Service - Manual

BW 24/27 RH
S/N 101 538 00 .... S/N 101 538 10 ....

Rubber tire roller

Catalogue number.
008 911 17 03/2008
Table of Contents

General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 24
Maintenance 29
2.1 General notes on maintenance 30
2.2 Fuels and lubricants 31
2.3 Table of fuels and lubricants 33
2.4 Running-in instructions 34
2.5 Maintenance chart 35
Technical data 37
3.1 Technical data 38
Fundamental electrics 43
4.1 Understanding circuit diagrams 44
4.2 Terminal designations 49
4.3 Battery ground and analog ground 53
4.4 Current and voltage 53
4.5 CAN-Bus 56
4.6 Resistance 58
4.7 Series / parallel connection 60
4.8 Ohm's law 62
4.9 Electrical energy 62
4.10 Formula diagram 63
4.11 Metrology 64
4.12 Diodes, relays, fuses 67
4.13 Batteries 70
4.14 Three-phase generator 73
4.15 Electric starter 81
4.16 Telemecanique switch 84
4.17 Inductive proximity switches 87
4.18 Angle sensors 88
4.19 Plug connectors 90
4.20 Deutsch plug, series DT and DTM 90
4.21 Plugs and terminals in spring clamping technology 97
4.22 Electric modules 100
Special tools, electrics 101
5.1 Special tools, electrics 102
Electronic modules 111
6.1 Module description A04 113
6.2 Module description A100 123
Speedometer Module 133
7.1 Speedometer module 134
Engine 137
8.1 Diesel engine, general 138
8.2 Service side 139

008 911 17 BOMAG 3

Table of Contents

8.3 Starter side 140

8.4 Compressor 141
8.5 Lubrication oil circuit 144
8.6 Oil pressure switch and low oil pressure circuitry 146
8.7 Check the engine oil level 147
8.8 Changing engine oil and oil filter cartridges 148
8.9 Coolant circuit 150
8.10 Coolant temperature switch 152
8.11 Disassembling and assembling the coolant temperature switch 153
8.12 Replacing the thermostat 154
8.13 Checking the thermostat in disassembled state 155
8.14 Check the coolant level 156
8.15 Change the coolant 156
8.16 Clean the cooling fins on engine and hydraulic oil cooler 157
8.17 Three-phase generator 158
8.18 Checking / replacing the ribbed V-belt 159
8.19 Check the engine mounts 160
8.20 Fuel supply 161
8.21 Injection system 164
8.22 Injection pump replacement during service 166
8.23 Injection valve replacement during service 174
8.24 Checking / repairing injection valves 177
8.25 Fuel filter 182
8.26 Check, clean the water separator 184
8.27 Change the fuel pre-filter cartridge 184
8.28 Change the fuel filter cartridge 185
8.29 Checking the compression 186
8.30 Check, adjust the valve clearance 187
8.31 Boost fuel solenoid valve 189
8.32 Engine shut-down solenoid 190
8.33 Air filter, differential pressure switch 191
8.34 Combustion air filter service 192
8.35 Heating flange on engine (option) 195
8.36 Checking the heating flange control 199
8.37 Engine monitoring 200
8.38 Engine 204
8.39 Special tools, Deutz engine (BFM 2012) 206
Front axle 219
9.1 Repair overview for front axle 220
9.2 Dismantling the front axle 221
9.3 Assembling the front axle 228
Service Training 251
10.1 Service Training Hydraulics 253
Air conditioning system 325
11.1 Physical basics 327
11.2 Refrigerant R134a 330
11.3 Compressor oil / refrigeration oil 331
11.4 Working principle of the air conditioning system 332

4 BOMAG 008 911 17

Table of Contents

11.5 Monitoring devices 332

11.6 Description of components 333
11.7 Checking the compressor oil level 339
11.8 Checking the magnetic clutch 340
11.9 Inspection and maintenance work 341
11.10 Checking, replacing the refrigerant compressor V-belt 341
11.11 Service the air conditioning 342
11.12 Drying and evacuation 345
11.13 Emptying in case of repair 345
11.14 Leak test 346
11.15 Filling instructions 347
11.16 Trouble shooting in refrigerant circuit, basic principles 350
11.17 Trouble shooting, refrigerant circuit diagram 354
11.18 Trouble shooting procedure 355
11.19 Steam table for R134a 365
11.20 Heating control / air conditioning control 371
Replacing the cab window panes 377
12.1 Assembly of window panes 378
12.2 Special tools 379
12.3 Auxiliary materials 380
12.4 Removing and installing the window pane 382
Suppliers documentation 387
13.1 Travel pump A4VG 71 ... 180 389
13.2 Travel motor A6VM/VE 451
13.3 Travel gear 505
Circuit diagrams 579
14.1 Wiring diagram 581
14.2 Hydraulic diagram 601
14.3 Pneumatic diagram 605
Supplement to circuit diagram 609
15.1 Control elements 610
15.2 Monitoring board A15 613
15.3 Terminal box 615
15.4 Engine compartment 616

008 911 17 BOMAG 5

Table of Contents

6 BOMAG 008 911 17

1 General

008 911 17 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 17

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 17 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 17

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 17 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 17

Safety regulations 1.2
l Always shield eyes and face towards the battery. l There is a danger of scalding when draining off en-
l Do not use battery chargers or jump leads without gine or hydraulic oil at operating temperature.
following the operating instructions. l on machines with rubber tires a tire may busr if in-
l Keep the cell plugs closed. correctly assembled. This can cause severe injury.
l After an accident with acid flush the skin with water l Do not exceed the specified highest permissible tire
and seek medical advice. pressure.
l Do not allow children access to batteries.
l When mixing battery fluid always pour acid into wa-
ter, never vice-versa.

Special safety regulations

l Use only genuine BOMAG spare parts for repair
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.
l Do not heat up oil higher than 160 °C because it
may ignite.
l
Wipe off spilled oil and fuel.
l Do not smoke when refuelling or when checking the
acid level in the battery.
l Do not check the acid level of the battery with a na-
ked flame, danger of explosion!
l Old batteries contain lead and must be properly dis-
posed of.

008 911 17 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 17

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 17 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 17

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 17 BOMAG 17

1.3 General repair instructions

tion colouring matter makes any warranty claims Fuel hoses

null and void.
l Tools used on refrigeration circuits must be of ex-
cellent condition, thus to avoid the damage of any
connections.
l The dryer is to be installed last, after all connections
in the refrigerant circuit have been tightened.
l After completion of repair work screw locking caps
(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 Fig. 1
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- ! Caution
pressor/control valve switched off. - Once the idle All fuel hoses have two layers of material, a rein-
speed of the engine has stabilized switch on the forced rubber coating outside and an internal Vi-
compressor and run it for at least 10 minutes at idle ton hose. If a fuel hose has come loose one must
speed and maximum cooling power. make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
l
Never operate the compressor over longer periods
layer. In case of a separation the hose needs to be
of time with high engine speeds without a sufficient
replaced.
amount of refrigerant in the system. This could
probably cause overheating and internal damage.

18 BOMAG 008 911 17

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. 3
compound does not enter into oil galleries or blind l Lubricate the outer rim 1 (Fig. 3) 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. 3), 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. 2
l
Lubricate sealing lips 1 (Fig. 2) 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. 2), to pro-
tect the lip from being damaged by sharp edges,

008 911 17 BOMAG 19

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. 4
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. 5
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.

20 BOMAG 008 911 17

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. 6 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. 6).
When fitting the bearing into the housing load
must only be applied to the outer race (2).

008 911 17 BOMAG 21

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. 8 Identification of nuts

In a connection with a screw, these nuts 1 (Fig. 8)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).

Strength class of Strength class of associated

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
Fig. 7 Identification of screws 6 6.8
8 8.8
Example: A screw is identified with 12.9.
9 9.8
The first number corresponds with 1/100 of the nomi- 10 10.8
nal tensile strength (minimum tensile strength) in N/ 12 12.8
mm2.
Nuts for screw joints with limited load factor (04,
l
The nominal tensile strength is 12 X 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. 8) in this group are only able to
tween lower yield point and nominal tensile strength withstand the force of a screw to a limited extent.
(yield point ratio). Nut height below 0.8 d (d = nominal dimension).

Nuts for screw joints without specified load factor

i Note
(11H, 14H, 17H, 22H)
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas- This standard contains strength classes (hardness
tic deformation). classes) for nuts 3 (Fig. 8), for which no load values
can be specified, e.g. because of their shape and di-
When exceeding the upper yield point the material will mensions, but which can only be classified by their
not restore its original shape after being relieved. hardness.
l The lower tensile strength is 9/10 X 1200 N/mm2 = Nut height below 0,5 d (d = nominal dimension).
1080 N/mm2.

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

22 BOMAG 008 911 17

General repair instructions 1.3
Identification in clock system

Fig. 9 Identification of nuts in clock system

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

008 911 17 BOMAG 23

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

24 BOMAG 008 911 17

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 17 BOMAG 25

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

26 BOMAG 008 911 17

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 17 BOMAG 27

1.4 Tightening torques

28 BOMAG 008 911 17

2 Maintenance

008 911 17 BOMAG 29

2.1 General notes on maintenance

2.1 General notes on maintenance sult the customer service of BOMAG or the customer
service of the engine manufacturer.
When performing maintenance work always comply
with the appropriate safety regulations. Notes on the hydraulic system
Thorough maintenance of the machine guarantees far
During maintenance work on the hydraulic system
longer safe functioning of the machine and prolongs
cleanliness is of major importance. Make sure that no
the lifetime of important components. The effort need-
dirt or other contaminating substances can enter into
ed for this work is only little compared with the prob- the system. Small particles can produce flutes in
lems that may arise when not observing this rule. valves, cause pumps to seize, clog nozzles and pilot
The terms right/left correspond with travel direction bores, thereby making expensive repairs inevitable.
forward. l
If, during the daily inspection of the oil level the hy-
l Always clean machine and engine thoroughly be- draulic oil level is found to have dropped, check all
fore starting maintenance work. lines, hoses and components for leaks.
l For maintenance work stand the machine on level l Seal external leaks immediately. If necessary in-
ground. form the responsible customer service.
l Perform maintenance work only with the engine l Do not store drums with hydraulic oil outdoors, or at
shut down. least under a cover. Water can be drawn in through
l Relieve hydraulic pressures before working on hy- the bunghole when the weather changes.
draulic lines. l Always use the filling and filtering unit (BOMAG
l
Before working on electric parts of the machine dis- part-no. 007 610 01) to fill the hydraulic system.
connect the battery and cover it with insulation ma- This unit is fitted with a fine filter to clean the hydrau-
terial. lic oil, thereby prolonging the lifetime of the filter.
l
Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt.
Environment
During maintenance work catch all oils and fuels
l
Do not leave the tank opening unnecessarily open,
and do not let them seep into the ground or into but cover it so that nothing can fall in.
the sewage system. Dispose of oils, coolant and
fuels environmentally. Notes on the cooling system
Prepare and check coolant with highest care, since
Notes on the fuel system otherwise the engine may be damaged by corrosion,
The lifetime of the diesel engine depends to a great cavitation and freezing.
extent on the cleanliness of the fuel. The coolant is prepared by mixing a cooling system
l Keep fuel free of contaminants and water, since this protection agent (Etylene Glycol / Propylene Glycol) to
will damage the injection elements of the engine. the cooling water.
Mixing with cooling system protection agent is neces-
l Drums with inside zinc lining are not suitable to
sary in all climatic zones. It prevents corrosion, lowers
store fuel.
the freezing point and raises the boiling point of the
l
The fuel drum must rest for a longer period of time coolant.
before drawing off fuel.
l Do not let the hose stir up the slurry at the bottom of
the drum.
l Do not draw off fuel from near the bottom of the
drum.
l The rest in the drum is not suitable for the engine
and should only be used for cleaning purposes.

Notes on the performance of the engine

On diesel engines both combustion air and fuel injec-
tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
gas quality of the engine.
If your engine has to work permanently in "thin air" (at
higher altitudes) and under full load, you should con-

30 BOMAG 008 911 17

Fuels and lubricants 2.2
2.2 Fuels and lubricants 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
Engine oil as low as possible, occassional exceeding of the limits
should not happen over a longer period of time.
Quality
With their better temperature and oxidation stability
Lubrication oils are classified according to their per-
synthetic lubrication oils offer quite a few benefits.
formance and quality class. Oils according to other
comparable specifications may be used. Lubrication oil change intervals
Approved engine oils The longest permissible time a lubrication oil should
remain in an engine is 1 year. If the following oil
ACEA change intervals are not reached over a period of 1
E3-96/E5-02 year, the oil change should be performed at least once
per year, irrespective of the operating hours reached.
API
BW 24 RH / DEUTZ BFM 2012
CG-4/CH-4
The exact assignment of the approved oil qualities ACEA1
and oil change intervals can be taken from the follow- E3-96/E5-02 = 500 operating hours
ing section "Lubrication oil change intervals".
API2
Consult your local service station if in doubt.
CG-4/CH-4 = 500 operating hours
Oil viscosity
BW 27 RH / DEUTZ BFM 2012C
Multi-purpose oils should be generally used.
Since lubrication oil changes its viscosity with the tem- ACEA
perature, the ambient temperature at the operating lo- E4-99/E6-04 = 500 operating hours
cation of the engine is of utmost importance when
choosing the viscosity class (SAE-class) .
!Caution
These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight and
for ambient temperatures higher than -10 °C.
When using fuels with a sulphur content of more
than 0.5% to 1% or under ambient temperatures
below -10 °C the oil change intervals specified in
the table must be halved. For fuels with a sulphur
content of more than 1% you should consult the
responsible service agency.

Coolant, anti-freeze agent

Use only soft tap water (drinking water) to prepare the
coolant mix.
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any cli-
matic conditions.
The proportion of cooling system protection agent
must be between min. 35% and max. 45% to the wa-
ter.

