mover and run at
inlet and outlet ports will promote de-aeration and
the lowest possible RPM until charge pressure is
reduce surging of the fluid.
established. Excess air may be bled from the high
No funnel-shaped eddying at the reservoir outlet pressure lines through the high pressure gauge ports.
(charge pump inlet) or formation of foam at the
Once charge pressure is established, increase speed
reservoir inlet (fluid return) is permitted.
to normal operating RPM. Note the charge pressure.
Start-Up Procedure If charge pressure is incorrect, shut down and deter-
mine cause for improper pressure.
The following start-up procedure should always be
followed when starting-up a new Series 51 installa- Shut down prime mover and connect external control
tion or when restarting an installation in which either input signal. Start prime mover, checking to be
the pump or motor has been removed from the certain pump remains in neutral. With prime mover at
system. normal operating speed, slowly check for forward and
reverse machine operation.
WARNING
Charge pressure should be maintained during for-
The following procedure may require the ve- ward or reverse operation. Continue to cycle slowly
hicle/machine to be disabled (wheels raised off between forward and reverse for at least five (5)
the ground, work function disconnected, etc.) minutes.
while performing the procedure in order to
prevent injury to the technician and bystand- Shut down prime mover, remove gauges, and plug
ers. Take necessary safety precautions before ports. Check reservoir level and add fluid if neces-
operating the vehicle/machine. sary.
Prior to installing the motor, inspect the unit for The transmission is now ready for operation.
damage incurred during shipping and handling. Make
certain all system components (reservoir, hoses,
valves, fittings, heat exchanger, etc.) are clean prior
to filling with fluid.

30 - 3 25

008 911 83 BOMAG 661

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Start-Up Procedure and Maintenance (Continued)
Maintenance Changing the Fluid and Filter
Cleanliness
To insure optimum service life on Series 51 products,
The reservoir breather air filter (if equipped) must be regular maintenance of the fluid and filter must be
kept clean. Clean the area around the filler cap before performed.
opening the reservoir. The hydraulic fluid should be
The fluid and filter must be changed per the vehicle/
filtered before it enters the reservoir.
machine manufacturer’s recommendations. In the
Follow the guidelines presented in Sauer-Sundstrand absence of such recommendations, the following
publication BLN-9887 or 697581 for required fluid intervals may be used:
cleanliness levels during machine operation.
• System with a sealed type reservoir - 2000 hrs.
Recommended Fluids • System with a breathing type reservoir - 500 hrs.

Hydraulic fluids used with Sauer-Sundstrand prod- It may be necessary to change the fluid more fre-
ucts should be carefully selected with assistance quently if the fluid becomes contaminated with for-
from a reputable supplier, following the guidelines eign matter (dirt, water, grease, etc.) or if the fluid has
presented in Sauer-Sundstrand publication BLN-9887 been operating at temperature levels greater than the
or 697581. maximum recommended. Never reuse fluid.

Checking for Leaks The filter should be changed when changing the fluid,
or whenever the filter indicator shows that it is neces-
Check the system components for leakage at regular sary to change the filter.
intervals. Tighten any leaking connections while the
system is not under pressure. Replace any defective
seals and gaskets.

Check hydraulic hoses for damage or aging. When

installing replacements, be certain that the hoses are
clean and connected properly.

Checking the Fluid Level

Check the reservoir daily for proper fluid level, the

presence of water (noted by a cloudy or milky appear-
ance, or free water in bottom of reservoir), and rancid
fluid odor (indicating excessive heat).

26 30 - 4

662 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Component Inspection and Adjustment

WARNING

The following procedures may require the ve-

hicle/machine to be disabled (wheels raised off
the ground, work function disconnected, etc.)
while performing the adjustments to prevent
injury to the technician and bystanders.

Charge Pressure Relief Valve Adjustment

An appropriate combination of pump and motor charge
pressure settings should be maintained to insure the
proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all
conditions of operation to maintain pump control
performance in closed loop systems.

To measure motor charge pressure, install a 0 to 60

bar or 0 to 500 psi pressure gauge in the motor charge 51000042

pressure gauge port. Install a gauge to measure case Fig. 30-6 - Adjusting Charge Pressure
pressure. Operate the system with the prime mover Relief Valve
at normal operating speed and the pump at half
stroke (forward or reverse) when measuring motor
charge pressure.

In most applications, the motor charge relief valve is

set 2 to 4 bar (29 to 58 psi) below the setting of the
pump charge relief valve (measured with the pump in
its “neutral” or zero-angle position). This setting as-
sumes a reservoir temperature of 50° C (122° F), and
is referenced to case pressure.
51000043
Series 51 motors are equipped with an external screw
Fig. 30-7 - Tighten Charge Pressure Relief
adjustable charge pressure relief valve. To adjust the
charge pressure, loosen the lock nut (with a 1-1/16" Valve Lock Nut
hex wrench) and turn the adjustment plug with a large
screwdriver. Clockwise rotation of the plug increases
the setting, and counter-clockwise rotation decreases
the setting (at a rate of approximately 3.4 bar [50 psi]
per turn). The lock nut should be torqued to 52 Nm (38
ft•lbsf).

Once the desired charge pressure setting is achieved,

remove the gauges and reinstall the port plugs.

30 - 5 27

008 911 83 BOMAG 663

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Minimum Displacement Limiter Adjustment
The minimum displacement is set at the factory, and
the adjustment screw is covered with a tamper-
resistant cap
WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The sealing lock nut must be retorqued
510000434
Fig. 30-8 - Loosen Minimum Displacement after every adjustment to prevent an unex-
Limiter Lock Nut pected change in operating conditions and to
prevent external leakage during unit operation.
NOTE: Changes in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor, while maintaining the motor at
minimum displacement and monitoring the
motor output shaft speed. An increase in
displacement will result in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed.

To adjust the minimum displacement, first remove

51000045
Fig. 30-9 - Rotate Minimum Displacement and discard the cap covering the adjusting screw.
Adjusting Screw Using a 17 mm hex wrench for 060 and 080 frame
size motors or a 19 mm hex wrench for 110 through
250 frame size motors, loosen the lock nut retaining
Approximate Change in the minimum displacement limiter adjusting screw.
Minimum Displacement Using a 5 mm internal hex wrench for 060 and 080
Frame Per Revolution frame size motors or a 6 mm internal hex wrench for
Size of Adjusting Screw 110 through 250 frame size motors, rotate the adjust-
060 1.5 cc/Rev (.09 in3/Rev) ing screw to limit the minimum displacement of the
080 2.1 cc/Rev (.13 in3/Rev) motor.
110 3.1 cc/Rev (.19 in3/Rev) Rotating the adjusting screw clockwise will increase
180 4.0 cc/Rev (.24 in3/Rev) the minimum displacement of the motor, while rotat-
250 6.2 cc/Rev (.38 in3/Rev) ing the adjusting screw counter-clockwise will de-
crease the minimum displacement.
Min. Displacement Screw Size
Frame Range and Length For each full revolution, of the adjusting screw, the
Size cc/Rev (in /Rev)
3
mm (in) displacement will change according to the accompa-
nying chart.
060 12 to 29 (.73 to 1.77) M10x65 (2.56)
30 to 40 (1.83 to 2.44) M10x80 (3.15) Different minimum displacements may require differ-
080 16 to 35 (.98 to 2.14) M10x65 (2.56) ent length adjusting screws. The various lengths are
36 to 54 (2.20 to 3.20) M10x80 (3.15) shown in the accompanying chart.
110 22 to 46 (1.34 to 2.81 ) M12x70 (2.76) After establishing the desired minimum displacement
47 to 74 (2.87 to 4.52) M12x80 (3.15) setting, tighten the lock nut on the adjusting screw to
160 32 to 72 (1.95 to 4.39) M12x75 (2.95) 51 Nm (38 ft•lbsf) for 060 and 080 frame size motors
73 to 107 (4.45 to 6.53) M12x90 (3.54) or 86 Nm (63 ft•lbsf) for 110 through 250 frame size
250 50 to 90 (3.05 to 5.49) M12x75 (2.95) motors. Install a new tamper-resistant cap on the
91 to 130 (5.55 to 7.93) M12x90 (3.54) adjusting screw.
131 to 167 (7.99 to 10.19) M12x100 (3.94)

28 30 - 6

664 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Maximum Displacement Limiter
Adjustment
The maximum displacement of the Series 51 motors
can be limited by limiting the stroke of the setting
piston, and the resulting movement of the valve
segment. A displacement stop screw is installed on
the setting piston (under the minimum angle servo
cover) to limit the stroke of the piston.

Spacers may be installed on the displacement stop

screw to limit the stroke. A longer or shorter screw
must be used to retain a thicker or thinner spacer.

WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The stop screw must be retorqued
after adjustment to prevent an unexpected
change in operating conditions.
NOTE: Changes in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor, while maintaining the motor at 51000046
maximum displacement and monitoring the Fig. 30-10 - Remove Minimum Angle Servo
motor output shaft speed. An increase in Cover Screws
displacement will result in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed. Approximate Change in
Frame Maximum Displacement
To adjust the maximum displacement, first remove Size with Change in Spacer Thickness
the screws retaining the minimum angle servo cover cc/mm (in3/.1 in)
to the end cap with an 8 mm internal hex wrench (060,
080, 110, and 160 units), or a 10 mm internal hex 060 0.98 (.15)
wrench (250 units). Remove the minimum angle 080 1.14 (.18)
servo cover and O-rings. Remove the displacement 110 1.48 (.23)
limiter screw with an 8 mm internal hex wrench. 160 1.93 (.30)
Installing a thicker spacer on the end of the setting 250 2.63 (.41)
piston will reduce the maximum displacement of the
motor. Installing a thinner spacer will increase the
maximum displacement. The displacement will
change according to the accompanying chart.

Torque the displacement limiter screw to 54 Nm (40

ft•lbsf).

Install the minimum angle servo cover and its O-rings.

Install the cover screws and torque to 78 Nm (58
ft•lbsf) for 060, 080, 110, and 160 motors, or 110 Nm
(81 ft•lbsf) for 250 motors.
51000070
Fig. 30-11 - Torque Maximum Displacement
Limiter Screw

30 - 7 29

008 911 83 BOMAG 665

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Displacement Control Adjustments
NOTE: A change in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor and monitoring the motor output
shaft speed while adjusting the control. An
increase in displacement will result in a de-
crease in shaft speed, while a decrease in
displacement will result in an increase in shaft
speed.

Hydraulic 2-Position Control (Type N2)

No adjustments are provided for the N2 control.

A minimum of 25 bar (360 psi) servo pressure is

required to change the motor displacement with the
motor shaft turning. A minimum of 70 bar (1015 psi)
servo pressure is required to change the motor dis-
placement with the motor shaft locked.
50000009
Fig. 30-12 - Hydraulic 2-Position Control,
Type N2)

Electrohydraulic 2-Position Control (Types E1•E2

and F1•F2) and Electric 2-Position Control (Type
S1)

These controls do not require adjustment.

CAUTION

Do not tamper with the adjusting screw in the

end cap (opposite the control).
50000012
Fig. 30-13 - Electrohydraulic 2-Position Pilot pressure for the E1•E2 or F1•F2 electric sole-
Control, Types E1•E2 and F1•F2 noid valve is internally supplied. When the solenoid is
energized, motor charge pressure should be present
at test ports M7 and M8. When the solenoid is not
energized, test port M8 should drop to case pressure.

The S1 control utilizes a direct acting solenoid to

operate the control valve spool in the end cap.

Servo pressure supply oil is usually provided inter-

nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
50000162 displacement with the motor shaft turning, and a
Fig. 30-14 - Electric 2-Position Control, minimum of 70 bar (1015 psi) is required with the
Type S1 motor shaft locked.

30 30 - 8

666 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Hydraulic Proportional Control (Types HZ, HS,
H1•H2, and K1•K2)
The control start pressure for these controls may be
adjusted with the adjusting screw on the end cap
(opposite the control block). Control start is that pilot
pressure at which the motor displacement starts to
decrease.
To check the control start setting, install a gauge to
monitor the pilot pressure (connect to port M7 or tee 51000015
into the pilot line connected to port X1), and the Fig. 30-15 - Hydraulic Proportional Control,
minimum angle servo pressure (port M3). If adjusting Type HZ
an H1 or H2 control, the override solenoid must be
energized. If adjusting a K1 or K2 control, the sole-
noid must not be energized.
NOTE: The pilot signal may be determined by prime
mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.
Increase the pilot signal to the required control start
pressure. An increase in minimum angle servo pres-
sure will be noted as the motor displacement starts to 51000018
decrease. Fig. 30-16 - Hydraulic Proportional Control,
To adjust the control start pressure, loosen the lock Type HS
nut using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm internal hex wrench. Turning the
screw clockwise increases the control start pressure.
Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjust-
ing.
For the H1•H2 controls, the pilot signal pressure
supplied to port X1 should also be present at test port
M7 when the solenoid is energized. When the sole-
noid is not energized, test port M7 should drop to case
pressure.
51000020
For the K1•K2 controls, the pilot signal pressure Fig. 30-17 - Hydraulic Proportional Control
supplied to port X1 should also be present at test port with Electric Override, Type H1•H2 (K1•K2
M7 when the solenoid is not energized. When the Similar)
solenoid is energized, test port M7 should drop to
case pressure.
Shut down the prime mover. Remove the gauges and
install the gauge port plugs. Return the pump and
motor controls to their normal operation.
Servo pressure supply oil is usually provided inter-
nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
51000047
displacement with the motor shaft turning, and a Fig. 30-18 - Adjusting Control Threshold,
minimum of 70 bar (1015 psi) is required with the Types HS, HZ, H1•H2, and K1•K2
motor shaft locked.

30 - 9 31

008 911 83 BOMAG 667

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Two Line Hydraulic Proportional Control
(Type HP)
The differential control start pressure for this control
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
differential pilot pressure at which the motor displace-
ment starts to decrease.

To check the control start setting, install gauges to

51000023 monitor the pilot pressures (tee into the pilot lines
Fig. 30-19 - Two Line Hydraulic connected to ports X1 and X2), and the minimum
Proportional Control, Type HP angle servo pressure (port M3).

NOTE: The pilot signals may be determined by prime

mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.

Increase the pilot signal differential to the required

control start pressure. An increase in minimum angle
servo pressure will be noted as the motor displace-
ment starts to decrease.
51000047 The differential control start pressure should be the
Fig. 30-20 - Adjusting Control Threshold same no matter which pilot pressure is higher. Differ-
(Type HP) ences in control operation when the pilot pressure
differential is reversed indicate a problem with the
shuttle spool in the control block.

To adjust the control start differential pressure, loosen

the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm internal hex wrench.
Turning the screw clockwise increases the control
start pressure. Torque the lock nut to 9 Nm (6.6 ft•lbsf)
after adjusting.

Shut down the prime mover. Remove the gauges and

install the gauge port plugs. Return the pump and
motor controls to their normal operation.

Servo pressure supply oil is usually provided inter-

nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
displacement with the motor shaft turning, and a
minimum of 70 bar (1015 psi) is required with the
motor shaft locked.

32 30 - 10

668 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Two Line Hydraulic Proportional Control
for “Dual Path” Vehicles (Type HC)
The differential control start pressure for this control
may be adjusted with the adjusting screw on the
control housing. Control start is that differential pilot
pressure at which the motor displacement starts to
decrease.

To check the control start setting, install gauges to

monitor the pilot pressures (tee into the pilot lines 51000158

connected to ports X1 and X2), and the minimum Fig. 30-21 - Two Line Hydraulic
angle servo pressure (port M3). Proportional Control, Type HC

NOTE: The pilot signals may be determined by prime

mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.

Increase the pilot signal differential to the required

control start pressure. An increase in minimum angle
servo pressure will be noted as the motor displace-
ment starts to decrease.

The differential control start pressure should be the 51000159

same no matter which pilot pressure is higher. Differ- Fig. 30-22 - Adjusting Control Threshold
ences in control operation when the pilot pressure (Type HC)
differential is reversed indicate a problem with the
shuttle spool in the control block.

To adjust the control start differential pressure, loosen

the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm internal hex wrench.
Turning the screw counter-clockwise (CCW) increases
the control start pressure. Torque the lock nut to 9 Nm
(6.6 ft•lbsf) after adjusting.

Shut down the prime mover. Remove the gauges and

install the gauge port plugs. Return the pump and
motor controls to their normal operation.

Servo pressure supply oil is provided internally from

the main system ports of the motor.

30 - 11 33

008 911 83 BOMAG 669

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Electrohydraulic Proportional Control
(Types EP and EQ)
The control start current for the EP and EQ controls
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
current supplied to the PCP (Pressure Control Pilot)
valve at which the motor displacement starts to de-
crease.
51000026 To check the threshold setting, install instruments to
Fig. 30-23 - Electrohydraulic Proportional monitor the PCP current, and the minimum angle
Control, Type EP (EQ Similar) servo pressure (port M3).

NOTE: The current supplied to the PCP may be

determined by prime mover speed, other
shaft speeds, control pressures, or other elec-
trical signals, depending upon the design of
the vehicle / machine control circuit.

Increase the PCP current to the required control start

current. An increase in minimum angle servo pres-
sure will be noted as the motor displacement starts to
decrease.
51000047
Fig. 30-24 - Adjusting Control Threshold To adjust the control start current, loosen the lock nut
(Type EP•EP) using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm internal hex wrench. Turning the
screw clockwise increases the control start current.
Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjust-
ing.

PCP supply pressure oil is provided externally. PCP

supply pressure must be a minimum of 20 bar (290
psi) and no more than 70 bar (1015 psi).

Shut down the prime mover. Remove the gauges and

install the gauge port plugs. Return the pump and
motor controls to their normal operation.

Servo pressure supply oil is usually provided inter-

nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
displacement with the motor shaft turning, and a
minimum of 70 bar (1015 psi) is required with the
motor shaft locked.

34 30 - 12

670 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Pressure Compensator Over-Ride (PCOR)
and Pressure Compensator Regulator
(Type PC) Adjustment
The PCOR or PC regulator valve setting may be
adjusted with the adjusting screw on the PCOR/PC
valve block attached to the multi-function block. The
regulator start pressure is that system pressure at
which the PCOR or PC regulator starts to increase
the motor displacement.
In order to measure the regulator start pressure
setting of the PCOR or the PC regulator, the motor
output shaft must be loaded to increase the system 51000031

working pressure. This can accomplished by apply- Fig. 30-25 - PCOR Block on Multi-Function
ing the vehicle’s brakes or by loading the work func- Block (K1•K2 Control Shown)
tion.
WARNING

The following procedures may require the ve-

hicle/machine to be disabled (wheels raised off
the ground, work function disconnected, etc.)
while performing the adjustment to prevent
injury to the technician and bystanders.
Install gauges to monitor system pressure (connect
to ports M1 and M2), the minimum angle servo
pressure (port M3), and the maximum angle servo
pressure (port M4).
51000034
Start the prime mover and operate at normal speed.
Fig. 30-26 - Pressure Compensator
Provide a signal to the pump control to provide a
Regulator (Type PC)
constant flow of hydraulic fluid to the motor. Provide
a signal to the motor control to maintain the motor at
its minimum displacement.
Increase the load on the motor to increase the system
pressure to the required regulator start pressure. The
maximum angle servo pressure (M4) will increase
and the minimum displacement servo pressure (M3)
will decrease as the PCOR or PC regulator operates.
The servo pressures will equalize, and the maximum
angle servo pressure continue to increase, as the
motor displacement starts to increase.
51000048
During the transition from minimum to maximum Fig. 30-27 - System Pressure Gauge Ports
displacement, an additional 10 bar (145 psi) increase (Side Port End Cap)
in system pressure may be noted.
Once the motor is at maximum displacement, further
increases in load will result in increasing system
pressure until the maximum system pressure (deter-
mined by the system relief valve or pump pressure
limiter) is reached.