Caution
!

Do not mix different coolants and additives of any

other kind.

Fig. 10
Optimal operating conditions can be achieved by us-
ing the opposite oil viscosity chart (Fig. 10) as a refer- 1 European Engine Oil Sequences
ence. 2 American Petroleum Institute

008 911 17 BOMAG 31

2.2 Fuels and lubricants

Environment
l Avoid longer periods of standstill (formation of resin,
corrosion in injection system)
Cooling system protection agents must be dis-
posed of environmentally. l RME-fuel can damage the paint finish of the ma-
chine.
Fuels l Fuel dilution of engine oil, therefore shortening of oil
change intervals to half.
Quality
l Rubber parts, such as leak fuel return lines, seats
You should only use commercially available brand will be damaged in the long run and need to be re-
diesel fuel with a sulphur content below 0.5% and en- placed on a regular basis or should be replaced by
sure strict cleanliness when filling in. A higher sulphur parts made of fluorinated rubber. However, fluori-
content has a negative effect on the oil change inter- nated rubber is not resistant against normal diesel
vals. Use only winter-grade diesel fuel under low am- fuel.
bient temperatures. The fuel level should always be
topped up in due time so that the fuel tank is never run
l If the fuel filter is clogged the filter change intervals
dry, as otherwise filter and injection lines need to be must be shortened accordingly.
bled.
When using fuels with a Cetan number < 49 poor Hydraulic oil
starting and white smoke can be expected, in particu- The hydraulic system is operated with hydraulic oil HV
lar in connection with low ambient temperatures. 46 (ISO) with a kinematic viscosity of 46 mm2/s at
The following fuel specifications are permitted: DIN/ 40°C. For topping up or for oil changes use only high-
EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS quality hydraulic oil, type HVLP according to DIN
2869: A1 and A2; ASTM D 975-78: 1-D and 2-D. 51524, part 3, or hydraulic oils type HV according to
ISO 6743/3. The viscosity index (VI) should be at least
l DIN/EN 590 150 (observe information of manufacturer).
l BS 2869
Bio-degradable hydraulic oil
l ASTM D 975-78: 1-D and 2-D.
On request the hydraulic system can also be filled with
l Nato Codes: F-54, F-34, F44 and XF63 ester based biodegradable hydraulic oil (Panolin HLP
Synth. 46). The biologically quickly degradable hy-
Winter fuel draulic oil meets all demands of a mineral oil based
hydraulic oil according to DIN 51524.
Danger
! In hydraulic systems filled with Panolin HLP Synth. 46
Fire hazard! always use the same oil to top up. When changing
from mineral oil based hydraulic oil to an ester based
Diesel fuels must never be mixed with gasoline.
biologically degradable oil, you should consult the lu-
For winter operation use only winter diesel fuel, to brication oil service of the oil manufacturer for details.
avoid clogging because of paraffin separation. At very
Check the filter more frequently after this change.
low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel.
In most cases a sufficient cold resistance can also be !Caution
achieved by adding flow enhancing fuel additives. Oil change bio-degradable hydraulic oil:
Consult the engine manufacturer. Perform regular oil analyses for content of water
Operation with rape seed oil methyl ester (RME and mineral oil.
„Bio Diesel“) Replace the hydraulic oil filter element every 500
Due to the extreme quality differences of RMEW-fuels operating hours.
available on the market, which are caused by the non-
existence of a standardization, BOMAG does general- Oil for travel gears/wheel hubs
ly not approve any RME-fuels. If this is neglected the For the drive axle use only multi-purpose transmission
warranty will become null and void! oil of API-class GL4/GL5 with viscosity class SAE
However, if you still intend to operate the machine 75W/90.
with RME-fuels you should observe the following in- The additives in this oil ensure low wear lubrication
formation: under all operating conditions.
l Reduced engine power (approx. 7%), higher fuel
consumption. Lubrication grease
l The quality of RME-fuel should be in compliance For lubrication use only EP-high pressure grease, lith-
with DIN draft 51606. ium saponified (penetration 2).

32 BOMAG 008 911 17

Table of fuels and lubricants 2.3
2.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine BW 24 RH Engine oil ACEA E3-96/E5-02 API: CG-4/CH-4 with oil filter change

Engine oil ACEA E4-99/E6-04 approx. 9,5 litres

SAE 15W/40

(-15 °C to +40 °C)

Fuel

Diesel Winter diesel fuel approx. 250 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity 46 mm2/s at approx. 60 litres
40 °C

Travel gear/wheel hubs Gear oil SAE 75W/90, API GL4/GL5 approx. 7,5 litre per side

Cooling system Coolant approx. 20 litres

Sprinkler system Water approx. 400 litres

Ballast compartment Water approx. 3500 litres

Air conditioning system Refrigerant R134A approx. 1200 g

Lubrication points lithium saponified multi-purpose grease, penetration 2 as required

008 911 17 BOMAG 33

2.4 Running-in instructions

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 50 operating hours

l Retighten the wheel studs

After 250 operating hours

l Change the engine oil
l 1st oil change in drive gear/wheel hubs
l Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts.
l Retighten the bolted connections on the machine.

After 500 operating hours

l 2. oil change in drive gear

34 BOMAG 008 911 17

Maintenance chart 2.5
2.5 Maintenance chart

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 250 operating hours

every 500 operating hours

after 250 operating hours
after 50 operating hours
Running-in instructions

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 coolant level Inspection glass X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Draining the air pressure vessel X
5.11 Checking/filling up the water provi- X
sion in the sprinkler system
5.12 Checking/adjusting the scrapers X
5.13 Check the fuel level X
5.14 Multi-disc brake, function test X
5.15 Clean the cooling fins on engine X
and hydraulic oil cooler
5.16 Check the oil level in the drive X
gear/wheel hub
5.17 Change engine oil and oil filter car- min. 1x per year X X
tridge1
5.18 Change the fuel filter cartridge X
5.19 Drain the sludge from the fuel tank X
5.20 Battery maintenance Pole grease X
5.21 Change the fuel pre-filter cartridge X
5.22 Check, replace the refrigerant X
compressor V-belt
5.23 Service the air conditioning X
5.24 Checking hydraulic, pneumatic min. 1x per year X
hoses and electric cables
5.25 Check, adjust the valve clearance Intake = 0,3 mm X
Exhaust = 0,5
mm
5.26 Check, replace the ribbed V-belt X
5.27 Check the engine mounts X X

008 911 17 BOMAG 35

2.5 Maintenance chart

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 250 operating hours

every 500 operating hours

after 250 operating hours
after 50 operating hours
Running-in instructions

Running-in instructions
No. Maintenance work Remark

as required
5.28 Tighten the wheel nuts X X
5.29 Check the ROPS X
5.30 Brake system air drier min. 1x per year X
5.31 Travel gears/wheel hubs min. 1x per year X X
5.32 Change hydraulic oil and breather at least every 2 X
filter2 years
5.33 Change the hydraulic oil filter3 at least every 2 X
years
5.34 Change the coolant at least every 2 X
years
5.35 Checking the supply lines for the X
compressor
5.36 Check the injection valves X
5.37 Service the combustion air filter min. 1x per year, X
safety cartridge
at least every 2
years
5.38 Servicing the water sprinkling sys- X
tem
5.39 Maintenance in case of frost X
5.40 Filling the windscreen washer sys- X
tem
5.41 Change the fresh air filter in the X
cabin
5.42 Change the tires X
5.43 Check bolted connections for tight X
fit
5.44 Temporary taking out of service X
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Also in case of repair in the hydraulic system.
3 Also in case of repair in the hydraulic system.

36 BOMAG 008 911 17

3 Technical data

008 911 17 BOMAG 37

3.1 Technical data

3.1 Technical data

Fig. 11

Dimensions in A B H H2 K L W
mm
BW 24 RH 3700 2118 2360 3090 300 4985 2042
BW 27 RH 3700 2118 2360 3090 300 4985 2042

1
BW 24 RH BW 27 RH

Weights
Operating weight (CECE) kg 8400 13200
with ROPS-cabin
Max. operating weight kg 24000 27000
(CECE)
Max. mean wheel load kg 3000 3338

Travel characteristics
Travel speed (1) km/h 0 ... 7 0 ... 7
Travel speed (2) km/h 0 ... 10 0 ... 10
Travel speed (3) km/h 0 ... 20 0 ... 20
Max. gradability % 30 27

Engine
Engine manufacturer Deutz Deutz
Type BF4M 2012 BF4M 2012 C
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 9249 kW 74,9 98
Rated speed rpm 2300 2300
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 1 1

Brakes
Service brake pneum./hydr. pneum./hydr.
Parking brake Spring accum./hydr. re- Spring accum./hydr.
leased released

38 BOMAG 008 911 17

Technical data 3.1
1
BW 24 RH BW 27 RH

Steering
Type of steering 2-point pivot steering 2-point pivot steering
Steering operation hydrostatic hydrostatic

Tires
Tire size 11.00-20, 18 PR smooth 11.00-20, 18 PR
smooth
Air pressure min./max. bar 2 ... 8,1 2 ... 8,1

Tank contents
Water Litres 400 400
Fuel Litres 250 250
Engine oil Litres 9,5 9,5
Hydraulic oil Litres 60 60
Coolant Litres approx. 20 approx. 20
1 The right for technical modifications remains reserved

008 911 17 BOMAG 39

3.1 Technical data

BW 24 RH BW 27 RH
Additional engine data
Combustion principle 4-stroke diesel 4-stroke diesel
Low idle speed rpm 900 ± 200 900 ± 200
High idle speed rpm 2400 ± 50 2430 ± 50
Spec. fuel consumption g/kWh 225 243
Valve clearance intake mm 0,3 0,3
Valve clearance exhaust mm 0,5 0,5
Injection valves opening pressure bar 220 220
Starter power kW 3,1 3,1

BW 24 / BW 27 RH
Travel pump
Manufacturer Bosch-Rexroth
Type A4VG 105 DA
System Axial piston/swash plate
Max. displacement cm3/rev. 105
Max. flow capacity l/min 241,5
High pressure limitation bar 480-20
Pressure override valve bar 430+10/-20
Charge pressure, high idle bar 30 ± 2
Absolute pressure at control start bar 50
Absolute pressure at control end bar 400

Travel motor
Manufacturer Bosch-Rexroth
Type A6VM 107 HA 2T
Quantity 2
System Axial piston – bent axle
Displacement (stage 1) cm3/rev. 107
Displacement (stage 2) cm3/rev. 36,5
Permissible leakage rate l/min 4
Control start change-over bar 215
Control end change-over bar 315
Perm. leak oil rate l/min 4

Check steering/
Type AZPF-22-016R
System Gear
Displacement cm3/rev. 16
Max. steering pressure bar 175 ± 10

Travel gear
Manufacturer Bonfiglioli
Type 606Y
Quantity 2
Reduction ratio 32

Front axle
Toe-in mm 2±1

40 BOMAG 008 911 17

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

determined at rated engine speed.

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 = 72 dB(A) BW 24 RH
LpA = 74 dB(A) BW 27 RH
The nose emission value for the machine according to the noise emission regulation 2000/14/EC is

guaranteed sound capacity level of the machine:

LWA = 102 dB(A) BW 24 RH
LWA = 103 dB(A) BW 27 RH
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 11204
for sound pressure level (LpA) at the place of the operator.

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

Vibration of the entire body (driver’s seat)

The weighted effective acceleration value determined 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 17 BOMAG 41

3.1 Technical data

42 BOMAG 008 911 17

4 Fundamental electrics

008 911 17 BOMAG 43

4.1 Understanding circuit diagrams

4.1 Understanding circuit diagrams

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

Structure
l Table of contents
l Function groups
l List of components

Table of contents
The table of contents lists all function groups.

Fig. 12 Table of contents

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

44 BOMAG 008 911 17

Understanding circuit diagrams 4.1
Function groups
On the individual pages the electric circuits are combined to function groups.

Arrangement of current paths

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

Fig. 13 Function groups

Potential cross references

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

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

Relay cross reference

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

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

008 911 17 BOMAG 45

4.1 Understanding circuit diagrams

Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 1) (0 ..... 20).

Fig. 1 Current paths

46 BOMAG 008 911 17

Understanding circuit diagrams 4.1
List of components
Here you find all components used in alphabetical order, related to the name of the component (A01, A02....).

Fig. 1 List of components

Component cross references

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

008 911 17 BOMAG 47

4.1 Understanding circuit diagrams

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

Fig. 2 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. 3 Graphic symbol

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

48 BOMAG 008 911 17

Terminal designations 4.2
4.2 Terminal designations
For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a ter-
minal designation. In Germany the designation of the individual connection terminals is determined by the stand-
ard DIN 72552. The following table represents a section with the most important terminals from this standard.

Terminal designa- Meaning

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

2 Short circuit terminal (magneto ignition)

4 Ignition coil, ignition distributor high voltage

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

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

15a Output from dropping resistor to ignition coil and starter

17 Preheating starter switch, preheating

19 Preheating starter switch, starting

30 Battery plus direct

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

31 Battery minus direct or ground

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

32 Electric motors, return line

33 Electric motors, main connection

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

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

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

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

49 Input flasher relay

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

50 Starter, starter control

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

008 911 17 BOMAG 49

4.2 Terminal designations

Terminal designa- Meaning

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

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

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

52 Trailer signals: further signals from trailer to towing vehicle

53 Wiper motor input (+)

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

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

55 Fog light

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

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

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

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

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

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

61 Generator control

71 Intermittent tone control unit, input

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

72 Alarm switch (flashing beacon)

50 BOMAG 008 911 17

Terminal designations 4.2
Terminal designa- Meaning
tion
75 Radio, cigarette lighter

76 Loudspeaker

77 Door valve control

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

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

82 Switch (maker), input

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

83 Switch (multi-position switch), input

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

84 Current relay, input drive and relay contact

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

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

86 Switching relay, input drive winding start

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

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

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

88 Relay contact for maker

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

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

008 911 17 BOMAG 51

4.2 Terminal designations

Terminal designa- Meaning

tion
DF2 Dynamo field 2 (generator excitation current)

U Three-phase generator, three-phase terminal

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

C Travel direction indicator (flasher relay) control light 1

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

52 BOMAG 008 911 17

Battery ground and analog ground 4.3
4.3 Battery ground and analog 4.4 Current and voltage
ground
General
GND, battery ground If one wants to describe electric current, this can most
simply be accomplished by means of a comparison:
The term "ground" (abbreviated GND) describes a
conductive body which is normally defined with the One simply compares electric current with water.
potential of "Zero" Volt and represents the reference
potential for operating voltages. Voltage
The positive pole of the supply voltage (symbol + ) and
all other electric voltages and electical signals in an
electrical circuitry refer to the ground potential.
On motor vehicles and also on motorbikes and bicy-
cles the ground potential is represented by the chas-
sis or the frame. As a conductive part, which covers
the entire vehicle, it also serves a return conductor for
the vehicle wiring system - the consumers only need
to be wired up.

Terminal designation for GND = terminale 31

AGND, analog ground

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

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

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

008 911 17 BOMAG 53

4.4 Current and voltage

The following statements concerning electric volt- Current

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

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

The electric amperage (I) is measured in Ampere

(A).

The technical flow direction is specified from

PLUS to MINUS.

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

Circuit

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

54 BOMAG 008 911 17

Current and voltage 4.4
Types of current Pulse width modulation (PWM)

Direct current (D.C.)

Fig. 1 Direct current (D.C.)

Direct current flows with steady voltage and amper-
age from the plus to the minus pole. Fig. 4 PWM
Pure D.C.-voltages are only delivered by accumula- The PWM signal is in most cases generated by a con-
tors or batteries. trol and can be used to trigger proportional valves.
The voltage in the vehicle wiring system is no pure The signal (square wave signal) is changed in its
D.C.-voltage. Even without the generator running, but pulse control factor, the period, however, remains un-
the consumers switched on, the voltage is not con- changed.
stant, but drops gradually according to the battery The following applies:
charge condition. l
The signal voltage cannot be measured.
The internal resistance of the battery also causes per- l
The current can be measured.
manent changes in the vehicle voltage, as soon as
consumers are switched on or off.
Caution
!
Alternating current (A.C.)
Solenoid valves must not be interference sup-
pressed with suppressor diodes.

Fig. 2 Alternating current (A.C.)

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

Pulsating direct current

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 17 BOMAG 55

4.5 CAN-Bus

4.5 CAN-Bus

Controller Area Network

created by Bosch at the end of the eighties for automobile applications.

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

Fig. 1 CAN

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

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

Measuring signals
Signals transmitted through the bus line can generally not be measured with simple measuring instruments.
Testing is therefore quite complicated for the user. Correct connection of lines can only be checked by means

56 BOMAG 008 911 17

CAN-Bus 4.5
of a continuity test. BOMAG display modules are connected to the BUS to give engineers and user the possibility
to detect faults or to receive information from the BUS.

008 911 17 BOMAG 57

4.6 Resistance

4.6 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.

58 BOMAG 008 911 17

Resistance 4.6
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 17 BOMAG 59

4.7 Series / parallel connection

4.7 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.

60 BOMAG 008 911 17

Series / parallel connection 4.7
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 17 BOMAG 61

4.8 Ohm's law

4.8 Ohm's law 4.9 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

62 BOMAG 008 911 17

Formula diagram 4.10
4.10 Formula diagram
Description:
l Select the desired value from the inner circle.
l Determine the formula variables in the quarter circle
l Calculate

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

Fig. 1 Formula diagram

Resistance, R Ohm Ω

Voltage, U Volt

Current, I Ampere

Power, P Watt

008 911 17 BOMAG 63

4.11 Metrology

4.11 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.

64 BOMAG 008 911 17

Metrology 4.11
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 17 BOMAG 65

4.11 Metrology

Magnet tester Power measurement

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

Fig. 1 Magnet tester

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

Fig. 2

66 BOMAG 008 911 17

Diodes, relays, fuses 4.12
4.12 Diodes, relays, fuses Diode logics and free-wheeling diode

Diodes

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

Fig. 2 Marking of the cathode

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

Fig. 3 Diode circuitry

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

008 911 17 BOMAG 67

4.12 Diodes, relays, fuses

Light emitting diodes Relays

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

Fig. 2 Relay circuitry

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

68 BOMAG 008 911 17

Diodes, relays, fuses 4.12
85 = Ground supply for coil Fuses
30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact

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

Caution
!

Fuses must not be repaired or bridged.

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

008 911 17 BOMAG 69

4.13 Batteries

4.13 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

70 BOMAG 008 911 17

Batteries 4.13
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:

008 911 17 BOMAG 71

4.13 Batteries

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.

72 BOMAG 008 911 17

Three-phase generator 4.14
4.14 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.

008 911 17 BOMAG 73

4.14 Three-phase generator

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.

74 BOMAG 008 911 17

Three-phase generator 4.14
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).

008 911 17 BOMAG 75

4.14 Three-phase generator

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.

76 BOMAG 008 911 17

Three-phase generator 4.14
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.

008 911 17 BOMAG 77

4.14 Three-phase generator

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

Fig. 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.

78 BOMAG 008 911 17

Three-phase generator 4.14
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).

008 911 17 BOMAG 79

4.14 Three-phase generator

Replacing carbon brushes

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

80 BOMAG 008 911 17

Electric starter 4.15
4.15 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.

008 911 17 BOMAG 81

4.15 Electric starter

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

82 BOMAG 008 911 17

Electric starter 4.15
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.

008 911 17 BOMAG 83

4.16 Telemecanique switch

4.16 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.

84 BOMAG 008 911 17

Telemecanique switch 4.16
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).

008 911 17 BOMAG 85

4.16 Telemecanique switch

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.

86 BOMAG 008 911 17

Inductive proximity switches 4.17
4.17 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.

008 911 17 BOMAG 87

4.18 Angle sensors

4.18 Angle sensors

Sensor with current output

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
Fig. 12 Circuit diagram, making contact
the magnetic field. Since the electrons are deflected in
The circuit diagram (Fig. 12) shows a proximity switch transverse direction by the magnetic field, they must
with normally open contact. enrich on the one side and reduce on the opposite
Brown = voltage supply side. If a very thin circuit board is now subjected to a
current that is uniformly distributed across its cross
Blue = ground supply
section, no voltage will be measured between two
Black = switching output points A and B, which have an identical distance to the
The initiator switches the relay (K05) current supply lines and are connected by a highly
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.

88 BOMAG 008 911 17

Angle sensors 4.18
Sensor with voltage output
The design is almost identical with the angle sensor
on the new single drum rollers of generation -4 with
electronic steering wheel, where a sensor with a volt-
age output of 0-8.5 V is mounted on the articulated
joint. The potentiometer inside the sensor transmits a
variable voltage potential to the control. Due to the
short distance between articulated joint and central
electrics it is in this case possible to use a voltage sig-
nal.

Fig. 2 Connection diagram

The angle sensor has 3 electric connections (Fig. 2).
Ub, supply voltage (+ 8.5 Volt)
Gnd, ground
Out, output current 4-20 mA.
l at -35° = 4 mA output current
l
at 0° = 12 mA output current
l at +35° = 20 mA output current.

008 911 17 BOMAG 89

4.19 Plug connectors

4.19 Plug connectors 4.20 Deutsch plug, series DT and

Duties and requirements
DTM
Electric plug connectors must provide a reliable con-
nection between different system components and General
thus ensure the safe function of the systems under Plug connectors DT and DTM have a wedge to hold
any operating condition. There design ensures that the pins and sockets in their position. This wedge can
they will withstand the applied loads throughout the be removed and replaced, without having to cut any
lifetime of the machine. leads.
Examples for these loads are:
l Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l Dampness
l Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
cuits in neighbouring lines. Electric plug connectors
must therefore have the following properties:
l
Low transition resistances of the conductive parts.
l
High insulation strength between conductive parts
with different voltage potentials. Fig. 3 Crimp connections
l
Excellent leak tightness against water and mois-
ture.
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).

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.

90 BOMAG 008 911 17

Deutsch plug, series DT and DTM 4.20
DT Series

Fig. 1 DT plug connection

Fig. 2 DT Series

Fig. 3 Sectional drawing

008 911 17 BOMAG 91

4.20 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.

92 BOMAG 008 911 17

Deutsch plug, series DT and DTM 4.20
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 17 BOMAG 93

4.20 Deutsch plug, series DT and DTM

DTM Series

Fig. 1 DTM plug connection

Fig. 2 DTM Series

Fig. 3 Sectional drawing

94 BOMAG 008 911 17

Deutsch plug, series DT and DTM 4.20
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 17 BOMAG 95

4.20 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.

96 BOMAG 008 911 17

Plugs and terminals in spring clamping technology 4.21
4.21 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 17 BOMAG 97

4.21 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

98 BOMAG 008 911 17

Plugs and terminals in spring clamping technology 4.21
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 17 BOMAG 99

4.22 Electric modules

4.22 Electric modules

In the latest generation of machines BOMAG uses machine programmable modules. A module mainly consists
of a programmable microprocessor with additional circuitry for inpiuts and outputs. With theses modules it is pos-
sible to cover the requirements of the individual machines.

Fig. 1
The modules have control lights on inputs and outputs to monitor the applied signals.

100 BOMAG 008 911 17

5 Special tools, electrics

008 911 17 BOMAG 101

5.1 Special tools, electrics

5.1 Special tools, electrics

Measuring equipment
45. Electric test case

BOMAG part-no.: 057 505 70

Fig. 2
46. Multimeter

BOMAG part-no.: 057 509 91

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

BOMAG part-no.: 079 900 53

48. 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. 4
49. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.

BOMAG part-no.: 079 900 51

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

BOMAG part-no.: 079 900 52

Fig. 5

102 BOMAG 008 911 17

Special tools, electrics 5.1
51. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 0.5 m.

BOMAG part-no.: 079 900 58

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

BOMAG part-no.: 079 900 59

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

BOMAG part-no.: 079 900 60

54. Measuring and connecting lines with 4mm plug,
Fig. 6 high flexible design, red, length 0.5 m.

BOMAG part-no.: 079 900 55

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

BOMAG part-no.: 079 900 56

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

BOMAG part-no.: 079 900 57

57. 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

58. 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

59. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 300 mm.
Fig. 7
BOMAG part-no.: 079 900 61
60. 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

61. 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. 8

008 911 17 BOMAG 103

5.1 Special tools, electrics

62. Magnetic coil tester

BOMAG part-no.: 057 555 54

Fig. 9
63. Clip-on measuring instrument

BOMAG part-no.: 079 900 50

Fig. 10
64. Battery - generator tester

BOMAG part-no.: 079 900 91

Fig. 11
Spring clamps (Wago or Weidmüller)
65. Cranked screwdriver (Fig. 12) to open spring
clamps (Fig. 13).

BOMAG part-no.: 972 024 68

Fig. 12

104 BOMAG 008 911 17

Special tools, electrics 5.1
66. Testing adapter to measure the signals from the
series spring clamps (Wago).

BOMAG part-no.: 057 564 26

Fig. 13
Deutsch contacts
67. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).

BOMAG part-no.: 079 900 84

Fig. 14
68. 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. 15
69. 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. 16

008 911 17 BOMAG 105

5.1 Special tools, electrics

70. 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. 17
ITT contacts
71. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 80

Fig. 18
72. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 81

Fig. 19
73. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 82

Fig. 20

106 BOMAG 008 911 17

Special tools, electrics 5.1
Schaltbau contacts
74. Disassembly tool for Schaltbau contacts of series
M1, M2.

BOMAG part-no.: 057 509 95

Fig. 21
75. 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. 22
FCI Burndy contacts
76. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO

BOMAG part-no.: 079 900 00

Fig. 23
AMP contacts
77. 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. 24

008 911 17 BOMAG 107

5.1 Special tools, electrics

78. 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. 25
79. 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. 26
80. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 14 - 10.

BOMAG part-no.: 079 900 88

Fig. 27
81. 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. 28

108 BOMAG 008 911 17

Special tools, electrics 5.1
82. Crimping tool for Powertimer contacts with indi-
vidual strand sealing (example: ESX control)

BOMAG part-no.: 079 900 25

Fig. 29
83. Crimping jaws for Crimping tool 079 900 25

BOMAG part-no.: 079 900 27

Fig. 30
84. 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. 31
Universal tools
85. 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. 32

008 911 17 BOMAG 109

5.1 Special tools, electrics

86. Precision pressing pliers for non-insulated flat

male and female connectors0.5 - 6,0 mm2.

BOMAG part-no.: 079 900 70

Fig. 33
Measuring adapter
87. Current measurement adapter for Hirschmann
plugs.

BOMAG part-no.: 057 503 83

Fig. 34
88. Voltage measurement adapter for Deutsch plugs,
8-piece (2 to 12 pole).

BOMAG part-no.: 079 900 68

Fig. 35
89. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.

BOMAG part-no.: 079 900 83

Fig. 36

110 BOMAG 008 911 17

6 Electronic modules

008 911 17 BOMAG 111

112 BOMAG 008 911 17
6.1 Module description A04

008 911 17 BOMAG 113

6.1 Module description A04

114 BOMAG 008 911 17

Module description A04 6.1

Description UPM1
Sprinkling module 27R

- 538 380 02 -

RS 232
LED 2

LED 3

LED 1
LED 4
LED 5

+ - 6 4 3 2 13

30

Version 1.0 from 29.06.2004

A. Hehner Page 1 from 29.06.2004

008 911 17 BOMAG 115
6.1 Module description A04

Table of Contents

1. Version history................................................................................................ 3
2. Description of hardware ................................................................................. 4
2.1. Pin assignment for digital inputs......................................................................................... 4
2.2. Pin assignment for analog inputs........................................................................................ 4
2.3. Pin assignment for outputs .................................................................................................. 4
3. Description of function................................................................................... 6
3.1. Total overview of sprinkling cycle ....................................................................................... 6
4. Software version history ................................................................................ 7

A. Hehner Page 2 from 29.06.2004

116 BOMAG 008 911 17
Module description A04 6.1

1. Version history

No. Version Date Description of version Resp.