30 - 13 35

008 911 83 BOMAG 671

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Allow the pump to return to its neutral position.
Repeat the procedure for the other side of the closed
circuit if so configured. The PCOR or PC regulator
must operate at the same start pressure as noted
previously. Any noticeable difference in operation
from side to side may indicate a problem with the
pressure supply shuttle spool or brake pressure de-
feat spool in the multi-function block.
NOTE: Some motors may be configured for the
PCOR or PC regulator to function on only
one (1) side of the closed loop. Refer to the
nomenclature on the motor nameplate.
In order for the PCOR or PC regulator to function
properly on motors equipped with a brake pressure
defeat spool, the defeat spool must be positioned
correctly. The control pressure for the defeat spool
should be applied to the appropriate port (XA or XB)
as shown in the following table to shift the defeat
spool and permit PCOR or PC regulator operation.
Maximum pressure across the brake pressure defeat
ports XA and XB is 50 bar (725 psi).
51000049 Pressure Compensator Override Defeat Operation
Fig. 30-28 - Loosen PCOR/PC Lock Nut Rotation High system Control
pressure port pressure on port
CW A XB
CCW B XA
The PCOR or PC regulator valve is screw adjustable.
To adjust, loosen the locknut with a 1-1/16" hex
wrench. Turn the adjusting screw with a large screw-
driver until the desired pressure setting is estab-
lished. Clockwise rotation of the adjustment screw
will increase the pressure setting at a rate of approxi-
mately 70 bar (1000 psi) per turn.
51000050
Fig. 30-29 - Rotate PCOR/PC Adjusting CAUTION
Screw A stop pin is installed in the adjusting screw to
prevent “overtravel” of the PCOR/PC valve
spool. The stop pin must protrude (distance
"X" “X”) 19 mm (.75 in.) from the spring seat for
settings of 270 to 370 bar (3900 to 5350 psi), or
24 mm (.94 in.) for settings of 110 to 260 bar
(1600 to 3750 psi). Refer to the appropriate
Service Parts Manual for further information.
While holding the adjusting screw from turning, torque
the lock nut to 52 Nm (38 ft•lbsf). Recheck the PCOR
or PC regulator setting.
51000051
Shut down the prime mover. Remove the gauges and
Fig. 30-30 - PCOR/PC Adjusting Screw Stop
install the gauge port plugs. Return the pump and
Pin motor controls to their normal operation.

36 30 - 14

672 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Troubleshooting
Fault-Logic Diagrams • Closed Circuit

Check Oil Level Check System Check Pump Check Prime Mover
OK OK OK Speed
in Reservoir Relief Valve Inlet Pressure
Pressure Low
Low Low OK
Settings

Fill to Proper Defective Inspect Inlet Filter Adjust

Level and Replace if
Adjust or Necessary
Replace

Replace Check System Check Charge and

Transmission OK Internal Leakage OK Control Pressures
(Pump and Motor)
High Incorrect

Repair as Required Repair as Required

SYSTEM RESPONSE IS SLUGGISH

Check Oil Air in System OK Check Pump Inspect Shaft Inspect Shaft
Level in
OK Inlet Pressure
OK Couplings
OK Alignment
Reservoir
Loose Fitting Low Defective Defective
Low

Fill to Proper Purge Air and Inspect Inlet Filter Repair or Align Shafts
Level Tighten and Replace if Replace
Fittings Necessary

EXCESSIVE NOISE AND/OR VIBRATION

Check Oil Level Inspect Heat Check Charge Check Pump Inlet
in Reservoir
OK Exchanger
OK Pressure
OK Pressure
Low Defective Incorrect Low OK

Fill to Proper Clean, Repair Repair as Inspect Inlet Filter

Level or Replace Required and Replace if
Necessary

Replace Check System Check for Internal Check System Relief

Transmission OK Pressure OK System Leakage OK Pressure Settings
(Pump and Motor)
High High Low

Reduce Load on Repair as Required Adjust or Replace

Transmission

SYSTEM OPERATING HOT

30 - 15 37

008 911 83 BOMAG 673

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Troubleshooting (Continued)
Fault-Logic Diagrams • Closed Circuit (Continued)

Check Charge Check Pump Interchange System Replace

Pressure OK Control System OK Relief Valves and/or OK Transmission
Charge Check (Pump and
Decays in One Defective Valves Motor)
Direction (Forward
Problem Changes
or Reverse) Only
Direction

Inspect and Repair Repair or Replace Repair or Replace

Loop Flushing Appropriate Valve
Valve

MOTOR OPERATES NORMALLY IN ONE DIRECTION ONLY

Check Inlet Check Outlet Motor at Incorrect Repair or Replace

Pressure at OK Pressure at OK (Minimum) Displacement OK Motor
Motor Motor

Low High / Low Incorrect

Correct System Correct System Check Control Supply

Pressure and/or Repair
LOW MOTOR OUTPUT TORQUE Displacement Control

Check Oil Check Charge Check Pump

Level in OK Pressure OK Output Flow OK Check Motor Displacement
Reservoir
Low Incorrect Improper Incorrect OK

Fill to Proper Repair Charge Repair Pump Check and Repair

Level System Control and/or Control System and
Pump Displacement Controls
(Pump and Motor)

Repair or Replace
Motor
IMPROPER MOTOR OUTPUT SPEED

38 30 - 16

674 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Notes

30 - 17 39

008 911 83 BOMAG 675

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Notes

40 30 - 18

676 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor
The following information is for general parts identi-
fication ONLY. Refer to the applicable Service Parts
List when ordering service parts.
Base Unit
L35

W10 OPTION
WNNT L40
W50
L50
B71
W25 B80
B71A B80
L70 L80

L75

L40
L50

B70
B70A

B70A

Y10
B70
Y20
W25
Y30

Y20

W50
Y10 Y10
W10 B70A
OPTION Y20
WNNS B70
Y30

Name Plate
saue
Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ

51V160 RF1N
E1A2 ANE1 NNN Model Code
050AA210322
Model No. Ident Nr
Model Number
516-40104 786673
Serial Number N 91 25 67890
Serial No. Fabr Nr
MADE IN GERMANY

Place of Manufacture
Name Plate (German Production)
40 - 1 41

008 911 83 BOMAG 677

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
End Cap
(....) = Applies to the indicated
G30 frame size(s).
G24

G30A
J70
G26
J60 G38

J50 G36

M18/M98 F10N, F10A–G

M16/M96 F20A–G
K90
K50
J40
K10
OR
K16 K70 OR
(250) K90N
G20
G20A K80
Q40 K90A
K14
K16 G50
(060—160)
G12 G50A G12
G12A G30 G30A K18N
(250) (250)
G80
(060, 080) G12A OR
G80A K16
G30 K18
(060, 080) (060—160) K16
(250)
G30A (250)
G30
(250) G30A K14
G20A
M11/T3A1-A9
T3B0-B6 G20
G12 T3C2-C7
G12A S20 OR
G12A
G12 S10
M11/T1A1-A9
T1B0-B6 (060, 080,
T1C2-C7 G30A 110)
G18 (250) OR S10
G90 (160, 250)
G12A G30
Y40 G12 (250)
N1U5 J30
T8A1-A9
Y50 T8B0-B6 J10A-D
T8C2-C7
J20/S70
G30A
G30 T7A1-A9
G42
G36 T7B0-B6
T7C2-C7
M11/T2A1-A9 G44
T2B0-B6
T2C2-C7 G38
F33
G38

G38
G42 F32

42 40 - 2

678 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Multi-Function Valve
N28 Q50
N28A N84
N84A

N52 OR

N32 N34
N34A
N72 N46/T5
N66 N72A N52/T4
N66A
N34
N34A N84
N30
N34
N34A OR
N52/T6
N34A N84A
N34
N34
N34A

N1A1-A6 N28
OR N28A
N90A
N66A
N90 OR N66
N26A
N26

N34
N34A
N58
N24
N82
N11

N29

Z10 & Z20

N82 N22 & N20

U7 N24
U6 N11 & N21
N14

N16
N18
N27A
N27 N29

N23
N27A
N23A
N27

Q60

40 - 3 43

008 911 83 BOMAG 679

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Controls

M28

M30
M24
M38

M36

M10 M30
M18
M28
M32A M32 M26 M14
M32
M24
M26
M30 M28
M1HS
M1HP
M16 M18
M16
M20 M22
M1EP•EQ
M14 M18 M16 M16
M12 M14
M12
EP•EQ M10 HS M18
M10

M36

HP

M16 M1S1
M10

M20 M14
M22
M1E1•E2•E5 M22A S1
M1F1•F2
M1H1•H2
M1K1•K2 M18A

M14
M18

M2E5

E1•E2•E5 / F1•F2 / H1•H2 / K1•K2

44 40 - 4

680 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Controls (Continued)
(....) = Applies to the indicated
frame size(s).
S50
S30
S20
S40
S60
S11T
(060, 080,
110)
OR
S11T
S10 (160, 250)
(060, 080, S10
110) (160, 250)
S10T S10T
M10 (060, 080, (160, 250)
M12 110)

S70

M44 M32
M34
M34A
M14
M40 M1HC
M1N2 M16
M38 M47
M16A M14 M46
N2
M18
M50A
M18A
M50
M10 M34A M48A
M18 M12 M11 M34
M18A M48
(060, 080, 110) M26

M18A M34A
M22 M10
M18 M16A J10 M34
M1HZ M16 M25
HZ
M24

M22
M20

M14

M12

M28 M18

M16
HC

40 - 5 45

008 911 83 BOMAG 681

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
PC Regulator

T7

F33
F32
M84
M28
M84A
M28A
M52
M34
M34A
M72 T5
M66 T4
M66A M72A
M34
M34A
M30
M34
M34A
T6 M84
M34A M84A
M34
M34 M34A

M10 M28
M28A
M90A
M90 M28A
M26 M28
M26A

M34A
M34
M58

Z10 & Z20

M24 M82 M22 & M20

U7
U6
M1PC & M21
M14

M16
M18
M27A
M27 M29

M23
M27A
M23A
M27
Q60

46 40 - 6

682 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
B000 COMMON PARTS GROUP (SAE FLNG) J00A-K CONTROL START SETTING
B80 O-RING 1 J10A-K SPRING-HEL COMP- CONT START 1
L35 FLANGE- SAE 1 J20 SEAT-SPRING 1
L40 SEAL- SHAFT 1 J30 SEAT-SPRING 1
L50 O-RING 1 J40 SCREW-ADJUSTING 1
L70 SCREW- SOC HD 8 J50 O-RING 1
J60 NUT-ADJUSTING SCREW 1
C000 COMMON PARTS GROUP (CARTRIDGE) J70 NUT-LOCK 1
L40 SEAL- SHAFT 1
L50 O-RING 1 J00N CONT START N/A (FOR 2 POS CONT)
L75 COVER- SEAL 1
L80 RING- RETAINING 1 M0EP CONTROL- ELHYD PRP, PACKARD
M0EQ CONTROL- ELHYD PRP, MS
F••• MAXIMUM DISPLACEMENT F32 BUSHING- VALVE ASSY 1
F10 SPACER- MAX DISPL LMTR 1 M1EP PCP VALVE, PACKARD CONN 1
F20 SCREW-SOC HD - MAX DISPL LMTR 1 M1EQ PCP VALVE, MS CONN 1
M10 HOUSING- CONTROL 1
G00A END CAP-AXIAL (160-250) M12 SCREW- SOC HD 4
G00B END CAP-AXIAL, CODE 61 (160-250) M14 COVER 1
G00R END CAP-SIDE, LOOP FL M16 GASKET 1
G00S END CAP-SIDE, LOOP FL, CODE 61 M18 SCREW- SOC HD 4
G12 PLUG-STR THD HEX 7 M24 PISTON- SHUTTLE, DELTA P 1
G14 PLUG-EXP 1 M26 SPRING- HEL COMPRESSION 1
G16 PLUG-MANDREL 2 M28 PIN 1
G18 SCREW-SET, FLAT PT 2 M30 O-RING 1
G20 PLUG- SPECIAL 2 M32 PLUG-SOC HD 2
G20N PLUG- STR THD HEX 2 M34 PLUG-MANDREL 6
G24 SCREW-SOC HD 4 M36 O-RING 1
G26 COVER-SERVO PISTON 1 M38 O-RING 1
G30 PLUG-STR THD HEX 3 M40 CONTROL SCREEN FILTER 1
G36 O-RING 2 M42 PLUG-SOC HD 1
G38 O-RING 4 M44 PLUG-PLASTIC 1
G42 O-RING 2 N90 PLUG-STR THD HEX 1
G44 O-RING 1
G50 PLUG-ST THD HEX 2 M0E1/E2 CONTROL- ELHYD 2 POS
G70 COVER-PORT 2 M0F1/F2 CONTROL- ELHYD 2 POS, MAX ANG
G90 CONTROL SCREEN FILTER 1 F32 BUSHING- VALVE ASSY 1
K10 ADJ PLUG ASSY-CHG RLF 1 M1E1 VALVE ASSY- SOLENOID,12V 1
K14 SPRING-HELICAL COMP 2 M1E2 VALVE ASSY- SOLENOID,24V 1
K16 GUIDE-SPRING (060 — 160) 2 M10 HOUSING-CONT, ELHYD, 2 POS (E) 1
K16 GUIDE-SPRING (250) 2 M10 HOUSING-CONT, ELHYD, 2 POS (F) 1
K18 SHUTTLE VALVE SPOOL 1 M12 PLUG-EXP 7
K18N LOOP FLUSH SPOOL- DEFEAT 1 M14 SCREW-SOC HD 4
K50 O-RING 1 M16 O-RING 2
K70 SPRING-HELICAL COMPRESSION 1 M18 PLUG-STR THD HEX 1
K80 POPPET-CHG RELIEF 1 M20 O-RING 1
K90 NUT-HEX LOCK 1 M22 PLUG-STR THD HEX 1
K90N PLUG- ST THD HEX 1 N90 PLUG-STR THD HEX 1

40 - 7 47

008 911 83 BOMAG 683

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
M0HC CONTROL- HYD PRPNL 2LN, DUAL PATH M0HS CONTROL- HYD PRP, 1 LN
F32 BUSHING- VALVE ASSY 1 F32 BUSHING-VALVE ASSY 1
M1HC HOUSING- HYD PRPNL (2LN),DUAL 1 M1HS HOUSING- VALVE, HYD PRPRNL 1 LN 1
M10 SCREW-SOC HD 4 M10 SCREW-SOC HD 4
M11 WASHER, FLAT (060, 080, 110) 4 M12 O-RING 1
M12 COVER 1 M14 PLUG-STR THD HEX 1
M14 GASKET 1 M16 PLUG-PLASTIC 1
M16 NUT-SEAL LOCK 1 N90 PLUG-STR THD HEX 1
M18 SCREW-SET, FL PT 1
M20 GUIDE- SPRING 1 M0HZ CONTROL- HYD PRP, 1 LN, CMPCT
M22 SPRING-HELICAL COMPRESSION 1 F32 BUSHING- VALVE ASSY 1
M24 PISTON- DELTA P 1 M1HZ HOUSING- VALVE, HYD PRP, 1 LN, CPT 1
M25 SEAT- SPRING 1 M10 VALVE ASSY- DBL CHECK 1
M26 PIN 1 M12 SCREW- SOC- DRILLED 1
M28 SCREW-SOC HD 4 M14 CONTROL SCREEN FILTER 2
M32 CONTROL SCREEN FILTER 2 M16 PLUG-STR THD HEX 2
M34 PLUG-SOC HD 4 M18 PLUG-STR THD HEX 3
M38 VALVE- BLEED 1
M40 NUT- SEAL LOCK 1 M0H1/H2 CONTROL- HYD PRP, 1 LN, MAX ANG
M44 VALVE, SHUTTLE- DELTA P 1 M0K1/K2 CONTROL- HYD PRP, 1 LN, MIN ANG
M46 SEAT- BALL CHECK 1 F32 BUSHING-VALVE ASSY 1
M47 BALL- SHUTTLE 1 M1H1 VALVE ASSY-SOLENOID,12V 1
M48 PLUG-STR THD HEX 1 M1H2 VALVE ASSY-SOLENOID,12V 1
M50 PLUG-STR THD HEX 1 M10 HSG-CONT,ELHYD, 2 POS 1
M12 PLUG-EXP 8
M0HP CONTROL- HYD PRPNL 2LN, W/BLD M14 SCREW-SOC HD 4
F32 BUSHING- VALVE ASSY 1 M16 O-RING 2
M1HP HOUSING- HYD PRPNL (2LN),W/BLD 1 M18 PLUG-STR THD HEX 1
M10 COVER 1 M20 O-RING 1
M12 GASKET 1 M22 PLUG-PLASTIC 1
M14 PISTON-SHUTTLE, DELTA P 1 N90 PLUG-STR THD,SOC HD 1
M16 SPRING-HELICAL COMPRESSION 1
M18 PIN 1 M0N2 CON-HYD, 2 POS, DIRECT
M24 O-RING 1 M1N2 COVER 1
M26 VALVE SHUTTLE,DELTA P 1 M10 PLUG 1
M28 PLUG-SEALING 1 M11 SCREW- SET,FLT PT 3
M30 O-RING 2 M12 O-RING 1
M32 PLUG-SEALING 1 M14 SCREW-SOC 4
M34 PLUG-EXP 6 M16 GASKET 1
M36 SCREW-SOC HD 4 M18 PLUG 1
N90 PLUG-STR THD HEX 1

48 40 - 8

684 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
M0PC REGULATOR- PRESS COMP N0A1-6 SVO PRS SPLY, PCOR, DFT
F32 PLUG- VALVE BUSHING BORE 1 N1A1-6 HOUSING-MULTI FUNCTION BLOCK 1
F33 O-RING 1 N11 HOUSING-VALVE 1
M1PC HOUSING- VALVE 1 N14 NUT-HEX LOCK 1
M10 HOUSING- MULTI FUNCTION BLOCK 1 N16 O-RING 1
M14 NUT-HEX LOCK 1 N18 SPRING-HELICAL COMPRESSION 1
M16 O-RING 1 N20 SEAT-SPRING, PCOR 1
M18 SPRING-HELICAL COMPRESSION 1 N21 BUSHING-VALVE 1
M20 SEAT-SPRING, PC 1 N22 SPOOL-PCOR VALVE 1
M21 BUSHING-VALVE 1 N23 PLUG-STR THD HEX 1
M22 SPOOL-PC VALVE 1 N24 O-RING 5
M23 PLUG-STR THD HEX 1 N26 PLUG-SOC HD (W/PCOR) 1
M26 PLUG-SOC HD 1 N26 PLUG-STR THD HEX (WO/PCOR) 1
M27 PLUG-STR THD HEX 10 N27 PLUG-STR THD HEX 17
M28 PLUG-STR THD HEX 4 N28 PLUG-PLASTIC (W/DFT) 2
M29 SCREW-SOC 4 N28 PLUG-STR THD HEX (WO/DFT) 2
M30 SPOOL, BI-DIRECTIONAL CHECK 1 N29 SCREW-SOC 4
M34 PLUG-STR THD HEX 10 N30 SPOOL, BI-DIRECTIONAL CHECK 1
M36 SCREW-SET,FLT PT 5 N32 PISTON 1
M38 PLUG-EXP 11 N34 PLUG-STR THD HEX 10
M50 PLUG-EXP 8 N36 SCREW-SET,FLT PT 5
M52 CONTROL SCREEN FILTER 2 N38 PLUG-EXP (060 - 110 ONLY) 11
M54 PLUG-EXP 1 N50 PLUG-EXP (060 - 110 ONLY) 6
M58 SCREW-SOC HD 4 N52 CONTROL SCREEN FILTER 2
M62 PLUG-EXP 1 N54 PLUG-EXP 1
M66 PLUG-STR THD HEX 2 N58 SCREW-SOC HD 4
M72 PLUG-STR THD,SOC HD 1 N62 PLUG-EXP 1
M82 O-RING 1 N66 PLUG-STR THD HEX (060-110) 2
M84 PLUG-STR THD HEX 2 N66 PLUG-STR THD HEX (160-250) 1
M86 SCREW-FL PT 1 N72 PLUG-STR THD,SOC HD 1
M90 PLUG-STR THD HEX 1 N74 SCREW-SET, FL PT 3
M96 GASKET 1 N82 O-RING 1
M98 PLUG 1 N84 PLUG, SPECIAL 2
N24 O-RING 5 N84 PLUG-STR THD HEX 2
N86 SCREW-SET 1
M0S1 CONTROL- ELECTRIC 2 POS, DIRECT U5 PLUG- SOC (EXT SUPPLY) 1
F32 BUSHING- VALVE ASSY 1 U6 ORIFICE, PCOR DAMPING 1
M1S1 SOLENOID,12V 1 U7 ORIFICE, PCOR DAMPING 1
M10 ADAPTER PLATE- SOLENOID 1
M14 SCREW-SOC HD 4 N0NN SERVO PRESS SPLY- NONE
M16 O-RING 1
M18 O-RING 1 P0AA SYS PRESS PROTECT- NONE
M20 PIN 1
M22 O-RING 1
N90 PLUG-STR THD HEX 1

40 - 9 49

008 911 83 BOMAG 685

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
S00D-G CONTROL RAMP- HP, HS, H1/H2, K1/K2 Y••• MINIMUM DISPLACEMENT
S10 GUIDE-SPRING (160-250) 1 Y10 SCREW- SET, FLT PT 1
S10D-G CONT RAMP SPRING (060-110) 1 Y20 NUT- HEX, SEAL LOCK 1
S10D-G CONT RAMP SPRING ASSY (160-250) 2 Y30 TAMPER RESISTANT CAP 1
S20 GUIDE-SPRING 1
S70 SEAT-SPRING 1 Z000 PRS COMP SET- NONE

S00N CONTROL RAMP-NONE Z0•• PCOR / PRESS COMP SETTING

Z10 ADJUSTER- THREADED 1
S00T CONTROL RAMP- HC Z20 PIN-STRAIGHT 1
S10 GUIDE-SPRING 1
S10T CONT RAMP SPRING 1
S11T CONT RAMP SPRING 1
S20 GUIDE-SPRING 1
S30 NUT- ADJUSTING SCREW 1
S40 O-RING 1
S50 NUT- LOCK 1
S60 SCREW- ADJUSTING 1
S70 SEAT-SPRING 1

S00U-Z CONTROL RAMP- EP/EQ

S10 GUIDE-SPRING (160-250) 1
S10U-Z CONT RAMP SPRING (060-110) 1
S10U-Z CONT RAMP SPRING ASSY (160-250) 1

T0A0 CON ORIFICE (A0)- NONE

T0A1 CON ORIFICE (A1)

T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 SCREW 2
T5 ORIFICE 1
T6 SCREW 1
T7 ORIFICE 2
T8 ORIFICE 1
U3 SCREW-FL PT 1

T0A2 CON ORIFICE (A2)

T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 ORIFICE 2
T5 SCREW 1
T6 ORIFICE 1
T7 ORIFICE 2
T8 ORIFICE 1

WNNN SPCL HDW-NONE

A10 SPEED SENSOR 51V 0
B70 PLUG-SOC HD 1
B71 PLUG-PLASTIC 1

50 40 - 10

686 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor

Charge Pressure
Relief Valve
Loop Flushing
Valve

Shaft
Seal

Control
Orifices
Multi-function
Block

Control
Minimum Displacement
Limiter

51000052
Variable Displacement Motor (SAE Flange Configuration)
Fig. 50-1 - Minor Repairs

Minor Repairs may be performed, following the proce- Protect all exposed sealing surfaces and open cavi-
dures in this section, without voiding the unit war- ties from damage and foreign material.
ranty. Although specific products are illustrated,
these procedures apply to all units in the Series 51 It is recommended that all gaskets and O-rings be
family. replaced. All gasket sealing surfaces must be cleaned
prior to installing new gasket. Lightly lubricate all O-
General rings with clean petroleum jelly prior to assembly.
Cleanliness is a primary means of insuring satisfac-
tory transmission life, on either new or repaired units.
Cleaning parts by using a solvent wash and air drying
is adequate, providing clean solvent is used. As with
any precision equipment, the internal mechanism
and related items must be kept free of foreign mate-
rials and chemicals.