1 1.0 29.06.04 1. version created Hehner

A. Hehner Page 3 from 29.06.2004

008 911 17 BOMAG 117
6.1 Module description A04

2. Description of hardware

The inputs were changed in such a way, that the following table applies:

Input Behaviour Remark

Input PIN13 LOW-active LED lights when applying ground potential!
Input PIN2 LOW-active LED lights when applying ground potential!
Input PIN3 HIGH-active LED lights when applying positive voltage!
Input PIN4 HIGH-active LED lights when applying positive voltage!

2.1. Pin assignment for digital inputs

Signal name Module Descr.
pin
Emulsion switch 13 Active LOW = Emulsion cycle ON LED on
HIGH = Emulsion cycle OFF LED off
Ground bridge (optional) 2 Active LOW = Sprinkling cycle 6/6 LED on
HIGH = Sprinkling cycle 6/12 LED off
Not used 3 Active HIGH = LED on
LOW = LED off
Not used 4 Active HIGH = LED on
LOW = LED off

2.2. Pin assignment for analog inputs

Signal name Module Descr.
pin
Not used + / -

2.3. Pin assignment for outputs

Signal name Module Descr.
pin
Relay contact 15 + 87 30 + 87 HIGH = Switch on emulsion sprinkling
(normally open) cycle LED on
LOW = Switch off emulsion sprinkling
cycle LED off
BTS 6 HIGH = Switch on emulsion sprinkling
cycle LED on
LOW = Switch off emulsion sprinkling
cycle LED off

A. Hehner Page 4 from 29.06.2004

118 BOMAG 008 911 17
Module description A04 6.1

The hardware is available under BOMAG part-no. 057 644 39.

PIN Signal Description

13 IN (Active LOW) Emulsion switch
RS 232 2 IN (Active LOW) Optional (ground bridge)
LED 2

3 IN (Active HIGH) not used

4 IN (Active HIGH) not used
LED 3

LED 1
LED 4
LED 5

6 OUT (BTS) OUT 15/54, 4A

OUT - PWM -
OUT + PWM +
30 Relay - Contact IN 12V, 15 A
+ - 6 4 3 2 13
87
87a
Relay - Contact Normally open
Relay - Contact Normally closed
15/45 Supply voltage 10-39 V
30 Ground
ŏ

Figure 1: Module

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

BOMAG part-number 538 380 02.

The following applies when measuring the signal level:

PIN Potential with LED on Potential with LED off

digit. inputs (HIGH active) Operating voltage Voltage < 1V

digit. input (LOW active) Ground Input open

Relay contact 30 +87 Connection between PIN 30 and No connection between PIN
(normally open) 87 30 and 87
Relay contact 30 +87a No connection between PIN 30 Connection between PIN 30
(normally closed) and 87a and 87a
digit. Outputs (BTS) Operating voltage < 1V

A. Hehner Page 5 from 29.06.2004

008 911 17 BOMAG 119
6.1 Module description A04

3. Description of function

The following sequences were realized in the UPM2 Software for realization of sprinkling cycles.

3.1. Total overview of sprinkling cycle

In order to realize a switching interval for the emulsion sprinkling system, the input (PIN 13) and
the output (PIN 6), as well as the relay of the module are used. The emulsion sprinkling system
is activated by the ground signal on input PIN13. If an additional ground signal (bridge) is
applied to input (PIN 2), the interval time is changed to the following values:

Impulse time Pause time

With ground bridge on PIN 2 6 seconds 6 seconds

Without ground bridge on PIN 2 6 seconds 12 seconds

As long as the emulsion sprinkling system is ACTIVE (ground signal on PIN 13), output PIN 6
(LED 5) and relay (LED 6) are cyclically set in intervals for 6 (6) seconds to ON or 12 (6)
seconds to OFF.
During an OFF-pause the emulsion sprinkling system can be triggered by switching input PIN13
short-term to Active LOW, the ON-phase at the output will start immediately from the beginning
for 6 (6) seconds. Triggering is not possible during an ON-phase.
If the emulsion sprinkling system is switched off during an ON-phase, the ON-phase will
continue to the end (6 seconds). An ON-phase cannot be interrupted (or only by switching off
the module).

A. Hehner Page 6 from 29.06.2004

120 BOMAG 008 911 17
Module description A04 6.1

4. Software version history

Version management: BOMAG Sprinkling Module 538 380 02

Module: BM UPM1
Controller: PIC16F84a

Version 1.00 from 29.06.2004:

----------------------------
Checksum: ba02

1. version created.

A. Hehner Page 7 from 29.06.2004

008 911 17 BOMAG 121
6.1 Module description A04

122 BOMAG 008 911 17

6.2 Module description A100

008 911 17 BOMAG 123

6.2 Module description A100

124 BOMAG 008 911 17

Module description A100 6.2

Description UPM03
Module steering column switch lock
BW24/27RH

538 380 06 Rechts

Rechts
Feststellbrem se
Links

Links

F r a n k r e ic h
O p tio n

Version 1.0 from14/09/06

008 911 17 BOMAG 125

6.2 Module description A100

Table of Contents
1 Versionshistorie............................................... Fehler! Textmarke nicht definiert.
2 Beschreibung Hardware.................................. Fehler! Textmarke nicht definiert.
2.1 Pinbelegung digitale Eingänge ............................................. Fehler! Textmarke nicht definiert.
2.2 Pinbelegung Ausgänge.......................................................... Fehler! Textmarke nicht definiert.
2.3 Notbetrieb................................................................................ Fehler! Textmarke nicht definiert.
3 Funktionsbeschreibung .................................. Fehler! Textmarke nicht definiert.
3.1 Einschaltvorgang ................................................................... Fehler! Textmarke nicht definiert.
3.2 Fehlersignal ............................................................................ Fehler! Textmarke nicht definiert.
3.3 Fahrtrichtung .......................................................................... Fehler! Textmarke nicht definiert.
3.4 Wechsel Lenkstockschalter .................................................. Fehler! Textmarke nicht definiert.
3.5 Ansteuerung Fahrtrichtungsumschaltung (Pin 4) .............. Fehler! Textmarke nicht definiert.
3.6 Startfreigabe ........................................................................... Fehler! Textmarke nicht definiert.
4 Versionshistorie Software............................... Fehler! Textmarke nicht definiert.

126 September 2006 BOMAG 008 911 17

Module description A100 6.2

1. Version history

No. Version Date Description of version Resp.

1 1.00 17.07.06 1. Version created on basis of 538 380 03 Hehner

008 911 17 BOMAG 127

6.2 Module description A100

2. Description of hardware

The module consists of the modified UPM2 module.

The inputs were changed in such a way, that the following table applies:

Input Behaviour Remark

Input PIN11 HIGH-active LED lights when applying positive voltage!
Input PIN12 HIGH-active LED lights when applying positive voltage!
Input PIN13 LOW-active LED lights when applying ground potential!
Input PIN14 HIGH-active LED lights when applying positive voltage!
Input PIN15 HIGH-active LED lights when applying positive voltage!

2.1. Pin assignment for digital inputs

Signal name Module Signal on input

pin
Steering column switch left/ 11 Active-HIGH = Left reverse LED on
reverse LOW = Left not reverse LED off
Steering column switch left/ 12 Active-HIGH = Left forward LED on
forward LOW = Left not reverse LED off
Parking brake 13 Active-LOW = Parking brake LEDon
released
HIGH= Parking brake applied LED off
Steering column switch right/ 14 Active-HIGH = Right forward LED on
reverse LOW = Right not reverse LED off
Steering column switch right/ 15 Active-HIGH = Right forward LED on
forward LOW = Right not forward LED off

2.2. Pin assignment for outputs

Signal name Module Signal on output

pin
Change of travel direction 4 +UB = switch on delayed Forward LED on
0V = switch off delayed BackwardLED off
Solenoid valve, forward travel 5 +UB = forward travel LED on
0V = no forward travel LED off
Output error message / both 6 +UB = error message LED on
steering column switches 0V = no error message LED off
actuated
Solenoid valve, reverse travel 7 +UB = reverse travel LED on
0V = no reverse travel LED off
Start release when both steering 8 +UB = start release LED on
column switches are in neutral 0V = no start release LED off

128 BOMAG 008 911 17

Module description A100 6.2

The hardware is available under BOMAG part-no. 057 667 68.

Rechts

Rechts
Feststellbrem se
Links

Links

F r a n k r e ic h
O p tio n

Figure 1: Module

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

BOMAG part-number 538 380 06.
The following applies when measuring the signal level:

PIN Potential with LED on Potential with LED off

digit. inputs (HIGH active) Operating voltage (UB) Voltage < 1V

digit. input (LOW active) Ground Input open

digit. outputs (HIGH active) Operating voltage < 1V
(UB - 0.7V)
digit. outputs (LOW active) Ground Operating voltage
(UB - 0.7V)

2.3. Limp home operation

If a bridge is inserted between PIN2 and PIN3, the outputs PIN4, "Reversal of travel
direction" and PIN5 "Solenoid valve for forward travel" are at HIGH potential and the
corresponding LED, as well as the red LED on PIN3, will light.
This means, that in case of a fault, the machine can drive forward in limp home mode.
This function can be used in emergencies (defect), to be able to move the machine for a
short time.

008 911 17 BOMAG 129

6.2 Module description A100

3. Description of function

3.1. Switching on
If operating voltage is applied to the module, the Stay-Alive LED will flash in intervals of one
second.

3.2. Fault signal

If both steering column switches are actuated at the same time, a fault signal is emitted by
output PIN 6. This fault is deactivated by returning both steering column switches to neutral
position.
If one steering column switch is actuated while the parking brake is closed, PIN 6 will also
emit a fault signal.

3.3. Travel direction

When the steering column switch is actuated forward (Pin 12 or Pin 15), the output (Pin5) will
switch.
When the steering column switch is actuated backward (Pin 11 or Pin 14), the output (Pin7)
will switch.
Outputs 5 and 7 will only submit a signal, when the parking brake is released (an Active LOW
signal is applied to PIN 13).

3.4. Steering column switch replacement

Replacing the steering column switches is only permitted when both travel levers are in
neutral position. When the left hand steering column switch is actuated, the right hand
steering column switch is locked (and vice-versa). Any changes to the locked steering
column switch are ineffective.

3.5. Triggering of travel direction change-over (Pin 4)

When actuating the steering column switch forward, output 4 is switched on with a delay of
0.8 seconds. When returning the steering column switch to position, this output is switched
off with a delay of 0.8 seconds.

3.6. Start release

If no steering column switch is actuated, a signal is submitted through the start release
output (PIN 8).

130 BOMAG 008 911 17

Module description A100 6.2

4. Software version history

_________________________________________________________________________

Version management:

Module: BMUPM 3

Controller: PIC16F84A
________________________________________________________________________

Version 1.00 from: 27.07.2006

-----------------------------------------
Checksum: e2e3

008 911 17 BOMAG 131

6.2 Module description A100

132 BOMAG 008 911 17

7 Speedometer Module

008 911 17 BOMAG 133

7.1 Speedometer module

7.1 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.

134 BOMAG 008 911 17

Speedometer module 7.1

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 17 BOMAG 135

7.1 Speedometer module

136 BOMAG 008 911 17

8 Engine

008 911 17 BOMAG 137

8.1 Diesel engine, general

8.1 Diesel engine, general

Fig. 1 Engine compartment The forged steel conrods are designed with balancing
Rubber tired rollers of type BW 24 RH and C550H are weights in the area of the conrod bearing seats. These
powered by a Deutz diesel engine type BF4M 2012 weights compensate manufacturing tolerances with
without intercooler. respect to weight and position of the centre of gravity.
Rubber tired rollers of type BW 27 RH and C560H are The pistons are made of aluminium alloy. The side
powered by a Deutz diesel engine type BF4M 2012 C walls of the slightly externally arranged combustion
with intercooler. The intercooler reduces the thermal trough are inclined towards the inside by 10°. All pis-
load on the engine, the exhaust temperature and the tons are fitted with three piston rings and a cast iron
fuel consumption and thus enables a higher power ring carrier for the first ring. The pistons are oil mist lu-
output. bricated.
The engines are characterized by the following posi- The forged crankshaft is designed with integrated
tive features: counter weights.
l
short and compact design The block-type cylinder head is made of cast steel.
l
low noise level Each of the cylinders has an inlet and an outlet valve.
The valve guides are shrunk into the cylinders. The
l
almost vibration free operation valve seat rings are made of high quality steel and
l
low fuel consumption also shrunk fit.
l
low exhaust emissions (EPA II)
l
high power reserves and
l excellent access to all service locations.
Crankcase and cylinders on this engine are made of
alloyed cast iron. This provides rigidness and high
wear resistance.