50 - 1 51

008 911 83 BOMAG 687

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Shaft Seal (SAE Flange Configuration)
Lip type shaft seals are used on the Series 51 motors.

Replacement of the shaft seal usually requires re-

moval of the motor from the machine.

Remove the screws holding the flange to the housing,

using a 6 mm internal hex wrench (060 and 080 units),
an 8 mm internal hex wrench (110 units), a 10 mm
internal hex wrench (160 units), or a 12 mm internal
hex wrench (250 units).

Remove the flange from the housing using a suitable

puller. Care must be taken so as to not damage the
housing bore or shaft.
51000178 51000179 CAUTION
Fig. 50-2 - Remove Fig. 50-3 - Remove
Screws Holding Flange (SAE) Do not allow the output shaft to move out of the
Flange to Housing housing while removing the flange. After the
(SAE) flange is removed, do not attempt to remove
the shaft from the housing. If the output shaft
moves out of the housing, the synchronizing
shaft and rollers could fall out of position,
requiring major disassembly of the unit.

Remove the old seal from the flange. Once removed,

the seal is not reusable.

Inspect the flange and the new seal for any damage
or nicks.

Using an arbor press, press the new seal into the

flange. Be careful not to damage seal.

NOTE: The outside diameter of the seal may be

51000053 51000054 lightly coated with a sealant (such as Loctite
Fig. 50-4 - Remove Fig. 50-5 - New Seal High Performance Sealant #59231) prior to
Old Seal from Flange Installed in Flange installation. This will aid in preventing leaks
(SAE) (SAE) caused by damage to the seal bore in the
flange.

Inspect the sealing area on the shaft for rust, wear, or

contamination.

52 50 - 2

688 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install a new O-ring on the flange. Prior to assembly,
lubricate the flange O-ring and the I.D. of the seal with
petroleum jelly.

Protect the seal lip from damage during installation by

wrapping the spline or key end of shaft with plastic
film, or by using a seal installation tool.

Assemble the flange and seal over the shaft and into
the housing bore. Install four (4) of the flange screws,
51000055 51000056
and tighten them evenly to pull the flange into posi- Fig. 50-6 - Install Fig. 50-7 - Torque
tion. Take care to not damage the O-ring or seal lip
Flange onto Housing Flange Screws (SAE)
during installation.
(SAE)
Install the flange screws and torque evenly to 32 Nm
(24 ft•lbsf) for 060 and 080 motors, 63 Nm (46 ft•lbsf)
for 110 motors, 110 Nm (81 ft•lbsf) for 160 motors,
and 174 Nm (128 ft•lbsf) for 250 motors.

Shaft Seal (Cartridge Configuration)

Lip type shaft seals are used on the Series 51 motors.
These seals can be replaced without major disas-
sembly of the unit. However, replacement of the shaft
seal requires removal of the motor from the wheel
drive or track drive gearbox.

Remove the seal carrier retaining ring from the hous-

ing.

Carefully pull the seal cover out of the housing. Care

must be taken so as not to damage the housing bore
or shaft.

Remove the O-ring from the housing.

Remove the old seal from the carrier. Once removed,

the seal is not reusable. 51000057 51000058
Fig. 50-8 - Remove Fig. 50-9 - Remove
Inspect the carrier and the new seal for any damage
Carrier Retaining Seal Carrier
or nicks.
Ring (Cartridge) (Cartridge)
Using an arbor press, press the new seal into the
carrier. Be careful not to damage seal.

NOTE: The outside diameter of the seal may be

lightly coated with a sealant (such as Loctite
High Performance Sealant #59231) prior to
installation. This will aid in preventing leaks
caused by damage to the seal bore in the seal
carrier.
51000059 51000060
Inspect the sealing area on the shaft for rust, wear, or
Fig. 50-10 - Seal Fig. 50-11 - Seal
contamination.
Carrier Removed Installed in Carrier
(Cartridge) (Cartridge)
50 - 3 53

008 911 83 BOMAG 689

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install the carrier O-ring into the groove in the hous-
ing. Prior to assembly, lubricate the carrier O-ring and
the I.D. of the seal with petroleum jelly.

Protect the seal lip from damage during installation by

wrapping the spline or key end of shaft with plastic
film, or by using a seal installation tool.

Assemble the carrier and seal over the shaft and into
the housing bore. Take care to not damage the O-ring
51000061 51000057
Fig. 50-12 - Install Fig. 50-13 - Install or seal lip during installation.
Seal Carrier Carrier Retaining Install the seal carrier retaining ring.
(Cartridge) Ring (Cartridge)
Loop Flushing Shuttle Valve (Option)
Using an 11/16" wrench, remove the hex plugs from
both sides of end cap.
Remove springs and spring seat washers. Note the
orientation of the washers.
NOTE The 250 frame size motors use thicker spring
seat washers.

51000062 51000063 Remove flushing valve spool.

Fig. 50-14 - Remove Fig. 50-15 - Remove
Shuttle Valve Plugs Valve Spool

Inspect parts for damage or foreign material.

51000066
Fig. 50-16 - Loop Flushing Shuttle Valve
Components

Install flushing valve spool in end cap, then install the

spring seat washers (thick washers on 250 frame size
motors) on each end of the spool. The step on the
spring seat washers should face out, toward the
springs.
Install the spool springs and hex plugs. Torque the
plugs to 41 Nm (30 ft•lbsf).

51000064 51000065
Fig. 50-17 - Install Fig. 50-18 - Install
Valve Spool and Plugs and Springs
Washers
54 50 - 4

690 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Charge Pressure Relief Valve
Before removing the screw adjustable relief valve
plug, mark the plug, lock nut, and end cap to allow
maintaining the original adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock nut (with a 1-1/16"
hex wrench), and unscrewing the plug with a large
screwdriver.

Remove the spring and relief valve poppet. 51000067 51000068

Fig. 50-19 - Remove Fig. 50-20 - Remove
Inspect the poppet and mating seat in the end cap for Charge Relief Valve Charge Relief Valve
damage or foreign material. Plug
Install the poppet and spring. Install the plug with its
lock nut, aligning the marks made at disassembly,
and torque the lock nut to 52 Nm (38 ft•lbsf).

Check and adjust, if necessary, the charge pressure.

51000069
Fig. 50-21 - Charge Relief Valve
Components

Minimum Angle Servo Cover

Thoroughly clean external surfaces prior to removal
of cover.

Remove the four (4) screws retaining the cover to the

end cap with an 8 mm internal hex wrench (060, 080,
110, and 160 units) or a 10 mm internal hex wrench
(250 units). Remove the cover. Remove the O-rings
between the cover and end cap.
51000046 51000006
Install new O-rings on the end cap and retain with Fig. 50-22 - Remove Fig. 50-23 - Install
petroleum jelly. Install the cover onto the end cap and Servo Cover Screws Servo Cover
install the screws. Torque the screws to 78 Nm (58
ft•lbsf) for 060, 080, or 110 units, or 110 Nm (81 ft•lbsf)
for 160 or 250 units.

The plug in the cover may be removed with a 7/16"

hex wrench. Torque this plug to 9 Nm (7 ft•lbsf).

50 - 5 55

008 911 83 BOMAG 691

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic 2-Position Control (Type N2)
Thoroughly clean external surfaces prior to removal
of cover plate.

Remove the four (4) screws retaining the cover plate

to the end cap with an 8 mm internal hex wrench (060,
080, and 110 units) or a 10 mm internal hex wrench
(160 and 250 units). Remove the cover plate.

51000071 51000072 Remove the solid plug from the valve sleeve bore in
Fig. 50-24 - Remove Fig. 50-25 - Remove the end cap. (An 8 mm threaded hole is provided in
Cover Plate Screws Cover Plate the plug for a puller screw.) Remove the O-ring from
the plug.

Remove the O-rings from the end cap.

Install new O-rings on the end cap and retain with

petroleum jelly.

Install a new O-ring on the solid plug and install the

solid plug into the end cap.

51000168
Fig. 50-26 - Remove Valve Sleeve Bore
Plug Install the cover plate onto the end cap and install the
screws. Torque the screws to 78 Nm (58 ft•lbsf) for
060, 080, or 110 units, or to 110 Nm (81 ft•lbsf) for 160
or 250 units.

Set screws are installed in control orifice holes in the

end cap to plug the valve sleeve bore passages. To
gain access to the screw plugs, remove the outer
plugs from the end cap with a 7/16" or 11/16" hex
wrench. Remove the screw plugs with a 3 mm internal
hex wrench. When installing, torque the screw plugs
51000010
to 4 Nm (35 in•lbsf). Torque the 5/16" outer plugs to
Fig. 50-27 - N2 Control Components 9 Nm (7 ft•lbsf), and the 9/16" outer plugs to 37 Nm (27
ft•lbsf). Refer to the “Control Orifices” topic for addi-
tional information.

The special plug and seal washer on the end cap

opposite the control may be removed with a 13 mm
hex wrench. When installing, torque this plug to 20
Nm (15 ft•lbsf).

51000073 51000074
Fig. 50-28 - Torque Fig. 50-29 - Torque
Cover Plate Screws Plug in End Cap

56 50 - 6

692 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Electrohydraulic 2-Position Controls
(Types E1•E2 and F1•F2)
Thoroughly clean external surfaces prior to removing
the control.

The solenoid may be removed from the valve by

removing the nut with a 3/4" hex wrench. The
solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.
51000075 51000076
Fig. 50-30 - Remove Fig. 50-31 - Remove
E1•E2 or F1•F2 Solenoid Valve
Control Solenoid
Remove the screws retaining the valve housing to the
multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.

The plugs on the control housing may be removed

with an 11/16" hex wrench. When reinstalling, torque
the plugs to 37 Nm (27 ft•lbsf).

51000013
Fig. 50-32 - E1•E2 and F1•F2 Control
Components

Install new O-rings onto the valve housing. Install the

valve housing onto the multi-function block, and
install the screws. Torque the screws to 6.4 Nm (4.7
ft•lbsf).

51000077
Fig. 50-33 - Install E1•E2 or F1•F2 Control
Valve Housing

When installing the solenoid valve into the valve

housing, the valve should be torqued to 20 Nm (15
ft•lbsf). When installing the solenoid onto the valve,
torque the nut to 15 Nm (11 ft•lbsf.).

51000078 51000079
Fig. 50-34 - Install Fig. 50-35 - Install
Solenoid Valve Solenoid

50 - 7 57

008 911 83 BOMAG 693

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Electric 2-Position Controls (Type S1)
Thoroughly clean external surfaces prior to removing
the control.

Remove the screws retaining the solenoid and sole-

noid adapter plate to the multi-function block with a 4
mm internal hex wrench. Remove the solenoid and
the solenoid adapter plate from the multi-function
block.
51000164 51000165
Fig. 50-36 - Remove Fig. 50-37 - Remove Remove the solenoid pin from the multi-function
S1 Control Screws Adapter Plate and block.
Solenoid
Install new O-rings onto the adapter plate and the
solenoid.

51000163
Fig. 50-38 - S1 Control Components

Install the solenoid pin into the hole in the multi-

function block.

51000086
Fig. 50-39 - Install S1 Control Solenoid Pin

Install the adapter plate with O-rings onto the multi-

function block.

Install the solenoid with O-ring onto the adapter plate.

Install the screws and torque to 6.4 Nm (4.7 ft•lbsf).

51000165 51000166
Fig. 50-40 - Install Fig. 50-41 - Torque
Adapter Plate and Control Solenoid
Solenoid Screws

58 50 - 8

694 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic Proportional Control (Type HZ)
Thoroughly clean external surfaces prior to removal
of control.

Remove the four (4) screws retaining the valve hous-

ing to the end cap with an 8 mm internal hex wrench
(060, 080, and 110 units) or a 10 mm internal hex
wrench (160 and 250 units). Remove the valve hous-
ing. Remove the O-rings between the valve housing
and end cap, and the O-ring on the valve spool 51000080 51000081

sleeve. Fig. 50-42 - Remove Fig. 50-43 - Remove

HZ Control Housing HZ Control Housing
The plugs on the control housing may be removed Screws
with a 7/16" or 11/16" hex wrench. When reinstalling,
torque the 5/16" plugs to 9 Nm (7 ft•lbsf), and the 9/16"
plugs to 37 Nm (27 ft•lbsf)

The valve housing is equipped with filter screens in

51000016
Fig. 50-44 - HZ Control Components

the passages between the housing and the end cap.

Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the valve
housing or end cap.

Units with external servo pressure supply have a plug 51000082 51000083
installed in the end cap passage leading to the valve Fig. 50-45 - HZ Fig. 50-46 - End Cap
spool sleeve. This plug may be removed with a 2.5 Control Housing O-Rings Installed
mm internal hex wrench. When installing this plug, Screens
torque to 2 Nm (18 in•lbsf).

Install a new O-ring onto the valve spool sleeve in the

end cap. Install new O-rings onto the end cap.

Install the valve housing onto the multi-function block,

and install the screws.

Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080,

or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250
units. 51000081 51000084
Fig. 50-47 - Install HZ Fig. 50-48 - Torque
Control Housing HZ Control Valve
Housing Screws
50 - 9 59

008 911 83 BOMAG 695

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic Proportional Control (Type HS)
Thoroughly clean external surfaces prior to removal
of control.

Remove the screws retaining the valve housing to the

multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.

51000087
Fig. 50-49 - Remove HS Control Housing
Screws

The plug on the control housing may be removed with

an 11/16" hex wrench. When reinstalling, torque the
plug to 37 Nm (27 ft•lbsf).

Install a new O-ring onto the valve housing.

51000019
Fig. 50-50 - HS Control Components

Install the valve housing onto the multi-function block,

and install the screws.

Torque the screws to 6.4 Nm (4.7 ft•lbsf).

51000088
Fig. 50-51 - Torque HS Control Housing
Screws

60 50 - 10

696 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic Proportional Control with
Maximum Angle Over-ride (Types H1•H2 or
K1•K2)
Thoroughly clean external surfaces prior to removing
the control.

The solenoid may be removed from the valve by

removing the nut with a 3/4" hex wrench.

51000089 51000090
Fig. 50-52 - Remove Fig. 50-53 - Remove
H1•H2 or K1•K2 Solenoid Valve
Control Solenoid
The solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.

Remove the screws retaining the valve housing to the

multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.

The plugs on the control housing may be removed

with an 11/16" hex wrench. When reinstalling, torque
the plugs to 37 Nm (27 ft•lbsf).
51000091
Fig. 50-54 - Remove Control Housing
Screws

Install new O-rings onto the valve housing.

Install the valve housing onto the multi-function block,

and install the screws. Torque the screws to 6.4 Nm
(4.7 ft•lbsf).

51000021
Fig. 50-55 - H1•H2 and K1•K2 Control
Components

When installing the solenoid valve into the valve

housing, the valve should be torqued to 20 Nm (15
ft•lbsf).

When installing the solenoid onto the valve, torque

the nut to 15 Nm (11 ft•lbsf.).

51000092 51000093
Fig. 50-56 - Install Fig. 50-57 - Install
Solenoid Valve Solenoid

50 - 11 61

008 911 83 BOMAG 697

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Two Connection Hydraulic Proportional
Control (Type HP)
Thoroughly clean external surfaces prior to removal
of control.

Hold the control housing in position, and remove the

screws retaining the cover and control housing to the
multi-function block with a 4 mm internal hex wrench.
Remove the housing cover and gasket. Remove the
51000094 51000095 valve housing with shuttle valve assembly and pilot
Fig. 50-58 - Remove Fig. 50-59 - Remove piston from the multi-function block.
HP Control Housing Control Housing
Screws Remove the O-rings from the valve housing. Remove
the pilot piston and spring from the valve housing.

Remove the pilot piston pin from the multi-function

block.

Remove the inner shuttle spool plug from the valve

housing. (A 5 mm threaded hole is provided in the
inner plug for a puller screw.) Remove the shuttle
spool from the valve housing. Remove the outer
shuttle spool plug. Remove the O-rings from the
51000096 51000086 plugs.
Fig. 50-60 - Remove Fig. 50-61 - Remove
Shuttle Spool Plug Pilot Piston Pin

Install new O-rings on the shuttle spool plugs.

Install new O-rings on the valve housing and retain

with petroleum jelly.

51000024
Fig. 50-62 - HP Control Components

62 50 - 12

698 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install the pilot piston pin in the multi-function block.

Install the outer (thin) shuttle piston plug with the large
chamfer toward the shuttle valve bore. Install the
shuttle spool into its bore and install the inner (thick)
plug with the large chamfer toward the shuttle valve
bore.

51000097 51000098
Fig. 50-63 - Pilot Fig. 50-64 - Install
Piston Pin Installed Shuttle Spool and
Plugs
Position the valve housing (with O-ring) on the multi-
function block.

Install the pilot piston into the housing and over the
pin. The end of the piston with the cross drilled hole
should engage the pin.

51000099 51000100
Fig. 50-65 - Install Fig. 50-66 - Install
Control Housing Pilot Piston

Install the small spring in the outer end of the pilot

piston.

Install the control cover and gasket. Align the control

assembly with the multi-function block and install the
four (4) screws.

Torque the control screws to 6.4 Nm (4.7 ft•lbsf).

51000101 51000102
Fig. 50-67 - Install Fig. 50-68 - Install
Spring Cover, Gasket, and
Screws

50 - 13 63

008 911 83 BOMAG 699

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Two Connection Hydraulic Proportional
Control for “Dual Path” Vehicles (Type HC)
Bleed Valve

Loosen the seal lock nut on the bleed valve with a 10

mm hex wrench, and remove the valve with a 4 mm
internal hex wrench.

Install the bleed valve and torque to 3 Nm (27 in•lbsf).

51000103 51000175
Fig. 50-69 - Remove Fig. 50-70 - Install
HC Control Bleed HC Control Bleed
Valve Valve
Install the seal lock nut and torque to 19 Nm (14
ft•lbsf).

Servo Pressure Shuttle Valve

Remove the servo pressure shuttle plug with an

11⁄16" hex wrench. Remove the shuttle ball seat with
a 5 mm internal hex wrench and remove the ball.

51000176 51000104
Fig. 50-71 - Install Fig. 50-72 - Remove
HC Control Bleed Servo Pressure Ball
Valve Seal Nut Shuttle Valve
Install the servo pressure shuttle ball.

Install the shuttle ball seat and torque to 11 Nm (8

ft•lbsf). Install the shuttle passage plug and torque to
37 Nm (27 ft•lbsf).

51000123 51000174
Fig. 50-73 - Install Fig. 50-74 - Torque
Servo Pressure Servo Pressure
Shuttle Ball Valve Shuttle Ball Seat
Control Pressure Shuttle Valve

Remove the shuttle spool plugs with a 1/4" internal

hex wrench. Remove the control pressure shuttle
spool.

Install the control pressure shuttle spool.

Install the shuttle spool plugs and torque to 20 Nm (15

ft•lbsf).
51000105 51000122
Fig. 50-75 - Install Fig. 50-76 - Torque
Control Pressure Shuttle Spool Plugs
Shuttle Spool
64 50 - 14

700 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Pilot Piston and Control Housing

Thoroughly clean external surfaces prior to disas-

sembly of control.

Remove the four (4) screws retaining the cover to the

control housing with a 4 mm internal hex wrench.

Remove the housing cover and gasket (with the

adjusting screw and seal lock nut).
51000177 51000106
Fig. 50-77 - Remove Fig. 50-78 - Remove
HC Control Housing HC Control Housing
Cover Screws Cover
Remove the control start adjustor spring seat and
spring from the pilot piston.

Remove the pilot piston from the control housing.

Remove the pilot piston pin seat and pin from the
control housing (or pilot piston).

Remove the control start spring from the control

housing.
51000107 51000108
Fig. 50-79 - Remove Fig. 50-80 - Remove
Adjustment Spring Pilot Piston Pin and
and Pilot Piston Control Start Spring
Remove the four (4) screws (and washers for 060,
080, and 110 units) retaining the control housing to
the end cap with an 8 mm internal hex wrench (060,
080, and 110 units) or a 10 mm internal hex wrench
(160 and 250 units).

Remove the control housing from the end cap. Re-

move the O-rings between the control housing and
the end cap, and the O-ring on the valve spool sleeve.
51000109 51000110
Fig. 50-81 - Remove Fig. 50-82 - Remove
HC Control Housing HC Control Housing
Screws

50 - 15 65

008 911 83 BOMAG 701

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
The plugs on the control housing may be removed
with a 7/16" hex wrench or a 1/4" internal hex wrench.
When reinstalling, torque the 5/16" plugs to 9 Nm (7
ft•lbsf), and the 9/16" plugs to 20 Nm (15 ft•lbsf).

51000111
Fig. 50-83 - HC Control Components

The control housing is equipped with filter screens in

the passages between the housing and the end cap.
Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the valve
housing or end cap.
51000112 51000113
Fig. 50-84 - HC Fig. 50-85 - End Cap Install a new O-ring onto the valve spool sleeve in the
Control Housing O-Rings Installed for end cap. Install new O-rings onto the end cap.
Screens HC Control

Install the valve housing onto the end cap, and install
the screws (with flat washers on 060, 080, and 110
units).

Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080,

and 110 units, or to 110 Nm (81 ft•lbsf) for 160 and
250 units.

51000110 51000114
Fig. 50-86 - Install Fig. 50-87 - Torque
HC Control Housing HC Control Housing
Screws
66 50 - 16

702 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install the control start spring into the control housing.

Install the pilot piston pin. The end of the pin must
engage the recess in the end of the control valve
spool.

51000115 51000116
Fig. 50-88 - Install Fig. 50-89 - Install
HC Control Start Pilot Piston Pin
Spring
Install the pilot piston pin seat.

Install the pilot piston into the housing and over the
spring and spring seat. The end of the piston with the
deeper bore and the cross drilled hole should engage
the start spring and pin seat.

51000117 51000118
Fig. 50-90 - Install Fig. 50-91 - Install
Pilot Piston Pin Seat HC Control Pilot
Piston
Install the adjustor spring in the outer end of the pilot
piston.

Install the adjustor spring seat.

51000119 51000120
Fig. 50-92 - Install Fig. 50-93 - Install
HC Control Start HC Control Start
Adjuster Spring Adjuster Spring Seat
Install the control cover and gasket (with adjusting
screw and seal lock nut).

Torque the control cover screws to 6.4 Nm (4.7

ft•lbsf).

51000106 51000121
Fig. 50-94 - Install Fig. 50-95 - Torque
HC Control Cover Control Cover
and Gasket Screws
50 - 17 67

008 911 83 BOMAG 703

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Electrohydraulic Proportional Control
(Types EP and EQ)
Thoroughly clean external surfaces prior to removal
of control.

The Pressure Control Pilot (PCP) valve may be

removed from the control valve housing, as de-
scribed under the following heading.

51000124 51000125 Remove the screws retaining the control housing

Fig. 50-96 - Remove Fig. 50-97 - Remove cover and control valve housing to the multi-function
PCP Valve EP•EQ Control block with a 4 mm internal hex wrench. Remove the
Housing Screws housing cover and gasket.

Remove the valve housing with the pilot piston from

the multi-function block.

Remove the O-rings from the valve housing. Remove

the pilot piston and spring from the valve housing.

Remove the pilot piston pin from the multi-function

block.

51000126 51000086
Fig. 50-98 - Remove Fig. 50-99 - Remove
EP•EQ Control Pilot Piston Pin
Housing
Install new O-rings on the valve housing and retain
with petroleum jelly.

The plugs on the control housing may be removed

with a 1/4" internal hex wrench. When reinstalling,
torque the 9/16" plugs to 20 Nm (15 ft•lbsf).

51000027
Fig. 50-100 - EQ Control Components (EP
Similar)

68 50 - 18

704 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install the pilot piston pin in the multi-function block.

Position the valve housing (with O-rings) on the multi-

function block.

51000097 51000127
Fig. 50-101 - Pilot Fig. 50-102 - Install
Piston Pin Installed Control Housing

Install the pilot piston into the housing and over the
pin. The end of the piston with the cross drilled hole
should engage the pin.

Install the small spring in the outer end of the pilot

piston.

51000128 51000129
Fig. 50-103 - Install Fig. 50-104 - Install
Pilot Piston Spring

Install the control cover and gasket. Align the control

assembly with the multi-function block and install the
four (4) screws.

Torque the control screws to 6.4 Nm (4.7 ft•lbsf).

Reinstall the PCP valve, if removed.

51000130 51000131
Fig. 50-105 - Torque Fig. 50-106 - Install
Cover, Gasket, and PCP Valve
Screws

50 - 19 69

008 911 83 BOMAG 705

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Pressure Control Pilot (PCP) Valve for
Electrohydraulic Proportional Control
(Types EP and EQ)
Thoroughly clean external surfaces of control.

Using a 4 mm internal hex wrench, remove the four

(4) screws and remove the PCP valve.

Check surfaces for nicks or damage. Clean internal

51000132 51000133 screens.
Fig. 50-107 - Remove Fig. 50-108 - PCP
PCP Valve Screws Valve Components

Install new O-rings on the PCP housing and retain

with petroleum jelly. Position the PCP on the control
valve housing and install the screws.

Torque the screws to 5.4 Nm (48 in•lbsf).

51000124 51000131
Fig. 50-109 - Install Fig. 50-110 - Torque
PCP onto Control PCP Valve Screws

70 50 - 20

706 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Multi-function Block
Removal and Installation
Remove the external control assembly as described
in the instructions for the specific control.
Remove the four (4) screws (and washers for 060,
080, and 110 units) retaining the multi-function block
to the end cap with an 8 mm internal hex wrench (060,
080, and 110 units) or a 10 mm internal hex wrench
51000087 51000134
(160 and 250 units).
Fig. 50-111 - Remove Fig. 50-112 - Remove
Remove the multi-function block from the end cap. External Control (HS Multi-function Block
Remove the O-rings between the multi-function block Shown) Screws
and the end cap, and the O-ring on the valve spool
sleeve.
The multi-function block is equipped with filter screens
in the passages between the block and the end cap.
Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the multi- 51000135 51000136

function block or end cap. Fig. 50-113 - Remove Fig. 50-114 - Multi-
Multi-function Block function Block
Units with external servo pressure supply have a plug
Screens
installed in the end cap passage leading to the valve
spool sleeve. This plug may be removed with a 2.5
mm internal hex wrench. When installing this plug,
torque to 2 Nm (18 in•lbsf).
Install a new O-ring onto the valve spool sleeve in the
end cap.
Install new O-rings onto the end cap.
Install the multi-function block onto the end cap, and
install the screws. 51000083 51000135

Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080, Fig. 50-115 - End Fig. 50-116 - Install
or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250 Cap O-Rings Multi-function Block
units. Installed
Reinstall the external control assembly as described
in the instructions for the specific control.

51000137 51000088
Fig. 50-117 - Torque Fig. 50-118 - Install
Multi-function Block External Control (HS
Screws Shown)
50 - 21 71

008 911 83 BOMAG 707

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Servo Pressure Supply Shuttle Spool

Remove the servo pressure supply shuttle spool plug

from the multi-function valve with a 9/16" hex wrench.

NOTE: If a pressure compensator valve block is

installed, the opposite end of the shuttle
spool bore in the multi-function valve is
plugged with an internal hex head plug lo-
cated under the valve block. If a pressure
51000138 51000139
Fig. 50-119 - Remove Fig. 50-120 - Remove compensator valve block is not installed, the
opposite end of the shuttle spool bore is
Servo Pressure Servo Pressure
plugged with a hex head plug.
Supply Spool Plug Supply Shuttle Spool
Remove the servo pressure supply shuttle spool from
the multi-function valve block.

Inspect the shuttle spool for burrs or scoring. The

spool must slide free in its bore. The shuttle ball in the
spool must be free to move.

51000030
Fig. 50-121 - Multi-function Block with
Servo Pressure Supply Shuttle Spool

Install the shuttle spool into the multi-function block.

Install the hex head plug into the multi-function valve

and torque to 37 Nm (27 ft•lbsf).

NOTE: If an internal hex head plug was removed

from the opposite end of the shuttle spool
bore, torque it to 20 Nm (15 ft•lbsf).

51000139 51000140
Fig. 50-122 - Install Fig. 50-123 - Torque
Servo Pressure Servo Pressure
Supply Shuttle Spool Supply Spool Plug

72 50 - 22

708 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Blocking Plate for Multi-function Block Without
PCOR

The blocking plate may be removed by removing the

four (4) screws with a 5 mm internal hex wrench.
Remove the O-rings from the plate.

Install new O-rings on the blocking plate and retain

with petroleum jelly. Install the plate on the multi-
function block and install the screws. Torque the
51000170 51000171
screws to 11 Nm (8 ft•lbsf). Fig. 50-124 - Remove Fig. 50-125 - Torque
Blocking Plate (Less Blocking Plate
PCOR) Screws (Less PCOR)
Pressure Compensator Valve for Pressure
Compensator Over-Ride (PCOR) and Pressure
Compensator Regulator (Type PC)

Loosen the adjusting screw lock nut with a 1-1/16"

hex wrench. Remove the adjusting screw from the
valve block with a large screwdriver.

Remove the pressure compensator valve spring and

the spool assembly from the block.
51000142 51000143
Fig. 50-126 - Remove Fig. 50-127 - Remove
PCOR•PC Adjustor PCOR•PC Spring
and Spool Valve
Remove the valve block plug with a 1" hex wrench.

Remove the four (4) screws retaining the valve block

to the multi-function block with a 5 mm internal hex
wrench. Remove the valve block and O-rings.

51000144 51000145
Fig. 50-128 - Remove Fig. 50-129 - Remove
PCOR•PC Plug PCOR•PC Valve
Block
Install new O-rings on the pressure compensator
valve block and retain with petroleum jelly. Install a
new O-ring on the adjusting screw.

The plugs on the valve block may be removed with a

7⁄16" hex wrench. When reinstalling, torque the 5⁄16"
plugs to 9 Nm (7 ft•lbsf).

51000146
Fig. 50-130 - Pressure Compensator Valve
Block Components

50 - 23 73

008 911 83 BOMAG 709

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install the valve block on the multi-function block and
install the screws. Torque the screws to 11 Nm (8
ft•lbsf).

Install the valve block plug and torque to 54 Nm (40

ft•lbsf).

51000147 51000148
Fig. 50-131 - Install Fig. 50-132 - Install
PCOR•PC Valve PCOR•PC Valve Plug
Block
Install the pressure compensator spool assembly
and the valve spring.

Install the adjusting screw and lock nut. Perform the

PCOR or PC regulator pressure adjustment as de-
scribed under “Component Adjustment."

51000143 51000142
Fig. 50-133 - Install Fig. 50-134 - Install
PCOR•PC Spring PCOR•PC Adjusting
and Spool Valve Screw
PCOR and PC Regulator Orifices

To gain access to the PCOR or PC regulator orifices,

remove the three (3) plugs located between the
defeat spool stop plugs on the multi-function block,
using a 7/16" hex wrench. Remove the PCOR brake
pressure defeat spool (if installed). Remove the ori-
fice plug(s) and plain plug(s) with a 2.5 mm internal
hex wrench.
51000149
Fig. 50-135 - PCOR and PC Regulator Refer to the appropriate Service Parts Manual for
information on orifice locations and sizes.
Orifices
Install the orifice plug(s) and plain plug(s), and torque
to 4 Nm (35 in•lbsf). Install the outer plugs and torque
to 6 Nm (4 ft•lbsf). Reinstall the PCOR defeat spool (if
removed).

Additional orifices are installed in the passages under

the pressure compensator valve block.

51000172
Fig. 50-136 - PCOR and PC Regulator
Orifices

74 50 - 24

710 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
PCOR Brake Pressure Defeat Spool

Remove the PCOR defeat spool bore plugs or fittings

with a hex wrench.

Remove the PCOR defeat spool stop plugs with a

7⁄16" hex wrench. Remove the defeat spool.

NOTE: The defeat spool may be removed from

either end of its bore in the multi-function block.
51000150 51000151
Fig. 50-137 - Remove Fig. 50-138 - Remove
PCOR Defeat Spool PCOR Defeat Spool
Plug or Fitting Stop Plug
Inspect the defeat spool for burrs or roughness. The
spool must slide freely in its bore. Inspect the pins in
the stop plugs for damage.

51000032
Fig. 50-139 - Multi-function Block With
PCOR Defeat Spool Components

Install the PCOR defeat spool into its bore in the multi-
function block.

Install the spool stop plugs into the multi-function

block. Torque the stop plugs to 6 Nm (4 ft•lbsf).

Install the defeat spool bore plugs or fittings and

torque to 27 Nm (20 ft•lbsf).

51000152 51000153
Fig. 50-140 - Install Fig. 50-141 - Install
PCOR Defeat Spool PCOR Defeat Spool
Stop Plug

50 - 25 75

008 911 83 BOMAG 711

17.2 Travel drive series 51

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Pressure Compensator Regulator (Type
PC)
The PC regulator utilizes the multi-function block and
pressure compensator valve to control the motor
displacement.
Service procedures for these components are in-
cluded in the “Multi-function Block” section of this
manual.
51000035
Fig. 50-142 - PC Regulator Components

A valve sleeve bore plug is installed in the motor end

cap in place of the valve spool sleeve. Remove the
plug from the valve sleeve bore in the end cap. (An 8
mm threaded hole is provided in the plug for a puller
screw.) Remove the O-ring from the plug.
A single servo drain orifice is installed in the valve
sleeve bore plug. This orifice limits oil flow from the
maximum displacement end of the servo piston to the
motor case.
51000169 51000173
Fig. 50-143 - Remove Fig. 50-144 - Servo Install a new O-ring on the valve sleeve bore plug.
Valve Sleeve Bore Drain Orifice (T7) Install the bore plug into the end cap.
Plug
The special plug and seal washer on the end cap
opposite the multi-function block may be removed
with a 13 mm hex wrench. When installing, torque this
plug to 20 Nm (15 ft•lbsf).

76 50 - 26

712 BOMAG 008 911 83

Travel drive series 51 17.2
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Control Orifices
Orifices are installed in the motor end cap to regulate
oil flow to the servo control valve and the servo piston.

To gain access to these orifice plugs, remove the

three (3) plugs located on the motor end cap nearest
the multi-function block or control, using a 7⁄16" or
9⁄16" hex wrench. Remove the orifice plugs (plain
plugs for N2 control) with a 3 mm internal hex wrench.
51000154 51000155
Install the orifice plugs, and torque to 4 Nm (35 Fig. 50-145 - Servo Fig. 50-146 - Servo
in•lbsf). Torque the 5⁄16" outer plugs to 9 Nm (7 Pressure Supply Orifice for Maximum
ft•lbsf), and the 9⁄16" outer plug to 37 Nm (27 ft•lbsf). Orifice (T1) Displacement (T2)
Orifices are also installed in the servo control valve
sleeve to control oil flow from the servo piston to the
motor case.

51000156 51000157
Fig. 50-147 - Servo Fig. 50-148 - Servo
Orifice for Minimum Drain Orifices (T7
Displacement (T3) and T8)
Plug / Fitting Torques
If any plugs or fittings are removed from the unit
during servicing, they should be torqued as indicated
in the accompanying table.

Item Torque
Pressure Gauge Ports 37 Nm
(9/16—18 O-Ring Hex) (27 ft•lbsf)
Construction Plugs 20 Nm
(9/16—18 O-Ring Int. Hex) (15 ft•lbsf)
Construction Plugs 9 Nm
(5/16—24 O-Ring) (7 ft•lbsf)
Screw Plugs 4 Nm
(M6 Int. Hex) (35 in•lbsf)

50 - 27 77

008 911 83 BOMAG 713

78

714
DO NOT REMOVE UNTIL CONTROL VALVE AND
17.2

SPRINGS ARE REMOVED!