138 BOMAG 008 911 17

Service side 8.2
8.2 Service side

Fig. 1 Service side

1 Oil filler neck
2 Lubrication oil cooler
3 Engine solenoid
4 Oil pressure switch (B06)
5 Radiator fan
6 Fuel pump
7 V-belt pulley
8 Main fuel filter
9 Lubrication oil filter
10 Oil sump
11 Oil dipstick
12 Compressor (only BW24/27 RH
13 Plug-in injection pumps
14 Generator
15 Heating flange (R19, option)
16 Hydraulic pump
17 Tensioning roller with torsion spring
18 Crankcase ventilation valve

008 911 17 BOMAG 139

8.3 Starter side

8.3 Starter side

Fig. 1 Starter side

1 Exhaust manifold
2 Exhaust turbo charger
3 Oil filling (optional)
4 Engine mounts
5 Oil return line from turbo charger
6 Relay (starter)
7 Ribbed V-belt
8 Coolant inlet
9 Coolant outlet
10 Coolant pump
11 Connection of compensation line

140 BOMAG 008 911 17

Compressor 8.4
8.4 Compressor Lines connect it to the lubrication oil supply of the en-
gine and the air is supplied by the air filter. The next
The compressor mounted to the DEUTZ diesel engine component is the pressure regulator, which will either
for the supply of compressed air systems is driven by force it to generate a pressure of 8 to 12 bar, or to rest
a gear drive on the flywheel side of the engine (power when the pressure is relieved into the atmosphere.
takeoff A).
The compressor has the function of assuring a high
degree of efficiency in supplying the compressed air
brake.

Fig. 1

! Caution
All lines connected with the compressor must be
permanently sealed air tight, they should be rout-
ed without tension and must be absolutely clean
from inside (free of foreign matter, rust, scale,
etc.).

008 911 17 BOMAG 141

8.4 Compressor

Fig. 2 Compressor
1 Control piston (Fig. 3)
2 Valve seat (Fig. 3)
3 Suction port
4 Blade-type check valves (Fig. 3)
5 Pressure port
6 Control line port

142 BOMAG 008 911 17

Compressor 8.4
The compressor is of similar design as a piston motor.
It works with blade-type check valves (4) instead of a
cam operated valve drive.

Fig. 3 Compressor
1 Control piston
2 Valve seat
3 Suction port
4 Blade-type check valves
5 Pressure port
6 Control line port

Fig. 4 Plug with ventilation bore

! Caution
The bore inside the plug must not be clogged!!

i Note
The port "control line" (6) on the compressor is closed
with a plug M 22 x 1 with 2 mm bore (Fig. 4). This ven-
tilation bore ensures that the control piston 1 (Fig. 3)
will remain in its position and full compressor power is
always assured.

008 911 17 BOMAG 143

8.5 Lubrication oil circuit

8.5 Lubrication oil circuit

Fig. 1 Lubrication oil circuit 18 Leak oil return line

1 Oil sump 19 Oil filter
2 Return flow from turbo charger to crankcase 20 Suction line
3 Turbo charger 21 Crankshaft bearings
4 Oil line to turbo charger 22 Conrod bearings
5 Line to mass balancing gear (2 x)
6 Oil pressure sensor
7 Valve with pulse lubrication
8 Push rod, oil supply to rocker arms
9 Line to spray nozzles
10 Rocker arm
11 Return flow to oil sump
12 Nozzle for piston cooling
13 Camshaft bearings
14 Main oil channel
15 Lubrication oil cooler
16 Oil pump
17 Pressure relief valve

144 BOMAG 008 911 17

Lubrication oil circuit 8.5
General
The oil inside the combustion engine has the function
of lubricating and cooling all drive components, re-
moving impurities and neutralizing chemically effec-
tive combustion products, transferring forces and
damping vibrations.. The oil is only able to fulfil this
function, if sufficient quantities are transported to the
critical points in the engine and if its properties are
adapted to the prevailing requirements by corre-
sponding manufacturing processes and refining (addi-
tives).
Figure (1) shows pressure circulation lubrication in
combination with splash and oil mist lubrication. Here
oil is transported under pressure to all bearing loca-
tions by the oil pump (16), while sliding surfaces are
splash or oil mist lubricated. After flowing through the
bearing locations and along sliding surfaces the oil is
collected in the oil sump (1) under the drive, where the
oil is cooled, defoamed by calming and stored.
The oil filter (19) removes solid foreign particles from
the engine oil (combustion residues, metal abrasion,
dust) and thus maintains the function of the lubrication
oil during the maintenance intervals.

008 911 17 BOMAG 145

8.6 Oil pressure switch and low oil pressure circuitry

8.6 Oil pressure switch and low oil

pressure circuitry

Fig. 1
1 Oil pressure switch

Pos. Designation in Designation Technical data

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

146 BOMAG 008 911 17

Check the engine oil level 8.7
8.7 Check the engine oil level

! Danger

Danger of injury!
Support the engine hood for all maintenance and
repair work.

i Note
The machine must be parked horizontally with the en-
gine shut down.

Fig. 2 Oil pressure switch

The oil pressure switch (B06) is mounted to the en-
gine oil filter. After starting it reports when a safe op-
erating pressure has been reached and causes the
warning light (H09) in the monitoring board (A15) to
light, if the engine oil pressure drops below approx.
0.8 bar.
In case of too low engine oil pressure with the engine
running, the monitoring module (A15, terminal X6:1)
will send a time delayed (10 sec.) signal to relay K22
(terminal 86). The relay interrupts the electric power Fig. 3
supply to the solenoid valve (Y13) and the diesel en-
gine is shut down.
l Pull the dipstick (Fig. 3) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
l Pull the dipstick back out again.
l If the oil level is below the "MAX" mark fill in oil.
l If the oil level is above the “MAX” mark, determine
the cause and drain off oil.

!Caution
Before longer work periods you should always top
the oil up to the "MAX"-mark.

For quality and quantity of oil refer to the table of

fuels and lubricants

008 911 17 BOMAG 147

8.8 Changing engine oil and oil filter cartridges

8.8 Changing engine oil and oil fil-

ter cartridges

!Caution
The oil change at 500 operating hours refers to
the use of oils of oil quality class API CG-4/CH-4 or
ACAE E3-96/E5-02 respectively.
Refer also to the chapter 5.2, fuels and lubricants.
Drain the engine oil only when the engine is warm.

Danger
!
Fig. 5
Danger of scalding! l Thoroughly clean the outside of both filter cartridges
When draining off hot oil. (Fig. 5).
By hot oil when unscrewing the engine oil filter. l Unscrew both filter cartridges using an appropriate
filter wrench.
Environment
Catch running out oil and dispose of environmen- i Note
tally together with the engine oil filter cartridge. The filter cartridges are fitted with a valve that pre-
vents engine oil from running out during removal and
installation.
l Clean the sealing face on the filter carrier from any
dirt.
l
Slightly oil the rubber seal on the new filter cartridg-
es.

Fig. 4
l Unscrew the drain plug (Fig. 4) and catch running
out oil.
l
Turn the drain plug tightly back in.

Fig. 6
l Turn the new filter cartridges (Fig. 6) on by hand,
until the seal contacts.
l Tighten the filter cartridges for another half turn.

148 BOMAG 008 911 17

Changing engine oil and oil filter cartridges 8.8

Fig. 7
l Fill in new engine oil (Fig. 7).

For quality and quantity of oil refer to the table of

fuels and lubricants.
l Tighten the oil filler cap properly.

! Caution
Before starting crank the engine with the starter
motor until the oil pressure warning light goes
out.
l
After a short test run check the oil level on the dip-
stick, if necessary top up to the top dipstick mark.
l
Check filter cartridge and drain plug for leaks after a
short test run.
l
Shut the engine down and wait for about 15 min-
utes, so that all oil can flow back into the oil sump.
l
Check the oil level again , if necessary fill up to the
Max.-mark.

008 911 17 BOMAG 149

8.9 Coolant circuit

8.9 Coolant circuit

Fig. 1 Coolant circuit

1 Radiator
2 To radiator
3 From radiator
4 Coolant pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder head cooling
8 Ventilation connection from cylinder head to heat
exchanger
9 Fan

150 BOMAG 008 911 17

Coolant circuit 8.9
General Heating
In order to avoid thermal overloads, burning of lubrica- Water-cooled DEUTZ diesel engines utilize the cool-
tion oil on piston sliding surfaces and uncontrolled ant to heat the driver's cab. For this purpose the en-
burns caused by high component temperatures, the gine coolant is guided directly to the heat exchanger
components surrounding the combustion chamber, and the heat is directly dissipated into the environ-
like cylinders, cylinder head, valves and possibly also ment (direct heating).
the pistons, must be cooled intensively.

Brief description
The coolant pump ("water pump") draws coolant
through the hose lines directly out of the radiator and
forces it first of all through the lubrication oil cooler,
which is integrated in the engine. The coolant then en-
ters into the engine, flows up along the cylinders into
the cylinder head and to the thermostat at the coolant
outlet. Form their the coolant is returned through the
corresponding lines to the radiator inlet. When the en-
gine is cold the coolant is pumped in a short circuit
through the engine, until the response temperature of
the thermostat (start of opening) is reached. The wa-
Fig. 2 Direct heating
ter pump draws cold coolant out of the radiator, as re-
quired to replenish the hot out flowing coolant. 1 Thermostat
The coolant is a mixture of water and anti-freeze 2 Coolant pump
agent. The anti-freeze agent increases the boiling 3 Lubrication oil cooler
temperature of the mixture and thus enables temper- 4 Heat exchanger
atures of up to 120° C at an overpressure of up to 1.4
bar.
The coolant compensation tank enables reliable gas
separation, thus avoiding cavitation in the cooling sys-
tem, which mainly occurs in the suction side of the
pump. The air volume inside the compensation must
be so high, that quick build-up of pressure in case of
heating and expansion of coolant is assured and any
escape of coolant during after-boiling is avoided.
The radiator (1) dissipates the waste heat generated
in the engine into the into the environment.
Part of the combustion heat is transferred to the lubri-
cation oil. The lubrication oil cooler (5) serves the
function of cooling the lubrication oil.

008 911 17 BOMAG 151

8.10 Coolant temperature switch

8.10 Coolant temperature switch

Fig. 1 Coolant temperature switch

Pos. Designation in Designation Technical data

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

152 BOMAG 008 911 17

Disassembling and assembling the coolant temperature switch 8.11
8.11 Disassembling and assem- Installation
bling the coolant temperature l Clean thread and seat for switch.
switch l Install the temperature switch with Loctite 577 and
a new seal, tightening torque 20 Nm.
Removal l Push the plug back on (plug interlock clicks into
l Turn the battery disconnecting switch to position place).
"OFF". l Check the plug interlock by lightly pulling on the wir-
l Open the lid on the coolant reservoir. ing loom.
l
Fill in coolant up to the “MAX” mark .
! Danger
For quality of coolant refer to the chapter 5.2, fuels
Danger of scalding! and lubricants.
Do not remove the cap from the compensation l Run the engine up to operating temperature.
tank when the engine is still hot.

i Note
Check the area around the coolant temperature sen-
sor for leaks.
l Let the engine cool down and check the coolant lev-
el again, top up if necessary.

Fig. 2 Temperature switch

l Press in the locking wire and disconnect the plug
(Fig. 2).
l Lay a cloth around the temperature switch and
catch running out coolant.

Environment
Dispose of escaping coolant environmentally
l Unscrew the temperature switch.

Fig. 3 Coolant temperature switch

l
Remove and dispose of the seal (Fig. 3).

008 911 17 BOMAG 153

8.12 Replacing the thermostat

8.12 Replacing the thermostat

l Open the lid on the coolant reservoir.

Danger
!

Danger of scalding!
Do not remove the cap from the compensation
tank when the engine is still hot.
l Drain the coolant from the engine and catch it.

Environment
Catch running out coolant and dispose of environ-
mentally. Fig. 6
l Assemble the outlet socket (Fig. 6).
l Tightening torque: 30 Nm
l Install the coolant hose again.
l Fill in coolant up to the “MAX” mark .

For quality of coolant refer to the chapter 5.2, fuels

and lubricants.
l
Run the engine up to operating temperature.

i Note
Check for leaks around the thermostat.
l Let the engine cool down and check the coolant lev-
Fig. 4 el again, top up if necessary.
l
Disconnect the coolant hose.
l Remove the outlet socket (Fig. 4).
l Remove the thermostat.

Fig. 5
l
Fit a new seal to the thermostat.
l Insert the new thermostat with the seal ring (Fig. 5).

i Note
Mind the installation position. The arrow (ventilation
groove) points up.

154 BOMAG 008 911 17

Checking the thermostat in disassembled state 8.13
8.13 Checking the thermostat in The temperature increase should not exceed 1°C/
min, as otherwise the start of opening will be delayed
disassembled state accordingly.
The thermostat serves the optimal temperature con-
trol of the coolant, in order to promote efficient com-
bustion and to bring the engine quickly to operating
temperature after starting. At temperatures below ap-
prox. 83°C the thermostat is closed. Once the coolant
temperature has reached about 83°C, the thermostat
will start to open, at about 95° C it is fully open. In this
condition the full coolant flow is guided through the ra-
diator.

Fig. 3
l Measure and write down the measurement "b" on
the thermostat . (Fig. 3).
l Calculate the stroke.

Stroke = b - a

i Note
Fig. 1 The stroke at the given temperature (T2) should be
min. 8 mm.
l Measure and write down the measurement "a" on
the thermostat (Fig. 4).

i Note
"a" = beginning of stroke at approx. 83 ± 2°C (T1)
"b" = end of stroke at approx. 95 °C (T2)

Fig. 2
l Warm up the thermostat in a water bath (Fig. 2).

i Note
In order to determine the exact start of opening the
temperature should be measured as close to the ther-
mostat as possible, but without touching it.
The water must thereby be stirred continuously, to en-
sure even temperature distribution.

008 911 17 BOMAG 155

8.14 Check the coolant level

8.14 Check the coolant level 8.15 Change the coolant

! Danger ! Danger

Danger of scalding! Danger of scalding!

Do not remove the cap from the compensation Change the coolant only when the engine is cold.
tank when the engine is still hot.
Environment
Catch running out coolant and dispose of environ-
mentally.

Fig. 4
l
Check the coolant level (Fig. 4).