Remove as an assembly to preserve adjustment.
INSTALL BEFORE INSTALLING SPRINGS AND
CONTROL VALVE!
J70 For Proportional Controls
J60 [Except HC]
J40 (060 — 110 Frame Sizes)
For Proportional Controls
Items T1, T2, and T3: [Except HC]
3 mm internal hex wrench; (160 — 250 Frame Sizes)
J50
Torque to 5 Nm (44 lbsf•in)
4 mm internal S20
hex wrench T2
saue

S10

S20
J30
J10
S10 S70

BOMAG
J30
J10
T1 S70
T3
Remove Item T1 BEFORE removing Item F32! T7
Install Item T1 AFTER installing Item F32! F32
J30
Install O-ring J10 F33
a
Genuine

on adjustor screw J20 T8

Service Parts

Minor Repair Instructions

13 mm hex wrench
Torque to 20 Nm Items T7 and T8:
(15 lbsf•ft) For 2-Position Controls 2.5 mm int. hex wrench
4-Way Valve and Feedback Springs

10 mm hex wrench [Except N2] Torque to 2 Nm (18 lbsf•in)

Torque to 9 Nm (6.6 lbsf•ft) 5 mm threaded holes
after adjustment for puller screws
FOR 2-POSITION CONTROLS,
Sheet 1 of 2

Install O-rings
DO NOT DISTURB ADJUSTMENT! on valve sleeve
Series 51 MV
Travel drive series 51

008 911 83
DO NOT REMOVE UNTIL CONTROL VALVE AND

008 911 83
SPRINGS ARE REMOVED!
Remove as an assembly to preserve adjustment (060 — 110).
INSTALL BEFORE INSTALLING SPRINGS AND
CONTROL VALVE!
S50
S30
Travel drive series 51

For 060 — 110 Frame Sizes

S60
Items T1, T2, and T3: For 160 — 250 Frame Sizes
S40 3 mm internal hex wrench;
Torque to 5 Nm (44 lbsf•in)
4 mm internal
hex wrench T2 S20
saue

S11T
S10
S20 S10T

BOMAG
S70
S11T
T1 S10
T3 S10T
S70
Remove Item T1 BEFORE removing Item F32!
T7
Install Item T1 AFTER installing Item F32!
F32
Install O-ring
a
Genuine

on adjustor screw F33

Service Parts

Minor Repair Instructions

T8
13 mm hex wrench
Torque to 20 Nm Items T7 and T8:
(15 lbsf•ft) 2.5 mm int. hex wrench
Torque to 2 Nm (18 lbsf•in)
10 mm hex wrench
Torque to 9 Nm (6.6 lbsf•ft) 5 mm threaded holes
Sheet 2

after adjustment. for puller screws

Install O-rings
4-Way Valve and Feedback Springs - HC Control

on valve sleeve
Series 51 MV

79
17.2

715
17.2 Travel drive series 51

saue
Hydraulic Power Systems

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F000 685 F000 688 F000 690 F000 684

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Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts

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saue 2800 East 13th Street • Ames IA 50010 • U.S.A.
Phone: (515) 239-6000 • FAX: (515) 239-6618
Postfach 2460 • D-24531 Neumünster
Krokamp 35 • D-24539 Neumünster • Germany
TWX: 9105201150 Phone: (04321) 871-0 • FAX: (04321) 871 122
SM-VMV51E • 11/97 • 300 043A
BLN-10043 • November 1997

716 BOMAG 008 911 83

17.3 Vibration pump 42R 041

008 911 83 BOMAG 717

17.3 Vibration pump 42R 041

718 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42

Axial Piston
Pumps
Service Instructions

008 911 83 BOMAG 719

17.3 Vibration pump 42R 041

Series 42 Introduction

1. Introduction

1.1 Using This Manual

The Adjustment and Minor Repair procedures de- placed. Lightly lubricate all O-rings with clean petro-
tailed herein may be performed by trained personnel leum jelly prior to assembly. All gasket sealing sur-
without voiding the unit warranty. faces must be cleaned prior to installing new gaskets.
Cleanliness is a primary means of assuring satisfac- All exploded view drawings depict the 28cc frame
tory transmission life. Cleaning parts by using a clean size. For variances in the 41cc frame size, see the
solvent wash and air drying is usually adequate. As outline drawings in section 3. Differences in wrench
with any precision equipment, all parts must be kept size and torquing for the two frame sizes are noted in
free of foreign materials and chemicals. When per- the text. Note that exterior housing screws are mostly
forming service activities, protect all exposed sealing Torx-type T30 or T45.
surfaces and open cavities from damage and foreign
These symbols are used within drawings:
material.
Whenever removing a service component, it is rec- Apply petroleum jelly.
ommended that any gaskets and O-rings be re- Lubricate with clean hydraulic oil.

1.2 Safety Precautions

Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury.
The following general precautions should be taken into consideration whenever servicing a hydrostatic system.
Loss of Hydrostatic Braking Ability Fluid Under High Pressure

WARNING WARNING
When Series 42 units are used in vehicular Use caution when dealing with hydraulic fluid
hydrostatic drive systems, the loss of hydro- under pressure. Escaping hydraulic fluid un-
static drive line power in any mode of opera- der pressure can have sufficient force to pen-
tion (e.g. acceleration, deceleration or “neu- etrate your skin causing serious injury. This
tral” mode) may cause a loss of hydrostatic fluid may also be hot enough to burn. Serious
braking capacity. A braking system which is infection or reactions can develop if proper
independent of the hydrostatic transmission medical treatment is not administered immedi-
must, therefore, be provided which is adequate ately.
to stop and hold the system should the con-
dition develop. Flammable Cleaning Solvents

Disable Work Function WARNING

Some cleaning solvents are flammable. To
WARNING avoid possible fire, do not use cleaning sol-
Certain service procedures may require the vents in an area where a source of ignition may
vehicle/machine to be disabled (wheels raised be present.
off the ground, work function disconnected,
etc.) while performing them in order to prevent
injury to the technician and bystanders.

Copyright 1996-1998, Sauer-Sundstrand GmbH & Co.

F000719 All rights reserved. Contents subject to change. Printed in Germany.

720 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Introduction

Contents

1. Introduction ................................................................................................................................ 2
1.1 Using This Manual................................................................................................................................. 2
1.2 Safety Precautions ................................................................................................................................ 2

2. Model Code ................................................................................................................................. 4

3. Component and Port Locations ............................................................................................... 5

3.1 Component Locations ........................................................................................................................... 5
3.2 Ports and Pressure Gauges .................................................................................................................. 6

4. Adjustment and Minor Repair Instructions ............................................................................. 8

4.1 Size and Torque for Plugs and Fittings .................................................................................................. 8
4.2 Pump “Neutral” Adjustment ................................................................................................................... 9
4.3 Control “Neutral” Adjustment for MDC/EDC Controls .......................................................................... 10
4.4 MDC Control Module ............................................................................................................................ 11
4.5 EDC Control Module ........................................................................................................................... 12
4.6 MDC/EDC Control Spool, Control Linkage, and Control Neutral Adjustment Screw ........................... 13
4.7 MDC Neutral Start/Backup Alarm Switch ............................................................................................ 14
4.8 MDC Solenoid Override Valve ............................................................................................................. 16
4.9 FNR, NFPE, and NFPH Controls ........................................................................................................ 17
4.10 System Check Relief Valves (High Pressure Relief, Charge Check, & Bypass Valves) ...................... 18
4.11 Charge Relief Valve ............................................................................................................................. 19
4.12 Loop Flushing Valve ............................................................................................................................ 21
4.13 Shaft Seal and Shaft Replacement ..................................................................................................... 22
4.14 Auxiliary Mounting Pads ...................................................................................................................... 24
4.15 Charge Pump ...................................................................................................................................... 25
4.16 Filtration .............................................................................................................................................. 28
4.17 Servo Piston Covers ........................................................................................................................... 29
4.18 Displacement Limiter Adjustment ........................................................................................................ 30

5. Exploded View Parts Drawings............................................................................................... 31

5.1 Shaft Options ...................................................................................................................................... 31
5.2 Filtration, Charge Relief, System Relief, and Loop Flushing ............................................................... 32
5.3 Charge Pump, Auxiliary Pads, and Servo Covers ............................................................................... 33
5.4 Control Options ................................................................................................................................... 34

008 911 83 BOMAG 721

17.3 Vibration pump 42R 041

Series 42 Model Code

2. Model Code

Refer to the model code exhibited on the unit's name plate for information regarding the configuration of the unit.

Note: Some options listed here may not currently

Ames, Iowa, U.S.A. Neumünster, be available. Some options on your unit may not
Model Code Germany be listed here. This is not an order code. See the
42L28 - C - ANN1 - 01 Typ -
Model Code Series 42 Price Book for up-to-date ordering infor-
ANA - 2CNB - NN - NN - N - mation.
N - N - NNN - NNN
Model No. Ident Nr
428 2051 Serial No. X XX XX XXXXX
A 93 23 67890
Serial No. Fabr Nr Location Year Week Sequence No.
MADE IN U.S.A. T000 022E

A B C D E F G H J K L M N P

1 2 1234 123 12 34

A Series 42 x1 = Fast
E Control Response Time x2 = Medium
L = CCW
B 1 Rotation x3 = Slow
R = CW
F 1 Port Style A,J,P = SAE Threaded O-Ring Boss
28 = 28 cm3 (1.71 in3)
2 Displacement
41 = 41 cm3 (2.50 in3) N = None
2 Loop Flushing/Cooling
2,3 = Loop Flushing/Cooling Shuttle
C = 13T 16/32P Spline
D = 15T 16/32P Spline N = None (Ext. Charge Supply)
C Input Shaft Configurations E = 19T 16/32P Spline A = Suction (No Adapter Plate)
3 Filtration
G = 1.000 in. O.D. Straight Keyed C = Remote Pressure (Partial Flow)
K = 1.000 in. O.D. Tapered (1.5 in/ft) G = Suction (Adapter Plate)
N = None N = None
G 1 Charge Pump
A = MDC, Linear, Low Force 2 = 11 cm3/rev (0.67 in3/rev)
C = MDC, Non-Linear, Low Force C = 14 bar (205 psi)
D 1 Control Type 2 Charge Relief Setting
E = EDC (Electric Displacmt Contrl) F = 20 bar (280 psi)
F = FNR (3-Pos Forwrd-Neut-Revrs)
G = NFP (Non-Feedback Proport'l) N = None
3 Special Drive Features
1 = NFP
N = None or Not Applicable
1 = NSS / Weatherpack for MDC, N = None
or PCP Style for EDC A = SAE-A, 9 Tooth
4 Rear Auxilliary Mounting Pad
NSS for MDC or 12V Electric for NFP B = SAE-B, 13 Tooth
or PCP for EDC 2 = 12 V DIN for FNR T = SAE-A Special, 11 Tooth
2
or Connector for FNR 3 = NSS+BAS / CW Handle Rot. NN = Check Valve only, No HPRV
or Style for NFP / Weatherpack for MDC 14 = 140 bar (2030 psi)
or Hydraulic for NFP High Pressure Relief Setting - 17 = 175 bar (2450 psi)
H
5 = NSS+BAS / CCW Handle Rot. Port "A" 19 = 190 bar (2755 psi)
/ Weatherpack for MDC 21 = 210 bar (3045 psi)
N = None or Not Applicable 23 = 230 bar (3330 psi)
A = 12V Override / Weather Pack, 25 = 250 bar (3625 psi)
Solenoid Override with MDC 28 = 280 bar (4060 psi)
or EDC Input = 14-85 mA High Pressure Relief Setting -
3 or EDC Input J 30 = 300 bar (4350 psi)
or 400 - 1200 mA or 5-20 bar Port "B"
or Inching/Braking for NFP 34 = 345 bar (5000 psi)
for NFP
E = 12V Override / Brake Port 00 = No HPRV, No Check Valves
N = None or Not Applicable N = None
K Loop Bypass Valve
1,6 = Standard Handle fpr MDC B = Yes
Handle for MDC
or M/S Connector for EDC L Displacement Limiters - Side 1 N, 0 = None
4 or Connector for EDC
or Amp Connector for NFP A, 1 = Yes, Set at Max Disp
or Connector for NFP M Displacement Limiters - Side 2
2,5 = Clevis Handle for MDC
or Weather Pack for EDC N Special Hardware Features NNN = None
P Special Non-Hardware Features NNN = None

722 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Component and Port Locations

3. Component and Port Locations

3.1 Component Locations

A pump with a manual displacement control (MDC) and no filtration adapter is shown. With non-feedback and
automotive controls, the positions of the case drains vary (shown in gray). With a filtration adapter, the porting in
the "Filtration Options" area varies (see section 4.16).

Control Neutral Adjustment Pump Neutral Adjustment

Control Module (MDC/EDC)
(MDC Shown)
Servo Piston
Covers
System Check
Displacement
Relief Valves
Limiters
Charge
Pump Shaft
Seal

Filtration Options
Auxiliary (No Filtration Adapter Shown Here) Charge Relief Valve
Mounting Pad (Loop Flushing
Valve)

Left Side View (Side "2") Right Side View (Side "1")
P100101 E

Series 42 28cc Variable Pump

Control Neutral Adjustment Pump Neutral Adjustment

Control Module (MDC/EDC)
(MDC Shown)
Servo Piston
Covers
Displacement
Limiters System Check
Relief Valves
Charge
Pump
Shaft Seal

Auxiliary
Mounting Filtration Options
Pad Charge Relief Valve (No Filtration Adapter
(Loop Flushing Valve)
Shown Here)
Left Side View (Side "2") Right Side View (Side "1")
P100102 E

Series 42 41cc Variable Pump

008 911 83 BOMAG 723

17.3 Vibration pump 42R 041

Series 42 Component and Port Locations

3.2 Ports and Pressure Gauges

Proper servicing of pumps and motors requires that ments. The following outlines show the locations of
pressure be measured and monitored at various the various gauge ports. The tables show the recom-
points in the hydraulic circuit. The Series 42 pump mended gauge size and the fitting size for each port.
has several locations at which to take these measure- Refer to this page when installing pressure gauges.

Gauge Recommended Fitting

Pressure Measured
Port Name Gauge Size 028 041
System Pressure for
M1 & M2 600 bar or 10 000 psi 9/16-18 O-Ring Fitting 9/16-18 O-Ring Fitting
Ports A and B
M3 Charge Pressure 60 bar or 1000 psi 3/4-16 O-Ring Fitting 3/4-16 O-Ring Fitting
M4 & M5 Servo Pressure 60 bar or 1000 psi 9/16-18 O-Ring Fitting 9/16-18 O-Ring Fitting
L1 & L2 Case Pressure 35 bar or 500 psi 1-1/16-12 O-Ring Fitting 1-5/16-12 O-Ring Fitting
Charge Pump Inlet 1 bar, absolute
S 1-1/16-12 O-Ring Fitting 1-5/16-12 O-Ring Fitting
Vacuum or 30 in Hg Vacuum
T000 025E

System Pressure Servo Pressure

Gauge Port M2 Gauge Port M5
Charge Pressure
Servo Pressure Gauge Port M3
Gauge Port M4 (Charge Pressure
System
Case Drain Port L2 Supply For
Pressure
(Non-Feedback No Charge Pump
Port B
Controls) Option)
System
Pressure Case Drain
Port A Port L1

Case Drain Port L1 Charge Pump

(Non-Feedback Inlet Port S
Controls)
Case Drain
System Pressure
Port L2
Gauge Port M1

Left Side View (Side "2") Right Side View (Side "1")
P100103 E

28cc Base Unit with MDC and No Filtration Adapter

724 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Component and Port Locations

System Pressure Servo Pressure

Gauge Port M2 Gauge Port M5
Servo Pressure Charge Pressure
Gauge Port M4 Gauge Port M3
System (Charge Pressure
Pressure Case Drain Supply For
Port B Port L2 No Charge Pump
Option)

System
Pressure
Port A
Case Drain Charge Pump
Port L1 Inlet Port S

System Pressure
Gauge Port M1

Left Side View (Side "2") Right Side View (Side "1") P100104 E

41cc Base Unit with MDC and No Filtration Adapter

To Filter, Port D
(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Full Flow Pressure Filtration)

From Filter, Port E

(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Partial Flow Pressure Filtration)

Charge Pressure
Gauge Port M3
(Suction Filtration)
P100105 E

Filtration Adapter (28cc and 41cc Models)

008 911 83 BOMAG 725

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4. Adjustment and Minor Repair Instructions

4.1 Size and Torque for Plugs and Fittings

Plug and fitting sizes are given here. Place a fresh O-ring, lightly lubricated with petroleum jelly, whenever a plug
is removed. Each should be torqued as indicated. A 28cc unit with manual displacement control (MDC) is shown.

Servo Gage
Port M4

11/16 in Hex
27-47 Nm
(20-35 ft•lbf)

28cc: 9/16 in Int. Hex

95-135 Nm
(70-100 ft•lbf)
41cc: 5/8 in Int. Hex Case Drain
125-250 Nm Port L1
(90-190 ft•lbf) Charge Pressure Gage
Port M3 (Position Varies, Charge Pump Inlet
Refer to Filtration Options) Port S
Torque: 115 Nm (85 ft•lbf)

Case Drain 11/16 in Hex

Port L2 27-47 Nm
Port N (20-35 ft•lbf)
(Unused) Servo Gage
Port M5
System Gage
Ports M1 and M2
11/16 in Hex
27-47 Nm
(20-35 ft•lbf)

28cc: 9/16 in Int. Hex

95-135 Nm
(70-100 ft•lbf)
41cc: 5/8 in Int. Hex
125-250 Nm
(90-190 ft•lbf)

11/16 in Hex
System Ports 27-47 Nm
A and B (20-35 ft•lbf)
115 Nm (85 ft•lbf)
E100001 E

726 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

4.2 Pump “Neutral” Adjustment

The pump neutral adjustment sets the position of the
servo piston and pump swashplate relative to the
controlling mechanism.

WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
Pump "Neutral"
ground, work function disconnected, etc.) while Adjustment Screw
performing the procedure in order to prevent
injury to the technician and bystanders.

1. Disconnect machine function. Pump "Neutral"

Adjustment Seal
2. Connect a hose between gauge ports M4 and M5 Lock Nut
to equalize the pressures on both ends of the
pump servo piston.
3. Install pressure gauges in gauge ports M1 and
M2 to measure system pressure.
4. Start the prime mover and operate at normal E100002 E
speed.
Pump Neutral Adjustment Screw
5. Loosen the pump "neutral" adjustment seal lock (MDC Control Shown)
nut [28cc 13 mm Hex; 41cc 17 mm Hex]. Turn
the pump "neutral" adjustment screw [28cc 5
mm Hex; 41cc 7 mm Hex] until the system
pressure gauge readings are equal.
6. Turn the adjustment screw clockwise until one of
the gauges registers an increase in system pres-
sure. Note the position of the adjustment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in system pressure.
Note the position of the adjustment screw.
7. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The system pressure gauges should indicate
equal pressures.
8. While holding the adjustment screw in position,
torque the seal lock nut [28cc 20-26 Nm (15-19
ft•lbf); 41cc 28-51 Nm (21-37 ft•lbf)] .
9. Stop the prime mover and remove the hose
between gauge ports M4 and M5. Remove the
pressure gauges installed in gauge ports M1 and
M2. Reinstall the plugs in the gauge ports.
10. Reconnect work function.

IMPORTANT
If the pump is equipped with an MDC or EDC,
the CONTROL "neutral" adjustment MUST also
be performed before putting the pump into
service (see next section).

008 911 83 BOMAG 727

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.3 Control “Neutral” Adjustment for MDC/EDC Controls

The control neutral adjustment aligns the pump swash-

plate and the control spool so that a zero angle control MDC / EDC Control
setting provides a zero degree swashplate setting. "Neutral" Adjustment Screw
This adjustment should be performed whenever any
part of the control or swashplate mechanisms is
adjusted or removed or after the pump neutral setting
(previous section) is adjusted.

WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
ground, work function disconnected, etc.) while
performing the procedure in order to prevent
injury to the technician and bystanders.

1. Disconnect the work function. Disconnect the

external control linkage (for MDC) or control
signal input (for EDC) from the pump.
2. Install pressure gauges in gauge ports M4 and MDC / EDC Control "Neutral"
M5 to measure pressure on the pump servo Adjustment Seal Lock Nut
piston. E100003 E

3. Start the prime mover and operate at normal Control Neutral Adjustment Screw
speed. (EDC Control Shown)
4. Loosen the CONTROL "neutral" adjustment seal
lock nut (see drawing) [17 mm Hex] . Turn the
control "neutral" adjustment screw [5 mm Int.
Hex] until the servo piston pressure gauge read-
ings are as close to equal as possible.
5. Turn the adjustment screw clockwise until one of
the gauges registers an increase in pressure on
the servo piston. Note the position of the adjust-
ment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in pressure on the
servo piston. Note the position of the adjustment
screw.
6. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The servo piston pressure gauges should indi-
cate nearly equal pressures.
7. While holding the adjustment screw in position,
torque the seal lock nut [14-24 Nm (10-18 ft•lbf)].
8. Stop the prime mover and remove the pressure
gauges installed in gauge ports M4 and M5.
Reinstall the plugs in the gauge ports.
9. Reconnect the external control linkage (for MDC)
or control signal input (for EDC) to the pump.
Reconnect the work function.

10

728 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

4.4 MDC Control Module

The manual displacement control (MDC) module Nut
provides control of the pump servo piston through a Lock Washer
connection to the summing link pin within the pump Plug for MDC Handle
housing. The following procedure shows how to Visual
Inspection
remove and install the control housing. Section 4.6
explains how to remove and install the control spool
and linkage. Control
Retaining
1. Clean the external surfaces of the pump. If nec- Screws
essary, remove the MDC handle.
2. Remove the seven (7) control retaining screws Control
Gasket
[Torx T30] that secure the control to the pump
housing. Remove the control and control gasket Hold summing link
from the pump. (and control spool)
in position
Note: See section 4.6 for instructions on remov-
ing/installing the control spool and linkage.
3. Clean the sealing surfaces of the control and the
pump housing. Place a new gasket in position on
the housing.

CAUTION E100004 E
The control orifices are part of the control
gasket. Refer to the appropriate Service Parts MDC Control Module Assembly
List to determine the correct gasket.

4. Hold the summing link pin in position while install-

ing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the slot in the control
cam. A plug is provided on the MDC housing to
permit visual inspection of linkage pin engage- Summing
ment. link pin
MUST enter
Note: It may be easiest to lay the servo piston the slot in
side of the control down first, then watch the link the control
pin engage from the charge pump side of the cam!
E100005 E
pump.
Link Pin Into Cam Slot
5. Install and torque the control screws [15-17 Nm
(11-13 ft•lbf)]. Perform Control Neutral Adjust-
ment (Section 4.3).

WARNING
Failure to properly engage the link pin with the
control cam will result in incorrect control
operation, which may lead to loss of control of
the vehicle / machine.

F100201
Link Pin Into Cam Slot

11

008 911 83 BOMAG 729

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.5 EDC Control Module

The Electric Displacement Control (EDC) provides a

control function through connections to the summing EDC Control
link pin within the pump housing. The following pro- Pressure Gauge
cedure shows how to remove and install the control Port X1
housings. The next section explains how to remove
and install the control spool and linkage.
1. Clean the external surfaces of the pump. If nec-
essary, remove control input signal.
2. Remove the seven (7) control retaining screws
[Torx T30] that secure the control to the pump
housing. Note the position of the different length
screws. Remove the control and control gasket
from the pump.
Note: See next section for instructions on remov- EDC Control
ing/installing the control spool and linkage. Pressure Gauge
Port X2 P100106 E
3. Clean the sealing surfaces of the control and the
EDC Module Showing Port Locations
pump housing. Place a new gasket in position on
the housing.

CAUTION
The control orifices are part of the control
Control Retaining
gasket. Refer to the appropriate Service Parts Screws (note different sizes)
List to determine the correct gasket.

4. Hold the summing link pin in position while install-

ing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the hole in the control
piston fork.
Control
Note: It may be easiest to lay the servo piston Gasket Summing
side of the control down first, then watch the link link pin
Hold summing MUST enter
pin engage from the charge pump side of the link (and control the hole in
pump. spool) in the control
position piston fork!
5. Install and torque the control screws [15-17 Nm
(11-13 ft•lbf)]. Perform Control Neutral Adjust-
ment (Section 4.3).

WARNING
Failure to properly engage the link pin with
control piston fork will result in incorrect con- E100006 E
trol operation, which may lead to loss of con-
trol of the vehicle / machine. EDC Control Module Assembly

12

730 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

4.6 MDC/EDC Control Spool, Control Linkage, and Control Neutral

Adjustment Screw
The control spool, control linkage, and control neutral
adjustment screw can be removed for cleaning and to Summing Link
change the O-rings or the seal lock nut. Linkage Pivot Screw

Removal of Spool, Linkage, and Adjustment Opposite

Screw Feedback Link Bore Plug
Neutral
1. Clean the external surfaces of the pump. Adjustment
Seal Lock
Link
2. Remove the MDC or EDC module and the control Control Neutral Nut
Adjust Screw
gasket from the pump housing (see previous two Control
sections). Spool
and Spring
3. Remove the summing link. Note
orientation!
4. Remove the control spool bore plug [5/16 in Int.
Hex] or screws [Torx T30], cover, and gasket. Housing without
Remove the opposite bore plug [5/16 in Int. Hex], Filtration Adapter
and remove the control spool and spring.
5. Remove the linkage pivot screw [4 mm Int. Hex], Control Spool
feedback link, and neutral adjustment link. Bore Plug

6. Remove the seal lock nut [17 mm Hex] and the

control neutral adjustment screw [5 mm Int. Hex].

Installation of Spool, Linkage, and Adjustment Housing with

Gasket
Screw Filtration Adapter
1. Install the control neutral adjustment screw and
seal lock nut. Do not tighten the nut.
Control Spool
2. Assemble the "neutral" adjustment link and feed- Bore Cover E100007 E
back link, and install as shown. Install and torque
MDC/EDC Control Spool and Linkage
the linkage pivot screw [8-15 Nm (6-11 ft•lbf)].
3. Lubricate and install the control spool and spring
Feedback link
assembly noting proper orientation. must enter slot in
servo piston
WARNING Pivot screw
The control spool and spring assembly MUST
be oriented in the housing as shown for proper
control operation.

4. Install and torque the control spool bore plug [41- Fork on summing link
must engage flats on
94 Nm (30-70 ft•lbf)]. Or install the control spool
Slot in "neutral" adjust link control spool
cover (with a new gasket) or plug, and torque the must engage groove in
screws [15-17 Nm (11-13 ft•lbf)]. adjusting screw E100008 E

5. Install the summing link. Hold the control spool in Servo Piston Linkage and Control Spool
position while engaging the fork on the summing (Internal Parts Shown with Housing Removed)
link with the flats on the spool. If necessary, rotate
the spool to engage the summing link.
6. Install a new control gasket. Hold the summing
link and control spool in position while reinstalling
the MDC or EDC (see section 4.4 or 4.5). Perform
Control Neutral Adjustment (section 4.3).

13

008 911 83 BOMAG 731

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.7 MDC Neutral Start/Backup Alarm Switch

The Neutral Start Switch (NSS) prevents the engine NSS Cover
and pump from being started when the pump is out of NSS Control Nut
neutral. The NSS should be wired in series with the
NSS Cam
engine starting circuit. The switch contact is closed at
the control handle's neutral position and opens when
the control handle is rotated 1.5 to 2° from neutral.
The Backup Alarm Switch (BUA) outputs an elec- NSS Cavity
tronic signal when the control handle is in a reverse
position. This switch is normally wired in series with
an audio output. The switch contact is open until the NSS with
control handle is rotated 2.6 to 3.75° in the reverse Weatherpack
direction.

CAUTION
The control handle's neutral position must
NSS with Screw
agree with the pump's neutral position for the Terminals
NSS/BUA to work effectively (see section 4.3).
E100009 E
The Neutral Start / Backup Alarm Switch assembly
can be configured for three different settings. NSS Assembly on MDC
i. A Neutral Start Switch only.
ii. A Neutral Start Switch with Backup Alarm for
units where clockwise (CW) handle rotation re-
sults in "reverse" motion.
iii. A Neutral Start Switch with Backup Alarm for Control
units where counterclockwise (CCW) handle ro- Yolk Cam
tation results in "reverse" motion.
The setting must be in accordance with the configu-
ration of the unit. See the model code (section 2) if
NSS only NSS with BUA NSS with BUA
uncertain of the type of NSS you have.
(CW = Reverse) (CCW = Reverse)
Alignment of the NSS requires a special alignment P100107 E

tool. Dimensions are given at right. Top View of NSS Showing Cam Positions

(continued) 9/16 -18UNF 2A THD

.04 x 45 Chamfer
R.125 ø .236–.030
Knurl

35.0
1.250

.306 .354

2.000

Material: .75 DIA x 3 ETD150

(All Dimensions in inches)
P100108 E
Alignment Tool

14

732 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

Adjustment is performed by setting the cam position

within the NSS assembly.
1. The MDC module must be removed from the
NSS Cover NSS
pump housing. Refer to section 4.4.
NSS Control Nut
2. Remove NSS [7/8 in Hex].
NSS Cam
3. Remove the NSS cover by inserting a screw-
driver into the NSS cavity and popping off the
cover with a hammer. Be careful not to damage
the internal hardware.
P100109 E
4. Remove the control nut [8 mm Hex]. Side View of NSS and NSS Cavity

5. Use a screwdriver to pop off the cam.

6. Set cam in proper orientation according to the
unit's configuration (i, ii, or iii above).
7. Screw special alignment tool in NSS cavity to
hold cam in place.
8. On the underside of the MDC module, clamp a
pair of locking pliers around the spring contacts of
the control cam. The pliers should hold the nub on
the control cam to the pin underneath. This will
hold the control cam in neutral position.
9. Screw control nut on cam [4.1-6.8 Nm (3-5 ft•lbf)].
10. Press new cover on top of cam cavity. This
requires either an arbor press or a full-sized
punch (punch depth = 1.06 mm (0.0417 in),
punch width = 23.3 mm (0.916 in)). F100202
Underside of MDC Module Showing Where to Clamp
11. Remove the alignment tool and the locking pliers. Locking Pliers
12. Place a new lubricated O-ring on NSS.
13. Reconnect the NSS [25-29 Nm (18-22 ft•lbf)] to
the MDC.
14. Reinstall MDC module onto pump housing (refer
to section 4.4).

15

008 911 83 BOMAG 733

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.8 MDC Solenoid Override Valve

The solenoid override valve is a safety feature that
connects both ends of the servo control piston to- Port L4
gether when the solenoid is de-energized. Thus the
Port X7
pump can be put into stroke only when the solenoid
is energized.
The solenoid override with brake release includes
hydraulic control of a safety brake. When de-ener-
gized, a spring-applied, hydraulically-released brake
is drained through port X7. For conditions where case
back-pressure on the spring-applied brake is critical,
an external drain to the reservoir can be connected
through port L4.
The solenoid override valve can be removed to
inspect and remove foreign matter.

Removal Solenoid Override Valve

Assembly E100010 E
1. Remove retaining nut [9/16 in Hex].
Solenoid Override Valve Assembly
2. Remove solenoid housing.
3. Remove retaining ring at base of solenoid. Retaining Nut

4. Remove solenoid. This should be connected to Solenoid

internal spool. Housing

Installation
Washer
1. Replace O-ring. Retaining Ring
2. Place spring and plunger inside of solenoid.
Solenoid
3. Attach spool (male notch) to plunger (female
notch).
O-Ring
4. Insert solenoid/spool assembly in solenoid over- Spring
ride bore. Plunger
5. Snap retaining ring over base of solenoid.
Spool
6. Place washer at base of solenoid.
7. Install housing and retaining nut [2-4 Nm (1.5-3.5
ft•lbf)].

E100011 E

Exploded View of Solenoid Override Assembly

16

734 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

4.9 FNR, NFPE, and NFPH Controls

The 3-position FNR control and the electric and
hydraulic non-feedback proportional (NFPE and NFPH Ports
(Ports X1 and X2)
NFPH) controls are non-feedback type controls. The
FNR and NFPE controls consist of modules mounted
on the pump housing. The hydraulic input for NFPH
is received through ports on the top of the pump
[9/16–18 SAE O-ring fitting].
The non-feedback controls are set at the factory. The
control modules can be removed to clean the ports
and change the O-rings.
The orifice plugs for the FNR and NFPE are located
inside the servo piston covers. The orifice plugs for E100012 E

the NFPH are located in the NFPH ports. Orifice Position of NFPH Ports
plugs may be cleaned or replaced.
Note: Future models may contain orifice plate
Control Solenoid
between module and pump housing.
Control Module
Removal and Installation of FNR and NFPE
Modules
1. Clean pump and module housings.
2. Remove four (4) screws retaining module to
housing [4 mm Int. Hex], and remove module Control Ports
from pump housing. Locator Pin

3. Remove O-rings from the control ports. Examine

ports for cleanliness.
4. Clean sealing surfaces.
5. Replace locator pin.
6. Install new O-rings.
7. Replace screws [4.7-6.1 Nm (3.5-4.5 ft•lbf].
E100013 E
Removal and Installation of FNR and NFPE NFPE Assembly (FNR Similar)
Control Orifices
Note: Future models may contain an orifice plate Non-Feedback
between module and pump housing. This will Control Orifice
take the place of the orifice plugs beneath the
servo piston cover.
1. Remove servo piston cover (see section 4.17).
2. Remove orifice plug [1/8 in Int. Hex].
3. Examine orifice and port for cleanliness.
4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ft•lbf)].

E100014 E

Location of Non-Feedback Control Orifice

17

008 911 83 BOMAG 735

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.10 System Check Relief Valves (High Pressure Relief, Charge Check,
& Bypass Valves)
The charge check, high pressure relief, and the loop
bypass functions are all contained within the system
check relief (SCR) valve assembly. This assembly
may be removed for cleaning and installation of fresh With
Bypass Valve
O-rings. The model code specifies whether high Seat
pressure relief valves, combination charge check/ Without
Bypass
high pressure relief valves, and/or loop bypass valves Retaining
Valve Ring
are present or not. Standard
Seat
Plug Bypass
1. Remove the valve seat plugs [9 mm Int. Hex] or Plunger
valve seat/bypass plugs [1 in Hex] from the pump Outer O-Ring
housing. O-Ring Valve
Seat
2. Remove the check poppet or relief valve assem- Backup Plug
Ring
blies from the pump housing. The smaller end of Outer
Inner
each conical spring is crimped to retain it on the O-Ring
O-Ring
check poppet or relief valve. Do not remove. Backup
Ring
3. Inspect the valves and mating seats in the special Inner
plugs for damage or foreign material. O-Ring

CAUTION
The relief valves are factory set and should not
be tampered with, except for replacing the
entire valve.

4. The O-ring on the standard bypass plunger may Check Poppet or

High Pressure
be replaced by removing the retaining ring and Relief Valve
removing the plunger from the special valve seat Conical Spring
plug. Remove the O-ring from the plunger and
install a new O-ring. Reinstall the plunger and
retaining ring.
5. Install a new outer O-ring, new backup ring, and
new inner O-ring on each valve seat plug.
6. Check that the conical springs are properly re-
tained on the check poppets or relief valves.
Install the check poppet or high pressure relief
valve assemblies into the pump housing .

CAUTION
The conical springs MUST be correctly posi-
tioned on the check poppets or relief valves
after installation for proper pump operation. E100015 E

System Check Relief Valve Components

7. Install the valve seat plugs or valve seat/bypass
plugs into the pump housing and torque [40-95
Nm (30-70 ft•lbf)].

18

736 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

4.11 Charge Relief Valve

The charge relief valve may be removed for cleaning
and installation of fresh O-rings. The pressure setting
may be changed. However, note that the setting will
vary for different charge flows which depends on
charge pump size and pump speed. The factory
setting is set relative to case pressure at 1800 rpm.
The actual charge pressure will vary at different
speeds.

Shim Adjustable Style

1. Remove the shim adjustable charge relief valve Shim Adjustable
Charge Relief Valve Plug
plug [1 in Hex] from the pump housing. Remove O-Ring
the O-ring from the plug.
Shims
2. Remove the spring and poppet from the housing.
Spring
3. Do not alter the shims which may be installed Poppet
between the spring and valve plug, or inter-
change parts with another valve. Inspect the
poppet and mating seat in the housing for dam-
age or foreign material.
4. If desired, the charge relief valve setting can be
changed. An approximate rule of thumb is 4 bar
/ 1.25 mm (58 psi / 0.050 in). The effective setting
will vary.
To confirm the charge relief valve setting, mea- E100016 E
sure charge pressure (port M3) with the pump in Shim Adjustable Charge Relief Valve Components
stroke. The charge pressure should level off
when the relief setting is reached.
Approximate Relief Setting vs Shim Thickness
5. Install a new O-ring on the valve plug. Reinstall
4 bar / 1.25 mm (58 psi / 0.050 in)
the poppet, spring, and plug (with shims and O-
T000 023E
ring) into the pump housing [55-135 Nm (40-100
ft•lbf)].
(continued)

19

008 911 83 BOMAG 737

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

Screw Adjustable Style Charge Relief Lock Nut

1. Before removing the screw adjustable relief valve O-Ring

plug, mark the plug, lock nut, and housing so as Screw Adjustable
to approximately maintain the original adjust- Charge Relief Valve Plug
Spring
ment when assembling, Remove the screw ad- Poppet
justable charge relief valve plug by loosening the
lock nut [1-1/16 in Hex] and unscrewing the plug
[8 mm Int. Hex]. Remove the O-ring from the plug.
2. Remove the spring and poppet from the housing.
3. Inspect the poppet and mating seat in the hous-
ing for damage or foreign material.
4. Install a new O-ring on the valve plug. Reinstall
the poppet and spring. Reinstall the plug with its
lock nut [47-57 Nm (34-42 ft•lbf)], aligning the E100017 E
marks made at disassembly.
Screw Adjustable Charge Relief Valve Components
5. Check and adjust, if necessary, the charge pres-
sure. For screw adjustable "anti-stall" charge
relief valves, an approximate rule of thumb is 2.8 Approximate Relief Setting vs Screw Revolution
bar / quarter turn (40 psi / quarter turn).
2.8 bar / 1⁄4 turn (40 psi / 1⁄4 turn)
To confirm the charge relief valve setting, mea- T000 024E

sure charge pressure (port M3) with the pump in

stroke. The charge pressure should level off
when the relief setting is reached.

20

738 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

4.12 Loop Flushing Valve

The loop flushing function consists of the loop flush-

ing shuttle valve and the loop flushing relief valve. The Loop Flushing
assemblies may be removed for cleaning and instal- Relief Plug
lation of new O-rings. The relief valve poppet may be Loop Flushing Relief
Plug (Defeat) O-Ring
exchanged for one with a different flow rating, but the
O-Ring Shims
relief valve shims should not be changed out unless
specifically instructed so by Sauer-Sundstrand. The Spring
function also can be defeated.
Poppet
Loop Flushing Valve
1. Remove the loop flushing valve plug from the
Loop
pump housing [11/16 in Hex]. Remove the O-ring Loop Flushing
Flushing
from the plug. Plug (Defeat)
Plug
O-Ring
2. Remove the loop flushing valve spool assembly O-Ring
from the housing.
Loop
3. Inspect the parts for damage or foreign material. Defeat Flushing
Spool Spool
The centering spring must be securely retained to Assembly
the spool by the washer.
4. Install the loop flushing valve spool assembly into
its bore. Install a new O-ring on the loop flushing
plug and install [27-47 Nm (20-35 ft•lbf)].

Loop Flushing Relief Valve

1. Remove the loop flushing relief valve internal hex
plug [5/8 in Hex] from the pump housing. Remove
the O-ring from the plug.
2. Remove the spring and poppet from the housing.
3. Do not alter the shims which are installed be-
tween the spring and valve plug, or interchange
parts with another valve. Inspect the poppet and
mating seat in the housing for damage or foreign
E100018 E
material. Inspect the orifice in the valve poppet.
Loop Flushing Valve and Loop Flushing Defeat
4. Install a new O-ring on the valve plug. Reinstall Components
the poppet, spring, shims, and plug (with O-ring)
into the pump housing [15-34 Nm (15-25 ft•lbf)].

Defeating Loop Flushing

1. Remove the loop flushing valve from the pump
housing.
2. Install the defeat spool into the spool bore in the
housing. Install the plain plug with O-ring into the
housing [11/16 in Hex], and torque [27-47 Nm
(20-35 ft•lbf)].
3. Remove the charge relief valve (these parts are
not necessary).
4. Install the plain hex plug with O-ring into the end
cap [5/8 in Hex], and torque [15-34 Nm (15-25
ft•lbf)].

21

008 911 83 BOMAG 739

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.13 Shaft Seal and Shaft Replacement

A lip type shaft seal is used in Series 42 pumps. This

seal and/or the shaft can be replaced without major
disassembly of the unit. Replacement generally re- Retaining
Ring
quires removal of the pump from the machine.
1. Position the pump with the shaft facing up. Seal Carrier
Assembly
NOTE: If the unit is positioned horizontally when
the shaft is removed, the cylinder block could
move out of place, making shaft installation diffi-
cult.
2. Remove the retaining ring from the housing.
3. Pull out seal carrier assembly.
4. Remove the O-ring from the seal carrier. To
install a new shaft only, proceed to step 8.
5. Place the seal carrier in an arbor press with the
shaft bearing side down, and press out the old
seal. An appropriately sized pipe spacer or socket
wrench can be used as a press tool. Once re-
moved, the seal is not reusable. E100019 E

6. Inspect the seal carrier and the new seal for Shaft Seal Components
damage. Inspect the sealing area on the shaft for
rust, wear, or contamination. Polish the sealing
area on the shaft if necessary. O-Ring

7. Press the new seal into the shaft bearing side of

the seal carrier. The seal lip must face the outside Sealant may
Seal be used on
of the pump. Be careful not to damage the seal.
outside diameter
The outside diameter of the seal may be coated
with a sealant (e.g. Loctite High Performance Inside Lip
Seal Carrier (face down)
Sealant #59231) prior to installation. This aids in
preventing leaks caused by damage to the seal
bore in the seal carrier.
(continued)

Press Seal
to bottom of Seal Carrier
E100020 E

Installation of Shaft Seal

22

740 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

If the shaft is not being replaced proceed to step

11. Retaining Ring
8. Remove the shaft and roller bearing assembly Roller Bearing
from the pump or motor. The bearing assembly
can be transferred to the new shaft (steps 9 and
10).
9. Remove the retaining ring that secures roller Key Shaft
bearing assembly with a snap ring plier. Remove
the roller bearing assembly. OR
Shaft Assembly
10. Place roller bearing assembly on new shaft and OR
secure with the retaining ring.
11. Wrap the spline or key end of shaft with thin
plastic to prevent damage to the seal lip during
installation. Lubricate the inside diameter of the
shaft seal with petroleum jelly.
12. Place the O-ring onto the shaft bearing and
lubricate with petroleum jelly.
13. Slide the seal carrier assembly over the shaft and
into the housing bore. Press against O-ring. Hold
inward pressure against the shaft to compress
the cylinder block spring while pressing the seal
carrier into place.
14. Install the retaining ring.