!Caution Fig. 5

If, during the daily inspection the coolant level is l

Unscrew the plug (Fig. 5), let the coolant run out
found to have dropped, check all lines, hoses and and catch it .
engine for leaks. l
Screw the plug back in once all coolant has run out.
Do not use radiator sealant to seal leaks.
Do not fill cold coolants into a hot engine.
l
To top up unscrew the filler cap and fill in coolant up
to the MAX-mark.

For quality of coolant refer to the chapter 5.2, fuels

and lubricants.

Fig. 6
l Unscrew the cap and fill in coolant up to the MAX-
mark (Fig. 6).

For quality of coolant refer to the chapter 5.2, fuels

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

156 BOMAG 008 911 17

Clean the cooling fins on engine and hydraulic oil cooler 8.16
8.16 Clean the cooling fins on en-
gine and hydraulic oil cooler

Danger
!

Danger of injury!
Perform cleaning work only after the engine has
cooled down and with the engine stopped.
Wear safety goggles.

Caution
!

Do not damage any cooling fins on the cooler core

when cleaning.

i Note
Dirt on fan blades and oil cooler reduce the cooling ef-
fect. Dirt deposits in these areas are substantially sup-
ported by oil and fuel on these surfaces. For this
reason you should always seal any oil or fuel leaks in
the vicinity of the cooling fan or the oil cooler and clean
the cooling surfaces after.

Cleaning with compressed air

Fig. 7
l Remove the cover plate (Fig. 7).

i Note
Start to blow out from the exhaust side.
l Blow the radiator out with compressed air.

Cleaning with cold cleansing agent

Caution
!

Protect electrical equipment such as generator,

regulator and starter against the direct water jet.
l
Spray the engine with a suitable cleansing agent,
e.g. cold cleanser, let it soak in for a while and spray
it off with a strong water jet.
l
Run the engine warm for a while to avoid corrosion.

008 911 17 BOMAG 157

8.17 Three-phase generator

8.17 Three-phase generator

Fig. 1
1 Generator (G02)

Pos. Designation in Designation Technical data

circuit diagram
B+ B+ Battery Plus 14.4 Volt, 90 Amp.
D+ D+ Dynamo Plus 14.4 Volt, maximum load 0.2 Amp.
W W Rotational speed signal pulsing D.C. voltage to determine the
engine speed

158 BOMAG 008 911 17

Checking / replacing the ribbed V-belt 8.18
General 8.18 Checking / replacing the
The generator should be of light weight, have a high ribbed V-belt
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed. Danger
!

Danger of injury!
i Note Work on the V-belt must only be performed with
The generator is maintenance free. Function tests and the engine shut down.
repair work must only be performed in authorized
workshops. Checking the wear limit of the ribbed V-
belt
! 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
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter- Fig. 2
minal of the generator you must make sure that l Check the distance between the tongue of the
the polarity is correct (generator B+ to the + pole moveable tensioner arm and the fixed tensioner
of the battery). Mixing up the polarities by mistake housing (Fig. 2).
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
l If measurement "a" is smaller than 3 mm, replace
the ribbed V-belt.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
Changing the ribbed V-belt
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. 3
l Unscrew the fastening screws (Fig. 3) and slide the
fan forward.

008 911 17 BOMAG 159

8.19 Check the engine mounts

8.19 Check the engine mounts

Fig. 4
l
Release the idler pulley (Fig. 4) in direction of arrow
until the ribbed V-belt is free. Fig. 5
l
Pull the ribbed V-belt first to the smallest pulley. l Tighten fastenings of intake and exhaust manifolds
l Install the new ribbed V-belt. (Fig. 5) on the cylinder heads.
l
Release the idler pulley against the direction of ar-
l Check sockets and clamps between air filter, ex-
row until the V-belt is tensioned. haust turbocharger and charge air line as well as
the lubrication air line for tight fit and leaks.
l Measure the V-belt tension, tighten if necessary.
l Retighten the fastening screws for oil sump and en-
gine mounts.
i Note
Retighten the new fan V-belt after a running time of 20
minutes.

160 BOMAG 008 911 17

Fuel supply 8.20
8.20 Fuel supply

Fig. 1 Fuel supply 11 Pressure retaining valve - 5 bar

1 Water separator sensor connection 12 Return flow to tank
2 Flow to fuel lift pump 13 Fuel tank
3 Fuel lift pump 14 Manual fuel pump
4 Connecting line between fuel lift pump and main 15 Fuel pre-filter
filter (fuel pre-pressure up to 10 bar)
16 Water separator
5 Main fuel filter (pressure proof) 17 Fuel pre-heating connection (option)
6 Connecting line between main filter and flow to in- 18 Fuel pre-heating (R79) 200 Watt (option)
jection pumps
19 Water separator sensor (B124)
7 Single-cylinder injection pump
8 High pressure line
9 Injection nozzle
10 Leak oil line

008 911 17 BOMAG 161

8.20 Fuel supply

Work in the low pressure system

Service and repair work in the low pressure system,
including main fuel filter changes, are only permitted
under absolutely clean environmental conditions, be-
cause even smallest dirt particles entering into the
high pressure fuel system will cause considerable
damage. Air pollution, like dirt, dust, moisture etc.
must be strictly avoided. Before starting work in the
fuel system (including filter changes) the engine must
be thoroughly cleaned and dried (steam cleaning
equipment). Engine compartments in which dirt de-
posits may come loose, must be covered with new
and clean foil. When working in the open you may
need to apply protective measures against dust enter-
ing because of wind.

! Danger
For diesel fuel the ignition temperature, i.e. the
temperature at which fuel will ignite when coming
into contact with air, is approx. 220°C, but may de-
viate strongly because of impurities.
Fuel conducting components and lines therefore
are a source of danger inside the engine compart-
ment, because leaks may lead to fire resulting in
considerably damage to material and persons.

162 BOMAG 008 911 17

Fuel supply 8.20
Check valve reliably over their entire lifetime. If the throttle resist-
ances of pre-cleaner/main filter caused by contami-
According to our experience, it is not always assured
nated fuel are so high that the fuel pump is no longer
that only clean fuel will be used. Fuel tanks are fre-
able to ensure a sufficient fuel supply, the injection
quently filled without suitable precautions against con-
pumps will draw the required fuel through the leak fuel
tamination or fuel filters are inappropriately serviced.
return line from the tank without filtration. The engine
Many damage analyses on injection pumps and injec-
is no longer able to provide its full power, operation of
tion valves have revealed that most of these compo-
construction machine, however, may still be possible
nents had failed due to premature wear. Wear on
to a limited extent. After short time operation under
injection pump plunger and injection valve needle seat
such conditions the injection system components may
is caused by contaminated fuel. Modern exhaust opti-
already be pre-damaged.
mized diesel engines with high pressure injection sys-
tems strictly require clean fuel to be able to work

Fig. 1

008 911 17 BOMAG 163

8.21 Injection system

8.21 Injection system

The injection system serves the fuel supply for the die-
sel engine.
The low pressure side of an injection system includes
fuel tank, fuel filter and fuel lines.
In the high pressure side the injection pump generates
the pressure required for injection. The fuel is pumped
through the pressure line to the injection pump, from
where it is injected into the combustion chamber.
Load and speed of the diesel engine are adjusted via
the fuel quantity without throttling the intake air. With
a sufficient injection quantity the speed of an unloaded
diesel engine may therefore rise up to the point of self
destruction. A governor for engine speed limitation is
Fig. 2 Installation location therefore required.

i Note Single cylinder plug-in injection pumps

From August 2006 the check valve (Fig. 3) is installed Deutz diesel engines series 2012/1013 are equipped
in series machines. with Bosch cylinder plug-in injection pumps series PF
33.
! Caution The concept of plug-in injection pumps enables the re-
On machine produced before August 2006 this alization of high injection pressures, combined with
valve must unconditionally be installed into the short injection lines, which is necessary to ensure a
fuel return line by the customer. high hydraulic stiffness of the injection system. This, in
turn, creates the prerequisite for maintaining low ex-
haust emission values (soot) in combination with low
fuel consumption values.
The start of injection is influenced by:
l
the fuel consumption
l
the power
l
the exhaust emission
of the engine.
Fig. 3 Observe the direction of flow The term "start of injection" refers to the start of the in-
jection pump delivering fuel.

164 BOMAG 008 911 17

Injection system 8.21
Injection valves
Injection valves have the following functions:
l Preparation of fuel
l Forming of the injection sequence
l Sealing against the combustion chamber
The peak injection pressure of the diesel fuel is up to
1000 bar. Under these conditions the fuel no longer
behaves like a rigid fluid, but it is compressible. During
the short injection period (1ms) the injection system is
"blown up" and, depending on the nozzle size, more
or less fuel will enter into the combustion chamber.

Fig. 4 Single cylinder plug-in injection pump

The drive cams 2 (Fig. 4) for the single PF-injection
pumps are located on the camshaft (1) for engine
Fig. 5 Design of injection valve
valve control.
1 Tensioning nut
Permissible manufacturing tolerances for the compo-
nents: 2 Nozzle
l
Cylinder crankcase 3 Intermediate piece
4 Pressure bolt
l Camshaft
5 Pressure spring
l Roller-type plunger
6 Shim
l
Plug-in injection pump
are determined and eliminated by the adjustment of i Note
the start of injection. A thicker shim 6 (Fig. 5) increases the opening pres-
However, in cases of interest for BOMAG field engi- sure.
neers engines are not completely overhauled, but in-
dividual injection pumps are replaced. Crankcase,
camshaft and roller-type plunger remain unchanged. !Caution
This results in a certain installation measurement for When replacing an injection pump and/or an injec-
the drive, which is specified on the engine type plate. tion valve, you must also replace the high pres-
sure line between pump and valve.
It is stamped as "CODE" in the column "EP" for each
cylinder.

008 911 17 BOMAG 165

8.22 Injection pump replacement during service

8.22 Injection pump replacement

during service

Disassembly

!Caution
Ensure strict cleanliness when working on the in-
jection system.

Fig. 3
l Use the shut-down lever to push the governor rod to
stop position (Fig. 3).
l Insert and fasten the pressing device 100 830.

Fig. 1
l
Disassemble pressure control valve and cylinder
head cover (Fig. 1).
l
Disconnect the cable plugs from shut-down sole-
noid, governor and temperature sensor.
l Swing the holding plate to the side.

Fig. 4
l Use the knurled fastening screw to force the gover-
nor rod to stop position (Fig. 4).

i Note
Tighten the knurled fastening screw by hand.

Fig. 2
l Remove the engine shut-down assy (Fig. 2).

166 BOMAG 008 911 17

Injection pump replacement during service 8.22

Fig. 5 Fig. 7
l Set the cylinder of the injection pump to be disas- l Carefully remove the shim with a rod-type magneto
sembled to top dead centre (TDC) for ignition (Fig. 7).
(valves overlapping) (Fig. 5).
l Turn the crankshaft for approx. 120° against the
sense of rotation.

i Note
Illustration shows view on flywheel.

Fig. 6
l
Remove the injection line (Fig. 6).

i Note
Close the connections with protection caps.

008 911 17 BOMAG 167

8.22 Injection pump replacement during service

Determining the start of injection

Fig. 8 Injection pump code BFM 2012

i Note
Old injection pump and shim are not required for this
purpose.

Example:
The injection pump for cylinder 3 is to be replaced on
an engine BF6M 2012.

Procedure:
l Read the EP-code for cylinder 3 in the column "EP"
on the type plate (table) (Fig. 8), e.g. 295.

i Note
Sequence of reading: Line 1 = cyl.1, line 2 = cyl.2, etc.
l Take the corrected injection pump installation
measurement (EK) matching the EP-code from the
table (Fig. 11), e.g. 120.875 mm.

Fig. 10 Injection pump length "A" and Lo

i Note
Measurement "A" (Fig. 4) determines by how many 1/
100 of a mm the distance between cylinder crankcase
contact surface and plunger foot is longer than the ba-
sic measurement Lo.
Basic measurement of injection pump (Lo) = 117.5
mm.
l Determine the theoretical thickness of the shim
(TS).

TS = EK - (Lo + A/100)

TS = 120.875 mm - (117.5 mm + 42/100 mm)

TS = 2.955 mm
Fig. 9 Length of injection pump (A) l Choose the shim thickness (SS) from the table.
l Read the coefficient for the injection pump length
(A) (Fig. 9) on the new injection pump, e.g. 42.

168 BOMAG 008 911 17

Injection pump replacement during service 8.22
TS 2.955 mm = SS 3.0 mm

Theor. thickness "TS" Shim thickness "SS" Theor. thickness "TS" Shim thickness "SS"
(mm) (mm) (mm) (mm)
0.95 - 1.049 1.0 2.45 - 2.549 2.5
1.05 - 1.149 1.1 2.55 - 2.649 2.6
1.15 - 1.249 1.2 2.65 - 2.749 2.7
1.25 - 1.349 1.3 2.75 - 2.849 2.8
1.35 - 1.449 1.4 2.85 - 2.949 2.9
1.45 - 1.549 1.5 2.95 - 3.049 3.0
1.55 - 1.649 1.6 3.05 - 3.149 3.1
1.65 - 1.749 1.7 3.15 - 3.249 3.2
1.75 - 1.849 1.8 3.25 - 3.349 3.3
1.85 - 1.949 1.9 3.35 - 3.449 3.4
1.95 - 2.049 2.0 3.45 - 3.549 3.5
2.05 - 2.149 2.1 3.55 - 3.649 3.6
2.15 - 2.249 2.2 3.65 - 3.749 3.7
2.25 - 2.349 2.3 3.75 - 3.849 3.8
2.35 - 2.449 2.4

008 911 17 BOMAG 169

8.22 Injection pump replacement during service

Fig. 11 Table of injection pump codes BFM 2012

170 BOMAG 008 911 17

Injection pump replacement during service 8.22
Assembly

Fig. 15
l Slightly oil the receiving bore in the crankcase and
Fig. 12 the O-rings on the injection pump.
l
Carefully insert the injection pump control lever into
the governor rod. (Fig. 15).