E100021 E

Shaft Components

23

008 911 83 BOMAG 741

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.14 Auxiliary Mounting Pads

The following procedure can be used to remove and

install a new auxiliary mounting pad or to install a
fresh O-ring for the current auxiliary mounting pad.
Several auxiliary mounting pads are available.
Auxiliary mounting pads are integrated into the charge
pump cover. When nothing is mounted on the pads,
a flange cover is attached to protect the mounting Pad Cover Screws
flange. This cover is removed when mounting a
Charge Aux Mount Pad Cover
pump.
Pump Retaining
Cover
Removal of Auxiliary Mounting Pad Screws
1. Remove the auxiliary pump or remove the two O-Ring
screws retaining the flange cover ["A" Pad 9/16
in Hex; "B" Pad 3/4 in Hex]. Remove the O-ring.
2. Orient pump so that charge pump cover (auxiliary OR
pad) is facing up.
3. Remove the charge pump cover. The auxiliary
pad is integrated into the charge pump cover.
OR
Use a Torx T45 male driver to remove the screws. Auxiliary
Mounting
Note: If a different auxiliary pad is being installed, Pad "A"
then a new drive coupling must be installed. To do
Gasket
this follow the instructions in the section on re-
moving and installing the charge pump (next
section).
Auxiliary
Note: If the charge pump components come out Mounting
with the charge pump cover refer to section 4.15 Pad "B"
Locating
on how to properly reinstall them. No Charge Pin 1
Pump Defeat Charge Pump
4. Install a new charge pump cover gasket.
Components
5. Install the charge pump cover (auxiliary pump
mounting pad is integrated in cover).
NOTE: The threaded screw holes in the auxiliary Locating
Pin 2
pump mounting pad used on very early produc-
tion pumps with the SAE "A" pad option are drilled
through into the area between the gerotor cover
and charge pump cover. Any of these holes
which are not used to attach the flange cover or E100022 E
auxiliary pump should be plugged with internal
Auxiliary Pad Options and Components
hex set screws installed hand tight to prevent the
entrance of water or dirt into this area.
6. Attach the auxiliary pump. If no pump is to be
attached on an auxiliary mounting pad, the pad
should be protected with a flange cover and O-
ring to prevent leakage.

24

742 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

4.15 Charge Pump

The charge pump may be disassembled to inspect
and clean, or to change the auxiliary shaft drive
coupling.
(Screw used with
Note: For units without integral charge pumps "No Pad" and
"A Pad" Only)
see the last page of this section for additional
information. Cover
Retaining
1. Remove auxiliary pump, if necessary. Screws

Charge Pump Cover or Auxiliary Pad

2. Remove the screws retaining the charge pump
cover to the pump housing [Torx T45] (seven (7)
screws are used with the "no pad" or SAE "A"
auxiliary mounting pad charge pump cover, while
six (6) screws are used with the SAE "B" auxiliary
mounting pad charge pump cover). Remove the
charge pump cover, gasket, and the cover locat-
ing pins.
3. Remove the gerotor cover assembly from the
Gasket
charge pump cover or the back of the pump
O-Rings
housing. Remove the gerotor cover O-rings. Two
(2) O-rings are used on the gerotor cover of all
pumps. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.) Geroter
Cover

Charge Pump Components

4. Remove the gerotor assembly from the gerotor
cover or pump housing.
Geroter
5. Remove the gerotor drive pin and drive coupling. Assembly
Remove the gerotor cover locating pin from the Drive Coupling
pump housing.
Geroter Cover Geroter Drive Pin
6. Each part should be inspected separately if they Locating Pin
Charge Pump
are to be reused. If either of the gerotor assembly Charge Pump
Cover Locating
parts needs to be replaced, they must both be Cover
Pin
Locating
replaced. Always replace the O-rings and charge Pin
pump cover gasket. Inspect the journal bearing in
the gerotor cover for excessive wear.
7. Prior to assembly, lubricate the gerotor assembly
with clean hydraulic oil.
8. Install the gerotor drive pin into the hole in the
drive coupling, and retain with grease or petro-
leum jelly.
9. Install the drive coupling onto the pump shaft with
the smaller outside diameter oriented away from
E100023 E
the pump shaft. Different couplings are used
Charge Pump Components
with the different auxiliary pad options.
10. Install the gerotor assembly onto the coupling.
(continued)

25

008 911 83 BOMAG 743

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

11. Install the gerotor cover locating pin into the

pump housing. Install the gerotor cover assembly
over the gerotor. The locating pin must engage
the slot in the gerotor cover.
NOTE: The charge pump rotation is determined
by the location of the gerotor recess and pressure
balance hole in the gerotor cover. Different
gerotor covers are used for clockwise and
counterclockwise rotation pumps.
12. Install new pressure balance O-rings onto the
gerotor cover and retain with petroleum jelly or
grease. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.)
13. Install the charge pump cover locating pins and a
new charge pump cover gasket.
14. Install the charge pump cover. The cover must
engage the gerotor cover and the locating pins. CW CCW
Install the charge pump cover screws and torque P100110 E
evenly [36-43 Nm (26-32 ft•lbf)]. Determining Charge Pump Orientation Looking
Inside of Gerotor Pump Cover
15. If necessary, reinstall auxiliary pump.
For units without an integral charge pump see the
next section.
(continued)

26

744 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

Units without Integral Charge Pump

Variable Pumps without an integral charge pump do (Screw used with
not have a gerotor assembly, gerotor drive pin, or "No Pad" and
gerotor cover locating pin installed. The charge pump "A Pad" Only)
inlet port is plugged with an O-ring plug.
Cover
For these units that are equipped with housings Retaining

Charge Pump Cover or Auxiliary Pad

Screws
without filtration adapters, the gerotor cavity outlet
is plugged with a special plug installed in a housing
passage. The 3/4—16 charge inlet fitting should be
torqued to 68 Nm (50 ft•lbf).
For these units that are equipped with housings that
include filtration adapters, the gerotor cavity outlet
is plugged with an O-ring plug installed in the "To
Filter" port of a "Full Filter Flow" (charge relief valve
after filter) filter adapter. The 7/8—14 charge inlet
fitting should be torqued to 95 Nm (70 ft•lbf). Gasket
O-Rings
CAUTION
A "Partial Filter Flow" (charge relief valve be-
fore filter) adapter must not be used on variable

"No Charge Pump" Components

pumps without an integral charge pump. If this
design adapter is used, the charge relief valve Geroter
Cover
will be defeated.
Charge Pump
Cover Locating
Drive Coupling Pin 1
Charge Pump
Cover Locating
Pin 2

Geroter
Cavity
Outlet Plug
(Charge Charge
Pump Defeat) Inlet

Charge Pump
Charge Pump Inlet Plug Inlet Plug

Charge Inlet
(For Wrench Sizes
and Torquing
See Filtration Section)

E100024 E

No Charge Pump Option Components No Charge Pump Option Components

(Housing with Filtration Adapter) (Housing without Filtration Adapter)

27

008 911 83 BOMAG 745

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.16 Filtration
Filtration of foreign matter from the hydraulic fluid is M3 Gauge Partial Flow
of primary importance. Dirt and foreign fluids within Port Plug Pressure
Filtration
the hydraulic circuit will greatly reduce the life of the
Full Flow
hydraulic equipment. Pressure
Filtration
Filter-Related Pump Hardware Filtration Plate
Retaining Screws
Filtration mechanisms for the Series 42 pump may
be before (suction filtration) or after (charge pressure Suction
Filtration
filtration) the charge pump. Sauer-Sundstrand pro-
vides a filtration adapter to provide for each type of
filtration configuration. If filtration is provided for
elsewhere in the hydraulic circuit, the pump will not
have a filtration adapter.
Pumps equipped with housings without filtration
adapters have an additional construction bore next to
the charge relief valve which is unused and plugged
[5/8 in Hex, 21-33 Nm (15-25 ft•lbf)]. When these
pumps are equipped with suction filtration, the exter-
nal charge inlet is plugged [5/16 in Int. Hex, 41-94 Nm
(30-70 ft•lbf)].
Pumps equipped with housings that include filtration
adapters have the appropriate adapter and gasket
fastened to the housing with screws [Torx T30, 16
Nm (12 ft•lbf)]. The position of the M3 gauge port [11/ Housing with
16 in Hex, 11-13 Nm (8-10 ft•lbf)] will vary depending Filtration Adapter
on filtration type.

Filter Specifications
Charge Inlet
The selection of a filter depends on a number of
Plug
factors including the contaminant ingression rate,
the generation of contaminants in the system, the Plug
Construction
required fluid cleanliness, and the desired mainte- Bore Plug
nance interval. A filter capable of controlling the fluid
cleanliness to ISO 4406 Class 18/13 or better is
recommended and may be located either on the inlet
(suction filtration) or discharge (charge pressure
filtration) side of the charge pump. E100025 E
Housing without
Filter capacity depends on desired maintenance Filtration Adapter (Suction Filtration Only)
levels. As a rough guide, a capacity in grams equal
to twice the charge flow in gpm or 1/2 charge flow in
l/min has been found to be satisfactory for many Filtration Type β-ratio
closed circuit systems. Closed Circuit Suction Filtration or
β10 ≥ 2
Open Circuit Return Line Filtration
Filter efficiency as measured by a "Beta" (β) ratio* Systems Sharing a Reservoir with
should be as in the table at right. β10 ≥ 10
Other Gears, Clutches, or Cylinders
See Sauer-Sundstrand publication BLN-9887 or Charge Pressure Filtration β10 ≥ 10
697581 and ATI-E 9201 for more information on
* Filter ßx-ratio is a measure of filter efficiency defined by ISO
filtration. 4572. It is defined as the ratio of the number of particles greater
than a given size (x) upstream of the filter to number of particles
greater than the same size downstream of the filter. The ßx-ratio
applies to a specific particle size, measured in microns.

28

746 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Adjustments and Minor Repairs

4.17 Servo Piston Covers

The servo piston cover can be removed to change the
gasket or to inspect/change the control orifices for
NFP or FNR controls (section 4.9). Pump Neutral Ajustment
Seal Lock Nut
1. On the right side (side “1”) of the pump, remove
the pump “neutral” adjustment seal lock nut [13
mm Hex]. (Not necessary on side "2") Servo Piston
Servo Piston Cover Cover Screw
2. Remove the servo piston cover screws [Torx
T30]. Servo Piston Cover
(Non-Feedback and
3. The left side (side "2") servo cover can be re-
Automotive controls only)
moved directly.
On the right side (side “1”) of the pump, the cover Pump "Neutral"
Adjustment Screw
should be pushed away from the pump housing.
It is then necessary to turn the “neutral” adjust-
ment screw [5 mm Hex] clockwise (inward) far
enough for the servo cover to clear the nearby
drain port. Then pull the cover away from the
housing and turn the cover counterclockwise to
disengage it from the adjustment screw.
Servo Piston Cover – Right Side (Side "1")
4. Remove the gasket.
Note: FNR and NFPE control orifice plugs are
located here, see section 4.9 for more informa- Servo Piston
tion. Cover Screws

5. Install new gasket. Servo Piston

Cover
6. On the right side (side "1"), screw the servo piston
cover on the neutral adjustment screw. Then,
while holding the cover, turn the neutral adjust-
ment screw CCW to engage the cover to the
screw threads.
7. Install servo piston cover screws (15-17 Nm (11-
13 ft•lbf)].
8. On the right side (side "1"), loosely install neutral Servo Piston Cover – Left Side (Side "2")
adjustment seal lock nut. Perform pump neutral
adjustment (section 4.2). E100026 E
Servo Piston Cover Components
WARNING
After installing the servo piston cover on right
side (side “1”) of the pump, the pump “neutral”
adjustment and control neutral adjustment
MUST be performed before the vehicle / ma-
chine is put back into service.

CAUTION
Performance of the above procedure may ad-
just the position of the displacement limiter
somewhat.

29

008 911 83 BOMAG 747

17.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.18 Displacement Limiter Adjustment

Displacement limiters can limit the maximum swash- Displacement Limiter

plate position. For Series 42 pumps, displacement Seal Lock Nut
limiters are available on one or both sides of the servo
Displacement Limiter
piston.
Servo Piston
Adjustment of the displacement limiters should be Cover
performed on a test stand.

WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The limiter screw must have full thread
engagement in the servo piston cover, and the
seal lock nut must be retorqued after every
adjustment to prevent unexpected changes in
operating conditions and external leakage dur-
ing unit operation.
Displacement Limiter – Right Side (Side "1")
1. Mount pump on test stand. (Exploded View, No Need to Remove Limiter or Nut)
2. Loosen displacement limiter seal lock nut [13 mm
Hex]. Do not remove.
Displacement Limiter
3. Adjust displacement limiter [4 mm Int. Hex]. Seal Lock Nut
Tighten the seal lock nut every time the pump
Displacement
is to be tested [20-26 Nm (15-19 ft•lbf)].
Limiter
One full turn of the displacement limiter adjust-
ment screw will change the displacement of the Servo Piston
Cover
pump approximately as follows.

28 cc 3.6 cc/rev 0.22 in3/rev

41 cc 5.0 cc/rev 0.31 in3/rev
T000 026E

4. After reaching proper displacement tighten the

Displacement Limiter – Left Side (Side "2")
seal lock nut [20-26 Nm (15-19 ft•lbf)]. (Exploded View, No Need to Remove Limiter or Nut)
If necessary, repeat procedure for displacement lim- E100027 E
iter on other side. Displacement Limiters

30

748 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Exploded View Parts Drawings

5. Exploded View Parts Drawings

5.1 Shaft Options

F096
C020
C017

C018
C015

C005
C002

C003
C001
C015 F001
OR

C001

OR
C001

E100028

31

008 911 83 BOMAG 749

17.3 Vibration pump 42R 041

Series 42 Exploded View Parts Drawings

5.2 Filtration, Charge Relief, System Relief, and Loop Flushing

(F086)
(F086A)

(F043)
(F043A)
(F040)
(F042)
(F043)
(F043A)
(F040) OR
(F042)

F043
F043A OR K001
F040 OR K001
F042
K005
F091 K001A
K002
F091A K001B
F030 K001C K006
F030A K007
G043
F041
G042
G040 K008
G040A G043 K009
G041 G042 K010
G041
G040A
G040
OR
J005
J002
045A F062
G045 F061 J003
F063 H005
F060A
F060 H002
H003
OR F051 F0511
(F060A)
(F060) F0512
F0513
F0514
F0515
F050A
F050 (F091A)
F093
(F091)
OR F093A
F093
(F051)
(F050A) F093A
(F050) N002A
N002

E100029

32

750 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Exploded View Parts Drawings

5.3 Charge Pump, Auxiliary Pads, and Servo Covers

L010
L010A

F020
F020A
G005
G010
(G075)
G015
G002 G020
(G021)
G022
G065
G075
G030 G023

F009
G001
M001
OR

(M001)
OR
(G001)
M005
M010A
G036
M010
(M005) OR
(M010A)
(M010) (G080)
G085
M020
M025

(G001) (G036) G090

(G090)
(G036) (G080)

(G085)

E100030

33

008 911 83 BOMAG 751

17.3 Vibration pump 42R 041

Series 42 Exploded View Parts Drawings

5.4 Control Options

D038 D039
D037
D081
D003
D003A
(D017)
D080 D082 D019
D016

D002 OR

OR
D056 D017

D040

D010
F035 D012

F035A E001 D070

OR
OR
D011
D013 D004
F036

F035
F034 D081

D081

OR

D060
(F010)

F010

D090
D014

D015

D032A
E100031
D032

34

752 BOMAG 008 911 83

Vibration pump 42R 041 17.3

Series 42 Exploded View Parts Drawings

Notes

35

008 911 83 BOMAG 753

17.3 Vibration pump 42R 041

Hydraulic Power Systems

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Phone: (515) 239-6000 • Fax: (515) 239-6618 Phone: (04321) 871-0 • Fax: (04321) 871 465
SI-SPV42-E • 11/98 • 300 093B

754 BOMAG 008 911 83

17.4 Vibration motor A10FM

008 911 83 BOMAG 755

17.4 Vibration motor A10FM

756 BOMAG 008 911 83

Vibration motor A10FM 17.4

A10FM

A10FE

RDE92172-01-R/08.01
ersetzt / replaces 06.99

Reparaturanleitung - A10FM 28 - 60 Baureihe 5

A10FE28 - 60 Baureihe 5
Repair instructions - A10FM 28 - 60 Series 5
A10FE28 - 60 Series 5

008 911 83 BOMAG 757

RDE 92172-01-R/08.01
17.4
Hinweis / Inhalt
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Notice / Contents Repair Instructions A10FM / A10FE

HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen Specifications, descriptions and illustrative material shown
entsprechen dem Informationsstand zum Zeitpunkt der herein were as accurate as known at the time this
Drucklegung dieser Unterlage. publication was approved for printing.
Änderungen können den Service am Produkt beein- BRUENINGHAUS HYDROMATIK reserves the right to
flussen, Verpflichtungen entstehen uns daraus nicht. discontinue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für specifications, materials, or design without notice and
deren Resultat wir keine Haftung übernehmen können. without incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Anga- Optional equipment and accessories may add cost to the
be der Fabrik-Nr. bestellt, sind die Basis guter Reparatu- basic unit, and some options are available only in
ren. combination with certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf For the available combinations refer to the relevant data
dem Teststand vorzunehmen. sheet for the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vor- Adjustment and tests have to be carried out on the test
kehrungen sicherzustellen. bench under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, Protection of personnel and property has to be guar-
vermitteln wir in unseren Schulungskursen. anteed by appropriate measures.
Expert knowledge, the precondition of any service work,
can be obtained in our training courses.

INHALT Seite/ CONTENTS

Page

A10FM / A10FE A10FM / A10FE

Schnittbild 3 Sectional view

Allgemeine Reparaturhinweise 4 General repair guidelines
Triebwelle abdichten 5-7 Sealing the drive shaft
Motor demontieren 8-14 Disassemble the motor
Überprüfungshinweise 15 Inspection hints
Motor montieren 16-19 Motor assembly
Spülventil demontieren 20 Disassembly of the flushing valve
Abstimmung- Lagerung / Hinweise 21 Bearing adjustment / Note
Werkzeuge / Hilfswerkzeuge / Tools / auxiliary tools /
Anziehdrehmomente 27 tightening torques

2 Brueninghaus Hydromatik
758 BOMAG 008 911 83
RDE 92172-01-R/08.01
Vibration motor A10FM
Schnittbild
17.4
Reparaturanleitung A10FM / A10 FE
Sectional view Repair Instructions A10FM / A10FE

A10FM

A10FE

Optional Option
Ausführung mit Spülventil Unit with flushing valve
für geschlossenen Kreislauf for closed circuit application

008 911 83 BOMAG Brueninghaus Hydromatik

759 3
RDE 92172-01-R/08.01
17.4
Allgemeine Reparaturhinweise
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
General repair guidelines Repair Instructions A10FM / A10FE

Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!

Attention!
Observe the following guidelines when carrying out repairs
on hydraulic units!

Alle Öffnungen der Hydraulikaggregate verschließen.

Close off all openings of the hydraulic unit.

Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK
Ersatzteile verwenden.

Replace all of the seals.

Use only original BRUENINGHAUS HYDROMATIK
spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all sealing and sliding surfaces for wear.

Attention: Re-work of the sliding surfaces by using, for
example abrasive paper, can damage the surface.

Hydraulikaggregate vor Inbetriebnahme mit

Hydrauliköl befüllen.

Fill the hydraulic unit with hydraulic oil

before commissioning.

4 Brueninghaus Hydromatik
760 BOMAG 008 911 83
RDE 92172-01-R/08.01
Vibration motor A10FM
Triebwelle abdichten
17.4
Reparaturanleitung A10FM / A10 FE
Sealing the drive shaft Repair Instructions A10FM / A10FE

2
1

2 1. Sicherungsring, 2. Wellendichtring
1
1. Circlip, 2. Shaft seal

3 (Paßfeder ausbauen bei Ausführung Paßfeder))

Triebwelle abkleben.
Sicherungsring ausbauen.

(Remove key, version with keyway)

Protect the drive shaft.
Remove the circlip.

008 911 83 BOMAG Brueninghaus Hydromatik

761 5
RDE 92172-01-R/08.01
17.4
Triebwelle abdichten
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Sealing the drive shaft Repair Instructions A10FM / A10FE

4 Nach der Demontage des gelaufenen Wellendichtringes,

einfetten des neuen WDR.(Kontrolle der Laufflächen, Welle,
Gehäuse).

Change the shaft seal and check its sliding surface (drive shaft)
and housing, grease the sealing ring.

5 Welle mit Schutzhülse oder Klebeband versehen.

Use installation tool or plastic strip for assembling seal.

6 Mit geeignetem Rohr den WDR nur so tief montieren,

daß der Sicherungsring montierbar ist (zu tiefes Montieren
führt zum Ausfall: Berührung mit dem Wellenlager! ).

Use a suitable pipe to mount the shaft seal ring, but don't
push it too deap. If the shaft ring touches the bearing ring
you will damage the seal ring.

7 Sicherungsring einsetzen.

Assemble the snap ring.

8 Sicherungsring ganz einrasten.

Assemble the snap ring in the correct position.

6 Brueninghaus Hydromatik
762 BOMAG 008 911 83
RDE 92172-01-R/08.01
Vibration motor A10FM
Triebwelle abdichten
17.4
Reparaturanleitung A10FM / A10 FE
Sealing the drive shaft Repair Instructions A10FM / A10FE

Hinweis! Note!
Die hier beschriebene Möglichkeit zum Wechsel der This discription showes how th change the drive shaft
Antriebswellen - Abdichtung stellt nicht die serienmäßi- sealing ring but it isn't the way of serial assembly.
ge Montage dar. Für sicheres Dichtungsverhalten ist eine The sealing ring is assembled together with the taper
Montage des Dichtringes zusammen mit dem Kegel- roller bearing from inside the motor housing normally to
rollenlager von innen her durch das Montagegehäuse get a secure sealing condition. If you decide to repair the
durchzuführen. Soll aus Gründen der Vereinfachung im motor in the shown way be very careful while handling
Reparaturfall die vorgehend beschriebene Vorgehens- so that the drive shaft wouldn't be damaged during
weise durchgeführt werden, so ist beim Ausbau der disassembly of the shaft sealing ring.
Dichtung besonders darauf zu achten, daß die Antriebs-
welle nicht beschädigt wird.

008 911 83 BOMAG Brueninghaus Hydromatik

763 7
RDE 92172-01-R/08.01
17.4
Motor demontieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

A10FM

8 Brueninghaus Hydromatik
764 BOMAG 008 911 83
RDE 92172-01-R/08.01
Vibration motor A10FM
Motor demontieren
17.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE

A10FE

10

008 911 83 BOMAG Brueninghaus Hydromatik

765 9
RDE 92172-01-R/08.01
17.4
Motor demontieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

11 Demontageposition
Lage der Anschlußplatte zum
Gehäuse kennzeichnen.

Disassembly position
Mark the location of the connection plate
on the housing.

12 Anschlußplattenbefestigung über Kreuz lösen.

Remove the connection plate fixing bolts crosswise.

13 Anschlußplatte abheben.
Verteilerplatte
kann herunterfallen - festhalten.
Verteilerplatte abheben.

Remove the connection plate.

Distributor plate
can drop down - hold tight.
Remove distributor plate.

10 Brueninghaus Hydromatik
766 BOMAG 008 911 83
RDE 92172-01-R/08.01
Vibration motor A10FM
Motor demontieren
17.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE

14 Verteilerplatte abheben.

Remove control plate.

15 Lageraußenring mit Abziehvorrichtung ausbauen.

Dichtfläche Verteilerplatte nicht beschädigen.

Remove bearing outer ring with withdrawal tool.

Do not damage the sealing surface.

16 Abheben des Kegelrollenlagers (anschlußplattenseitig).

Entfernen der Abstimmscheibe.

Disassemble the taper roller bearing (near by port plate)

Remove the adjustment shim.

008 911 83 BOMAG Brueninghaus Hydromatik

767 11
RDE 92172-01-R/08.01
17.4
Motor demontieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

17 Triebwerk in horizontaler Lage herausziehen.

Remove the rotary group in a horizontal position.

18 Welle nach hinten herausziehen.

Remove the drive shaft to rear side.

19 Hubscheibe mit Sonderwerkzeug ausbauen (siehe Bild 20).

Remove swash plate with special tool (see picture 20).

20 Der Ausbau der Hubscheibe erfolgt mit einer Schleuder,

ein kleiner Haken - aus Rundmaterial Durchmesser 6 mm -
greift dabei unter die Hubscheibe.

Loosen the swash plate with a slide hammer ( a small

hook - diameter 6 mm - catches the end of the swash
plate at the bottom).

21 Lager mit Presse abziehen.

Press down bearing.

12 Brueninghaus Hydromatik
768 BOMAG 008 911 83
RDE 92172-01-R/08.01
Vibration motor A10FM
Motor demontieren
17.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE

22 Abziehen des Lageraußenringes im Pumpengehäuse.

Zweckmäßige Unterlage benutzen, zur Vermeidung von
Gehäusebeschädigungen (s. a. Hinweis Abb.xx).

The external front bearing ring is pulled out of the pump

housing (tool and surface infos see picture xx, too).

23 Sicherungsring entfernen.

Disassemblecirclip and shaft seal.

24 Wellendichtring und Fixierscheibe entnehmen

Remove shaft seal ring and shim.

008 911 83 BOMAG Brueninghaus Hydromatik

769 13
RDE 92172-01-R/08.01
17.4
Motor demontieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

25 Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

26 Sicherungsring demontieren.
Feder und Druckstifte ausbauen.

Remove circlip.
Remove spring and pressure pins.

27

14 Brueninghaus Hydromatik
770 BOMAG 008 911 83
RDE 92172-01-R/08.01
Vibration motor A10FM
Überprüfungshinweise
17.4
Reparaturanleitung A10FM / A10 FE
Inspection hints Repair Instructions A10FM / A10FE

28 Kontrolle!
Lauffläche (1) keine Kratzer, keine Metalleinlagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).

Check!
Check to see that there are no scratches or metal deposits
on the sliding surface (1), and that there is no axial play (2),
(pistons must only be replaced as a set).

29 Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).

Check!
Cylinder bores (1), splines (2).

30 Riefenfrei, keine Einlaufspuren

Free of grooves, no signs of wear.

31 Kontrolle!
Zylindergleitfläche riefenfrei, nicht eingelaufen, keine
Einlagerungen, Steuerplatte nicht riefig (nur satzweise
austauschen).

Check!
Cylinder sliding surface free of grooves, no wear, no
embedded foreign particles. That there are no scratches
on the control plate. (Only replace them as a set).

32 Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.

Check!
Mounting surface - control plate undamaged

008 911 83 BOMAG Brueninghaus Hydromatik

771 15
RDE 92172-01-R/08.01
17.4
Motor montieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Motor assembly Repair Instructions A10FM / A10FE

33 Sicherungsring ins Gehäuse montieren.

Fit the circlip into the housing.

34 Wellendichtring und Fixierscheibe gegen

Sicherungsring einsetzen.

Assemble shaft seal ring and shim

against circlip.

35 Montage des Wellendichtringes 1 gegen den Sicherungsring 2,

3 anschließend Fixierscheibe 3 einlegen.

1 Assembly of the shaft seal 1 against the safety ring 2,

back up the shim 3 down to the seal ring.

36 Lageraußenring ins Gehäuse pressen.

Welle mit Lager vormontiert ins Gehäuse einstecken.

Wellendichtring nicht beschädigen.

Wellenverzahnung mit Klebeband umwickeln.

Press outer bearing ring into housing.

Shaft seal with pre-assembled bearing into housing.

Protect splines of the shaft with plastic strip

against damage of the seal lip.

16 Brueninghaus Hydromatik
772 BOMAG 008 911 83
RDE 92172-01-R/08.01
Vibration motor A10FM
Motor montieren
17.4
Reparaturanleitung A10FM / A10 FE
Motor assembly Repair Instructions A10FM / A10FE

37 Hubscheibe montieren.

Assemble swash plate.

38 Mit Vorrichtung Druckstifte montieren.

Fit pressure pins using an assembly aid.

39 Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

40

41 Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note:
Oil piston and slipper pad.

008 911 83 BOMAG Brueninghaus Hydromatik

773 17
RDE 92172-01-R/08.01
17.4
Motor montieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Motor assembly Repair Instructions A10FM / A10FE

42 Rotationsgruppe montieren!

Montagehilfe:
Mit O-Ring Kolben festhalten.

Fit rotary group!

Assembly aid:
Hold the pistons by using an O-ring.

43 Lager (1) in Anschlußplatte montieren.

4 Zylinderstift (2) einsetzen.
O-Ring (3) einsetzen.
Verteilerplatte (4) aufsetzen.
3
Montagehilfe:
Teile mit Fett fixieren.
1

Fit bearing (1) in connection plate.

2 Fit cyilindrical pin (2).
Fit O-ring (3).
Fit distributor plate (4).

Assembly:
Hold the components in place with grease.

18 Brueninghaus Hydromatik
774 BOMAG 008 911 83
RDE 92172-01-R/08.01
Vibration motor A10FM
Motor montieren
17.4
Reparaturanleitung A10FM / A10 FE
Motor assembly Repair Instructions A10FM / A10FE

44 Verteilerplatte montieren.
Montagehilfe: Fett

Fit distributor plate.

Assembly aid: Grease

45 Anschlußplatte aufsetzen und mit Schrauben

über Kreuz anziehen.

Fit the connection plate and fix it with

the screws crosswise.

A10FM A10FE

46

008 911 83 BOMAG Brueninghaus Hydromatik

775 19
RDE 92172-01-R/08.01
17.4
Spülventil demontieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Disassembly of the flushing valve Repair Instructions A10FM / A10FE

47 Beidseitig Schrauben 1 lösen und Federn mit Scheiben 2

entnehmen.

Loosen screws 1, take out springs and shims 2.

1
2

2
1

48 Spülschieber 3 vorsichtig zu einer Seite heausdrücken.

Take out spool carefully.

49 Verschlußschraube Speisedruckventil 4 lösen,

Feder und Einsatz entnehmen.

Loosen the screw of the boost valve and take out

the spring and the cartridge.

Montage in umgekehrter Reihenfolge!

Assembling by opposite steps!

20 Brueninghaus Hydromatik
776 BOMAG 008 911 83
RDE 92172-01-R/08.01
Vibration motor A10FM
Abstimmung- Lagerung / Hinweise
17.4
Reparaturanleitung A10FM / A10 FE
Bearing adjustment / Note Repair Instructions A10FM / A10FE

Montage - Abstimmung (Kegelrollenlager) / Taper roller bearing initial tension

AA10FM Baureihe 50
AA10FM Series 50
0 .... 0,05 mm

Pos. 12

Abstimmung der Triebwerkslagerung Adjustment of stopper min displacement

Die Vorspannung der Triebwerkslagerung muß im Cast iron housing must have initial tension of bearings:
Gußgehäuse von 0 bis 0,05 mm durch Abschleifen der 0 ...... 0,05 mm , grind Pos. 12 if necessary.
Abstimmscheibe Pos. 12 hergestellt werden.
Adjustment: Qmin- stopper
Einstellhinweis: Qmin-Anschlag With a given inflow and pressureless circulation adjust
Bei gegebenem Zusatzstrom wird bei drucklosem the stopper Qmin displacement so that the measured
Umlauf der Anschlag Qmin so eingestellt, daß die gemes- speed of the motors results in a displacement of 12 cm3
sene Drehzahl des Motors einem Schluckvolumen von (vgmin).
12 cm3 entspricht (vgmin). Increase of adjustment is possible to vgmax = 45 cm3
Eine kontinuierliche Verstellung bis vgmax = 45 cm3 ist Differential volume is appr. 3,1 cm3 (see page 3).
möglich - Volumenänderung pro Gewindestiftum-
Q inflow x 1000
drehung ca. 3,1 cm3 (s. a. Seite 3). Displacement vgmin =
Measurement speed
Q Zulauf x 1000
Schluckvolumen vgmin =
Meßdrehzahl

Achtung: Falsch eingestellte Qmin Anschläge können zu Attention: Wrong adjustments of stopper Qmin
überhöhten Drehzahlen bis hin zum Ausfall der Bauteile displacement increases the speed of the motor up to a
führen. possible failure of parts of the unit.

008 911 83 BOMAG Brueninghaus Hydromatik

777 21
RDE 92172-01-R/08.01
17.4
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Tools / auxiliary tools / tightening torques Repair Instructions A10FM / A10FE

49 Plastikhammer

Soft hammer

50 Schleuder

...

Anziehdrehmomente /
Tightening torques

Festigkeitsklassen 8,8; 10,9; 12,9

Bolt tensile strength grade:

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8,8 2,3 5,0 8,5 21 41 72 115 176 240 350 600 1220

Ma 10,9 3,2 7,2 12 29 58 100 165 250 350 490 840 1670

12,9 4,1 8,5 14,5 35 70 121 195 300 410 590 990 2000

Ma (Nm) = max. Anziehdrehmoments (geölte Schrauben μ = 0,125)

Ma (Nm) = max. tightening torques (lubricated screws μ = 0,125)
51

22 Brueninghaus Hydromatik
778 BOMAG 008 911 83
17.5 Transmission CR

008 911 83 BOMAG 779

17.5 Transmission CR

780 BOMAG 008 911 83

Transmission CR 17.5

3ERIES #2
#OMPACT
2OLLER $RIVE

3ERVICE -ANUAL AND
2EPAIR )NSTRUCTION

008 911 83 BOMAG 781

17.5 Transmission CR

3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
)NTRODUCTION

).42/$5#4)/. 4HIS BROCHURE REPRESENTS INFORMATION FOR NORMAL SERVICE AS WELL AS AN INSTRUCTION FOR
MINOR REPAIRS OF 3AUER $ANFOSS PLANETARY DESIGNED COMPACT GEARS 3ERIES #2

-INOR REPAIRS INCLUDES REPLACEMENT OF BRAKE GEARS CARRIERS AND BEARINGS OF THE #2 GEAR

DRIVE

4HE ASSEMBLING OF THE SPINDLE GROUP " REQUIRES A SPECIAL TOOL IN ORDER TO HANDLE THE
TORQUE OF .M ; LBFsIN= FOR #2 AND .M ; LBFsIN= FOR THE #2

)N ANY CASE OF AN ECONOMICALLY REPAIRABLE FAILURE AT THIS GROUP THE WHOLE GEARBOX SHOULD
BE RETURNED TO 3AUER $ANFOSS .EUMàNSTER

¹ 3AUER $ANFOSS

3AUER $ANFOSS CAN ACCEPT NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGUES BROCHURES AND OTHER PRINTED MATERIAL 3AUER $ANFOSS RESERVES THE
RIGHT TO ALTER ITS PRODUCTS WITHOUT PRIOR NOTICE 4HIS ALSO APPLIES TO PRODUCTS ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS CAN BE MADE WITHOUT
SUBSEQUENT CHANGES BEING NECESSARY IN SPECIlCATIONS ALREADY AGREED !LL TRADEMARKS IN THIS MATERIAL ARE PROPERTIES OF THE RESPECTIVE COMPANIES
3AUER $ANFOSS AND THE 3AUER $ANFOSS LOGOTYPE ARE TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP !LL RIGHTS RESERVED
&RONT PAGE & & & & 0

$+-(03$ , 2EV ! n

782 BOMAG 008 911 83

Transmission CR 17.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
#ONTENTS

#/.4%.43 )NTRODUCTION
-ODEL #ODE
$ESCRIPTION
0OWER &LOW $IAGRAM
4ECHNICAL &EATURES
3CHEMATIC
$ESIGN
4YPE OF -OUNTING
$IRECTION OF 2OTATION
)NSTALLATION 0OSITION
,UBRICANTS
4EMPERATURE 2ANGE
,UBRICANT 6ISCOSITY ,IMITS
4ECHNICAL $ATA
"RAKE
3TART 5P AND -AINTENANCE 0ROCEDURE
-ECHANICAL 2ELEASING OF THE "RAKE
2EESTABLISH "RAKING #APABILITY
/UTLINE $RAWINGS
2OLLER $RIVE 'EARBOX WITH #ARTRIDGE -OTOR n #2
2OLLER $RIVE 'EARBOX WITH #ARTRIDGE -OTOR n #2
2EPAIR )NSTRUCTION
'ENERAL
$ISASSEMBLY
'EAR AND 0LANET #ARRIERS $ISASSEMBLY
"RAKE !SSEMBLY
!SSEMBLY
'EAR AND 0LANET #ARRIERS
"RAKE !SSEMBLY
3CREW 4ORQUE
%XPLODED 6IEWS
%XPLODED 6IEW n #2 !
%XPLODED 6IEW n #2 !
%XPLODED 6IEW n #2
#ROSS 3ECTION 6IEWS
#ROSS 3ECTION 6IEW n #2 !
#ROSS 3ECTION 6IEW n #2 !
#ROSS 3ECTION 6IEW n #2
0ARTS ,IST

$+-(03$ , 2EV ! n

008 911 83 BOMAG 783

17.5 Transmission CR

3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
-ODEL #ODE

490% $%3)'.!4)/. !.$ /2$%2 #/$%

# 2 !

3ERIES OR 0RODUCT 2EVISION STATUS OF UNIT
3ERIES #2
#2 #OMPACT 2OLLER
$RIVES

3PECIAL HARDWARE FEATURES
WITHOUT SPECIAL HARDWARE
/UTPUT TORQUE
4"
.M SPECIAL NAMETAG CUSTOMER
! 4$
; LB FsIN =
. M
!
; LB FsIN =
. M

; LB FsIN = 3HAFT SPLINE MOTOR 2 A T IO
# 7XXX M
# $ ). M
TEETH
3PINDLE AND MOTOR CONFIGURATION M
PITCH !.3)
WITH MECH BRAKE RELEASE
! M M
#
WITH SPECIAL BRAKE RELEASE
! M
+
WITH SPECIAL BRAKE RELEASE "RAKE
! M
+ / NOT AVAILABLE BRAKE
WITH SPECIAL BRAKE RELEASE WITH BRAKE
! M +
# STATIC BRAKE TORQUE INPUT SHAFT .M ; LBFsIN=

.OT AVAILABLE
M /PTIONAL

$+-(03$ , 2EV ! n

784 BOMAG 008 911 83

Transmission CR 17.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
$ESCRIPTION 0OWER &LOW $IAGRAM

$%3#2)04)/. 2OLLER $RIVES CONSIST OF TWO OR THREE SIMPLE PLANETARY STAGES CONNECTED IN SERIES

%ACH PLANETARY STAGE CONSISTS OF A SUN PINION INPUT GEAR AN INTERNAL TOOTH RING GEAR AND
A SET OF PLANET OR SATELLITE GEARS MOUNTED TO A PLANET CARRIER 4HE SUN GEAR hmOATSv WITHIN
THE PLANET GEARS TO ALLOW UNIFORM LOAD DISTRIBUTION AT THE MULTIPLE GEAR MESH POINTS

! HYDROSTATIC CARTRIDGE MOTOR DRIVES THE SUN PINION WHICH IN TURN DRIVES THE PLANET GEARS
WITHIN THE RING GEAR CAUSING ROTATION OF THE PLANET CARRIER 4HE PLANET CARRIER IS COUPLED
DIRECTLY TO THE SUN GEAR OF THE NEXT STAGE

4HE OUTPUT PLANET CARRIER IS lXED NON ROTATING AND THE RING GEAR TRANSMITS MAIN TORQUE

TO THE OUTPUT /UTPUT HUB ROTATION IS OPPOSITE TO THE INPUT ROTATION

4HE PLANET GEARS ARE SUPPORTED ON FULL COMPLEMENT ROLLER BEARINGS 4HE OUTPUT HUB IS
SUPPORTED ON TAPERED ROLLER BEARINGS TO PROVIDE LARGE EXTERNAL LOAD CARRYING CAPABILITY

!LL GEARS AND SHAFTS ARE MACHINED FROM CASE HARDENED STEEL OR HIGH TENSILE ALLOY STEEL AND
ALL HOUSINGS ARE CAST IRON OR NODULAR IRON OR STEEL ACCORDING TO LOAD REQUIREMENTS

0/7%2 &,/7 $)!'2!- #OMPACT 2OLLER $RIVE n #2

/UTPUT

)NPUT

0
0OWER mOW

$+-(03$ , 2EV ! n

008 911 83 BOMAG 785

17.5 Transmission CR

3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
4ECHNICAL &EATURES

3#(%-!4)#

0

$%3)'. 4WO OR THREE STAGE SERIES PLANETARY GEARING COMBINED WITH OPTIONAL lXED DISPLACE

MENT AXIAL PISTON AND VARIABLE DISPLACEMENT BENT AXIS HYDROSTATIC MOTORS

490% /&