Caution
!

The roller plunger for the corresponding injection

pump must be positioned on the base circle of
camshaft.

Fig. 13
l Lay the newly determined shim on roller plungers
(Fig. 12) and (Fig. 13).

Fig. 16
l Attach the flange (Fig. 16).

! Caution
The chamfer must face towards the injection
pump body.

Fig. 14
l Turn the injection pump control lever approx. to
middle position (Fig. 14).

008 911 17 BOMAG 171

8.22 Injection pump replacement during service

Fig. 20
Fig. 17
l Turn the screws in again for 60°, then tighten in
l
Slightly oil the screws and tighten with a torque of 5
steps to a torque of 7 Nm, 10 Nm and 30 Nm. (Fig.
Nm (Fig. 17).
20).

i Note
Always start with the outer screw furthest away from
the flywheel.

Fig. 18
l Loosen the screws again for 60° (Fig. 18).

Fig. 21
l Turn the knurled fastening screw back (Fig. 21).
l Remove the pressing device.

Caution
!

Check whether the governor rod is light moving

between stop and start position.
Operate the shut-down lever to do so.

Fig. 19
l Carefully turn the injection pump with an open end
spanner anti-clockwise against the noticeable end
stop (Fig. 19).

172 BOMAG 008 911 17

Injection pump replacement during service 8.22

Fig. 22
l Assemble a new O-ring (Fig. 22). Fig. 24

i Note Caution
!

Cover the O-ring slightly with oil. Take care that the sealing cones match exactly
when assembling the injection line. Subsequent
bending is not permitted. The injection line must
never be used twice.
l
Install the new injection line with the sealing rubber
(Fig. 24).
l Pre-tension the injection line cap nuts on injection
pump and injection valve with a torque of approx. 5
Nm (use claw spanner 8018).
l
Tighten the cap nut with 25 ± 3.5 Nm.

Fig. 23
l
Use the shut-down lever to push the governor rod to
stop position and hold it (Fig. 23).
l
Assemble the engine shut-down assy.
l
Tighten the screws with 21 Nm.
l Plug the cable plug onto the shut-down magneto.

Fig. 25
l Install the gasket (Fig. 25).

008 911 17 BOMAG 173

8.23 Injection valve replacement during service

8.23 Injection valve replacement

during service

i Note
Injection valves may wear mechanically over the
course of time. Spray pattern and injection pressure
should be tested on an injection valve test bench ("hy-
drostesting"). The nozzles must be disassembled for
this purpose. In case of excessive deposits on the
nozzles these may be cleaned in an ultrasonic bath
with gasoline. The injection pressure can be corrected
by means of shims.
Fig. 26
l
Assemble cylinder head cover and holding plate !Caution
(Fig. 26). Ensure strict cleanliness when working on the in-
jection system. Use only clean testing oil acc. to
l Tighten the screws with 11 Nm.
ISO 4113 or clean diesel fuel to test the injection
valves.
i Note
Ensure the sealing rubber is fitted correctly. Removal
l If necessary assemble the pressure control valve
with a new seal.
l Tighten the screws with 8.5 Nm.

Fig. 1
l
Disassemble pressure control valve and cylinder
head cover (Fig. 4).
l
Disconnect the cable plugs from shut-down sole-
noid, governor and temperature sensor.
l
Swing the holding plate to the side.

174 BOMAG 008 911 17

Injection valve replacement during service 8.23
Installation

Fig. 2
l Disassemble the injection lines (Fig. 2). Fig. 1
l Slide the new seal rings with some grease over the
i Note injection valves and insert the injection valves (Fig.
Close connections on injection valves and injection 1).
pumps with protective caps.
Caution
!

The chamfer on the injection valves must point

away from the claws.

Fig. 3
l
Disassemble the claws and take out the injection
valves (Fig. 3).
Fig. 2

i Note l Attach the claws and turn the screws in loosely (Fig.
In case of tight fit use the extracting device 150 800 2).
with puller 110 030.
Pull out the seal ring with the extracting device 120
680.

008 911 17 BOMAG 175

8.23 Injection valve replacement during service

Fig. 3 Fig. 5
l Pre-tension the injection line cap nuts on injection
Caution
! pumps and injection valves with a torque of approx.
Take care that the sealing cones match exactly 5 Nm (Fig. 5).
when assembling the injection line. Subsequent l Tighten the cap nuts with 25 + 3.5 Nm.
bending is not permitted. The injection line must
never be used twice.
i Note
l Install the new injection lines with the sealing rub-
Use a claw spanner 8018.
bers (Fig. 3).
l Tighten the cap nuts finger tight.

Fig. 6
l
Install the gasket (Fig. 25).
Fig. 4
l
Tighten the screws for the claws with 16 + 5 Nm
(Fig. 4).

176 BOMAG 008 911 17

Checking / repairing injection valves 8.24
8.24 Checking / repairing injection
valves
Special tools:

Nozzle tester 8008

Holder for Injection valve 110 110

Long socket 8012

!Caution
Ensure strict cleanliness when working on the in-
jection system. Use only clean testing oil acc. to
Fig. 7 ISO 4113 or clean diesel fuel to test the injection
l
Assemble cylinder head cover and holding plate valves.
(Fig. 26).
l Tighten the screws with 11 Nm. Check the injection valves

i Note i Note
Ensure the sealing rubber is fitted correctly. The injection valves are leak fuel free. Fuel cannot
flow off and will accumulate above the nozzle needle
l If necessary assemble the pressure control valve in the spring chamber of the nozzle holder. Operation
with a new seal. of the nozzle tester hand leever is in this case no long-
l Tighten the screws with 8.5 Nm. er possible. In order to eliminate the pressure inside
the spring chamber the clamping nut must be slack-
ened and retightened again before each test.

Fig. 1
l
Loosen the clamping screw by approx. 180° and
tighten it again (Fig. 1).

Tightening instructions: 30 - 40 Nm

i Note
Use injection valve holder 110 110.

008 911 17 BOMAG 177

8.24 Checking / repairing injection valves

Adjusting tze opening pressure on the in-

jection valve

i Note
If the opening pressure needs toi be corrected: De-
tach the injection valve from the nozzle tester 8008.
Unscrew the clamping nut and remove all parts. Use
injection valve holder 110 110.

Fig. 2
l
Mount the injection valve to the nozzle tester (Fig.
2).

! Danger

Keep your hands away from the nozzle spray jet.

Fuel will penetrate deeply into the flesh and may
cause blood poisoning.
Fig. 4
l Unscrew the clamping nut and remove all parts
(Fig. 4).

Fig. 3
l Slowly press the lever of the nozzle tester 8008
down with the pressure gauge connected (Fig. 3).
Fig. 5
Opening pressure: 220 bar Sequence of disassembly (Fig. 5):
1 Tensioning nut
i Note 2 Injection nozzle
The opening pressure is reached, when the pointer 3 Intermediate piece
stops or suddenly drops. 4 Pressure bolt
The pressure inside the spring chamber will have 5 Pressure spring
build up again after approx. 3 - 4 strokes. In order to 6 Shim
repeat the test the clamping nut needs to be slack-
ened and retightened again, as specified.
l Clean all parts with clean diesel fuel and blow off
with compressed air.
Once identical values are measured during 3 tests,
the values can be considered valid.

178 BOMAG 008 911 17

Checking / repairing injection valves 8.24

Fig. 6 Fig. 8
l
Assemble the shim (Fig. 8).
!Caution
Nozzle needle and nozzle body have been fitted i Note
by lapping and must never be mixed up by mis- Adjust the opening pressure by choosing the required
take or replaced individually. Do not touch the shim. A thicker shim increases the opening pressure.
nozzle needle with your fingers. With the nozzle
body in vertical position, the nozzle needle must
smoothly slide on its seat just by its own weight
(Fig. 6).

i Note
If the needle slides down jerkily, wash out the nozzle
body with diesel fuel again, replace if necessary.
Clean the new injection nozzle also in clean diesel fu-
el.

Fig. 9
l
Assemble the pressure spring.

Fig. 7
l Check the seat areas of the intermediate piece for
signs of wear. Make sure that the centring pins are
present (Fig. 7).

Fig. 10
l Install the pressure bolt with the centring collar to-
wards the pressure spring (Fig. 10).

008 911 17 BOMAG 179

8.24 Checking / repairing injection valves

Fig. 11 Fig. 13
l
Insert the centring pins of the intermediate piece l
Screw on the clamping nut.
into the bores of the nozzle holder (Fig. 11).

i Note
The chamfer points towards the pressure bolt.

Fig. 14
l Tighten the clamping nut.

i Note
Fig. 12
Use the injection valve holder 110 110 and a long
l Attach the centring bores of the injection nozzle to socket 8012.
the centring pins of the intermediate piece (Fig. 12).
Tightening torque: 30 to 40 Nm

i Note
The nozzle needle must not drop out of the nozzle
body.

180 BOMAG 008 911 17

Checking / repairing injection valves 8.24
Leak test Rattle and spray pattern test

Fig. 1 Fig. 1
l Dry nozzle and nozzle holder - blow dry with com- l
Switch off the pressure gauge on the tester.
pressed air.
l Press the hand klever of the tester slowly down, to i Note
a point about 20 bar before the previously indicated The rattle test enables audible testing of the nozzle
opening pressure (Fig. 1). needle movement inside the nozzle body. In compar-
ison with used injection valves, new ones have a dif-
ferent rattling behaviour. It becomes worse as the
wear in the needle seat area progresses.

!Caution
A used injection valve must audibly rattle and
spray off well atomized fuel when operating the le-
ver quickly. The spray pattern may be noticeably
different from the one produced by a new injection
valve.
If an injection nozzle does not rattle despite of
cleaning, it nees to be replaced by a new one!

Fig. 2

i Note
The nozzle is leak tight, if no drop drips off within a pe-
riod of 10 seconds.

! Caution
If a drop drips off (Fig. 2), the injection valve must
be dismantled and the leak must be eliminated by
thorough cleaning. If this does not lead to a suc-
cess, replace the injection nozzle.
Rework is not permitted!

008 911 17 BOMAG 181

8.25 Fuel filter

8.25 Fuel filter

Fig. 1 Fuel pre-filter

1 Hand pump
2 Bleeding valve
3 Filter element
4 Water and dirt collecting bowl
5 Drain valve
6 Water separator sensor connection (B124)
7 Fuel pre-heating connection (R79) 200 Watt (op-
tion)

182 BOMAG 008 911 17

Fuel filter 8.25
General l Open the drain valve and drain off approx. 0.5 l of
The quality of the fuel filter and the compliance with fuel. The fuel above the filter element presses
the specified service intervals are decisive for the life- through the filter element and frees the underside
time of the fuel injection system. The heart of the fuel from dirt.
filter is made of hydrophobic special paper, which is l Close the drain valve again.
spirally wound in form of a bag in order to offer the
largest possible filtering area under the prevailing spa- Perform
tial conditions and thus to achieve a high lifetime in
combination with a high dirt retaining capacity. A power drop or poor starting of the engine is mainly
caused by leaks in the fuel system. If you suspect a fil-
The fuel pre-filter / water separator mainly consists of:
ter problem, you should check whether bleeding
l
the dirt / water collecting bowl screw and drain valve are tightly closed and the filter
element is flush with the sight glass. Check the filter
l and the filter element
connections for leaks and the lines for clogging or po-
rous points.
Function
The fuel lift pump draws the fuel through this filter. Main fuel filter
Any water contained in the fuel deposits on the dirt
side of the filter paper and separates from the fuel in
form of large drops on the clean side of the filter (coa-
lescence effect).
Water is heavier than diesel fuel, it settles as a differ-
ent colour fluid on the bottom.
Once the water level reaches the height of the warn-
ing connections (sensor B124), the warning lamp
(H70) in the monitoring board (A15) will come on.

Fuel pre-heating (option)

In diesel engines the pre-heating of the fuel prevents
malfunctions caused by the formation of jelly (paraffin
separation) in the fuel under low temperatures.
Fig. 2 Main fuel filter
The integrated heating is a starting aid for cold weath-
er applications. The heating is delivered with an auto-
matic thermostat to start the heating when the fuel ! Caution
temperature drops below 7°C. The generated heat The main fuel filter is subjected to the approx. 10
works directly under the filter element and melts the bar fuel pre-pressure from the fuel lift pump. This
wax crystals that have formed, so that the fuel can pressure value is considerably higher than on oth-
flow through the filter element without restriction. The er engines. You should therefore only use original
heating automatically shuts down at a fuel tempera- filter elements (Fig. 2) at this point. Similar looking
ture of 24°C. The 200W heating is supplied with 12V filters with identical dimensions are not necessar-
D.C-current. The heater is activated when operating ily pressure proof!
the ignition switch; this should take place at least 5
A filter, with insufficient pressure resistance, will
minutes before starting the engine.
be destroyed and disintegrate by this high pres-
A normal On/Off switch may be installed to operate sure This will cause severe damage in the injec-
the relay. This can be used to e.g. interrupt the current tion system!
flow to the relay in the summer season.

Draining off water or fuel

Should the filter element be clogged prematurely (no-
ticeable e.g. by a drop in power), operation of the ma-
chine can be continued with the following procedure:
l Open the bleeding screw (this applies atmospheric
pressure to the filter element and loosens larger dirt
particles from the underside of the filter, which will
then drop down).

008 911 17 BOMAG 183

8.26 Check, clean the water separator

8.26 Check, clean the water separa- 8.27 Change the fuel pre-filter car-
tor tridge

Danger
! Danger
!

Danger of injury! Fire hazard!

Support the engine hood for all maintenance and When working on the fuel system do not use open
repair work. fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
i Note ground.
The service intervals for the water separator depend Do not inhale any fuel fumes.
on the water content in the fuel and can therefore not
be determined precisely. After taking the engine into
operation you should therefore check the water sepa-
rator every day for signs of water.
If a to high quantity is drained off, the filter must be re-
filled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.

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

Fig. 4
l
Unscrew the fuel filter cartridge (Fig. 4) using an ap-
propriate filter wrench.
l
Clean the sealing face on the filter carrier from any
dirt.

Fig. 3
l
Slacken the drain plug (Fig. 3) for a few turns and
catch running out fuel / water.
l Tighten the drain plug again and check for leaks, if
necessary replace the seal ring.

Fig. 5
l Unscrew the water separator from the filter car-
tridge (Fig. 5).

184 BOMAG 008 911 17

Change the fuel filter cartridge 8.28
8.28 Change the fuel filter cartridge

! Danger

Fire hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.

Fig. 6
l Apply a thin coat of oil to the rubber seal of the water
separator 1 (Fig. 6).
l Screw the water separator on by hand (2), until the
seal contacts.
l Tighten the water separator for another half turn (3).
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
l Tighten the filter element for another half turn (6). Fig. 8

l Check the filter cartridge for leaks after a short test

l
Loosen and unscrew the fuel filter cartridge (Fig. 8)
run. using an appropriate filter wrench.
l
Clean the sealing face on the filter carrier from any
dirt.
i Note
Air in the fuel system causes irregular running of the
engine, a drop in engine power, stalls the engine and
makes starting impossible.
Therefore bleed the fuel system after changing the
fuel prefilter.

Fig. 9
l Slightly oil the rubber seal (Fig. 9) on the new filter
cartridge.
l Fill the filter cartridge with clean diesel fuel.
l Turn the new filter cartridge on by hand, until the
Fig. 7 seal contacts.
l Slacken the bleeding screw (Fig. 7) on the fuel pre- l Tighten the filter element for another half turn.
filter for 2 to 3 turns. l Check the filter cartridge for leaks after a short test
l Operate the hand pump manually, until fuel flows run.
out of the slackened bleeding screw (Fig. 7) without
air bubbles.
l Then tighten the bleeding screw while pumping.

008 911 17 BOMAG 185

8.29 Checking the compression

8.29 Checking the compression

l Adjust the valves.
l Disassemble the injection valves.

Fig. 4
l Connect the compression tester 8005 (Fig. 4).
l
Crank the engine with the starter.

Fig. 1 i Note
l Insert the connecting piece 100 110 with seal ring Check the compression on each of the cylinders.
(Fig. 4).
Compression: 30 - 38 bar
The measured compression depends on the starter
speed during the measuring process and the altitude
of the engine location. Limit values can therefore not
be specified exactly. It is recommended to use the
compression measurement to compare the cylinders
of an engine among each other. Should a deviation of
more than 15% be measured, the affected cylinders
should be dismantled to examine the cause.
l Remove the compression tester 8005 and the con-
necting piece 100 110.
l Install the injection valves.

Fig. 2
l
Attach the claws (Fig. 2).
l Tighten the screw.

Fig. 3
l
Screw on the adapter for connecting piece 100 110
(Fig. 3).

186 BOMAG 008 911 17

Check, adjust the valve clearance 8.30
8.30 Check, adjust the valve clear-
ance

Caution
!

Before checking the valve clearance let the engine

cool down for at least 30 minutes. The engine oil
temperature must be less than 80 °C.
After a short test run check the engine for leaks.

Valve adjustment schematic

Fig. 7

Crankshaft position 2 (Fig. 7) (4 cylinder engine)

l Turn the crankshaft one revolution (360°) further.
l Perform the adjustment of the valve by following the
adjustment diagram "crankshaft position 2", black
mark.

Checking the valve clearance

l Loosen the crankcase ventilation valve and swing it
to the side.

Fig. 5
Valve 1 (Fig. 5) white = not adjustable
Valve (2) black = adjustable

Fig. 8
l
Remove the valve cover (Fig. 8).
l Crankshaft position as per "valve adjustment sche-
matic".
Fig. 6

Crankshaft position 1 (Fig. 6) (4 cylinder engine)

l Crank the engine with the starter or a spanner by
the V-belt pulley until both valves on cylinder 1 are
“overlapping”.
Overlapping means: Exhaust valve not yet closed, in-
take valve starts to open.
l Perform the adjustment of the valve by following the
adjustment diagram "crankshaft position 1", black
mark.
l
For control purposes mark the respective rocker
arm with while chalk once the corresponding valve
is adjusted.

008 911 17 BOMAG 187

8.30 Check, adjust the valve clearance

Fig. 9
l Check valve clearance 2 (Fig. 9) between rocker
arm (1) and valve (3) with a feeler gauge.
Intake valve = 0,3 mm
Exhaust valve = 0,5 mm
The feeler gauge must fit with little resistance.
l If the gap is too narrow or too wide for the feeler
gauge, the valve must be adjusted.

Adjusting the valve clearance

Fig. 10
l
Slightly slacken the counter nut. Adjust setscrew 7
(Fig. 10) with a screwdriver, until the feeler gauge
(6) can be inserted and pulled out with little resist-
ance after retightening the counter nut.
l
Perform tests and adjustments on all other adjusta-
ble valves.
l Check the gasket of the valve cover, replace it if
necessary.
l Reassemble the cylinder head cover.
l
Swivel the ventilation valve back to correct position
and fasten it.
l Fasten the air filter again and ensure correct fit of
combustion air hoses and clamps.

188 BOMAG 008 911 17

Boost fuel solenoid valve 8.31
8.31 Boost fuel solenoid valve

Fig. 1
1 Boost fuel solenoid valve

Pos. Designation in Designation Technical data

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

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

008 911 17 BOMAG 189

8.32 Engine shut-down solenoid

8.32 Engine shut-down solenoid

Fig. 1
1 Engine shut-down solenoid

Pos. Designation in Designation Technical data

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

General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the monitoring board (A15) in case of too low
oil pressure (terminal X6:1).

190 BOMAG 008 911 17

Air filter, differential pressure switch 8.33
8.33 Air filter, differential pressure
switch

Fig. 1
1 Differential pressure switch

Pos. Designation in Designation Technical data

circuit diagram
1 B03 Differential pressure switch switched to ground at a differential
pressure of > 50 mbar.

!Caution General
Combustion air lines between filter and engine The air filter retains the dust contained in the intake air
("clean air lines") must be absolutely leak tight and keeps it away from the engine in order to avoid
and withstand mechanical loads caused by en- engine wear.
gine vibrations and pressure pulsation. On paved roads the dust content in the air is 1 mg/m3
on average, on sealed roads or construction sites the
dust content can rise up to 40 mg/m3.
Dry air filters with integrated dust separator are char-
acterized by a good filtering effect (irrespective of en-
gine speed and inclination) and thus enable long
lasting and low wear engine operation.
The air filter has the additional function of damping the
air intake noise. This damping is achieved by the de-
sign of the air filter in from of a reflection silencer

008 911 17 BOMAG 191

8.34 Combustion air filter service

based on the principle of a Helmholz resonator, damp- 8.34 Combustion air filter service
ing the intake noise by its resonance frequency.
The differential pressure switch 1 (Fig. 1) in the air in-
take hose energizes the control light (H15) in the mon- ! Caution
itoring board (A15) when the pressure difference Perform cleaning, maintenance and repair work
between atmospheric pressure and intake pressure only with the engine shut down. Do not start the
exceeds > 50 mbar. This indicates that the air filter engine after removing the filter element.
does not allow sufficient air flow to the combustion Do not use gasoline or hot fluids to clean the filter
chamber. element.
Crankcase ventilation After cleaning the filter element must be inspected
During the combustion process in a diesel engine cer- for damage using a torch.
tain waste gas quantities escape through the ring Air filter elements with damaged paper bellows or
gaps on pistons and piston rings into the crankcase. seal lips must be replaced in any case.
The crankcase ventilation serves the discharge of The main filter element must be replaced after 3
these waste gases. times cleaning, but at the latest after one year, ir-
The engines are currently only equipped with open respective of the operating hours.
crankcase ventilation as standard. A crankcase venti- Each cleaning interval must be marked with a
lation valve with oil separator separates most of the oil cross on the cover of the filter element.
from the waste gas and returns it into the engine. The
waste gas itself escapes into the atmosphere. Cleaning does not make sense if the air filter ele-
ment is covered with a sooty deposit. Use a new
filter element.
Incorrectly handled filter elements may become
ineffective because of damage (e.g.: cracks) and
cause engine damage.

Fig. 2 old design

Fig. 3 new design

Maintenance of the dry air filter is due when control
light “c” (Fig. 2), "h"(Fig. 3) in the instrument cluster

192 BOMAG 008 911 17

Combustion air filter service 8.34
lights permanently when the engine is running, but at
the latest after one year.

i Note
Once the air filter service indicator lights up, work may
be continued until the end of the day.
l
Open the engine hood completely and secure it.

Fig. 6
l Pull the main filter element (Fig. 6) carefully out of
the housing.

Fig. 4
l
Release the locking hook (Fig. 4) and take the filter
hood off.
l
Clean filter hood and dust discharge valve.

Fig. 7
l Clean the sealing face on the outlet tube (Fig. 7).
Dust on the outer diameter of the outlet tube can im-
pair effective sealing.
l
Check the old main filter element.
The old main filter element can be of help to discover
foreign particles on the sealing face, which could lead
to leaks. A line of dust on the clean air side of the filter
may be a sign for such a leak. Eliminate this problem
Fig. 5 before installing a new main filter element.
l
Carefully loosen the main filter element (Fig. 5). l If the main filter element is damaged, the safety el-
The main filter element is located directly on the air in- ement must be replaced as well.
take tube, thereby providing a seal on the inside of the l Clean or replace the main filter element.
filter cover. Carefully remove the main filter element,
in order to reduce the released amount of dust. To re-
lease the seal pull the main filter element carefully up, i Note
down and sideways or turn it (Fig. 5) . We generally recommend to change the filter. A new
filter element is far less expensive than a possible en-
gine damage.
! Caution
Avoid contact between main filter element and
l Examine the main filter element thoroughly for dam-
housing. age.
Before installing the new main filter element check it
for possible damage from transport, cleaning or incor-
rect handling. Especially on the inside of the open end
(sealing area). Do not install damaged filter elements.
l If necessary use safety elements.

008 911 17 BOMAG 193

8.34 Combustion air filter service

l Blow the main filter element out with compressed

air (max. 5 bar) from inside to outside by moving the
tube up and down inside the element, until it if free
of dust.
l Examine the main filter element with a torch for
cracks and holes in the paper bellows.

! Caution
Do not continue to use a damaged main filter ele-
ment. If in doubt use a new main filter element.

Changing the safety filter element

Fig. 8
l Insert the main filter element (Fig. 8).
Caution
!
The radial sealing area is located at the inside of the The safety filter element must not be cleaned and
open filter edge. This critical sealing area must be un- should not be used again after it has been re-
der slight tension after the filter has been installed. In moved.
order to achieve a tight seal apply pressure to the out-
er edge of the filter and not to the moveable centre. The safety filter element must be replaced:
l Reinstall the filter hood with the dust discharge if the main filter element is defective,
valve. after three times cleaning of the main filter ele-
ment,
Caution
! at the latest after 2 years,
The dust discharge valve must point vertically if the warning light comes on again after servicing
downwards. the main filter cartridge.
l Remove the housing cover and pull the main filter
Dry cleaning of the main filter element element off.

Danger
!

Eye injury!
Wear protective clothing (goggles, gloves).

Fig. 10
l Pull the safety element (Fig. 10) out by turning it
lightly.
l Push in a new safety filter element.
Fig. 9 l
Reassemble main filter element and cover.

i Note
For cleaning purposes fit a tube to the compressed air
gun (Fig. 9), the end of which should be bent for ap-
prox. 90°.
The length should reach down to the bottom of the el-
ement.

194 BOMAG 008 911 17

Heating flange on engine (option) 8.35
8.35 Heating flange on engine (op- Machine with push button (S165)
tion)

Fig. 2 Push button (S165)

Fig. 1 Heating flange

The heating flange is a component with an electrically
i Note

operated heating wire and high energy density used to The heating process is started by single pressing of
heat up the intake air in case of very low ambient tem- the button (Fig. 2) when the ignition is on (12 Volt on
peratures. control unit A13, terminals 15(7) and S(2)). If the but-
ton is not operated, no preheating and subsequent
The heating power is approx. 2000 Watt. heating will take place.
The heating power improves the cold starting charac-
With a coolant temperature of -30°C the preheating
teristics and the exhaust emissions (white smoke) of
time will be max. 52 seconds, with +5°C the minimum
the diesel engine.
time will be 38 seconds. During the preheating period
A differentiation is made between preheating, to as- the control light (K) is permanently on. In case of a
sure the cold start ability of the engine, and subse- fault the lamp will flash.
quent heating.
After-heating is triggered in dependence on the tem-
perature by the voltage applied to the starter (terminal
50), or by operating the button (Fig. 2) while the en-
gine is running. With a coolant temperature of -30°C
the subsequent heating time will be max. 180 sec-
onds, with +25°C the minimum time will be 35 sec-
onds. This after-heating time is not indicated by the
control light (K) .

008 911 17 BOMAG 195

8.35 Heating flange on engine (option)

Machine without push button

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

Fig. 3 Heating flange (R19) with coupler flange BF4M 2012

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

Fig. 4 Heating flange (R19) with hose socket BF4M 2012 C

196 BOMAG 008 911 17

Heating flange on engine (option) 8.35

Fig. 5
1 Battery disconnecting switch (S30)
2 Heating control unit (A13)
3 Heating relay (K14)

Fig. 6 Coolant temperature sensor

1 Temperature sensor (B53) for heating flange con-
trol (A13)
2 Coolant temperature switch (B152)

008 911 17 BOMAG 197

8.35 Heating flange on engine (option)

Pos. Designation in Designation Technical data

circuit diagram
(Fig. 3) R19 Heating flange With a coolant temperature of -30°C
(Fig. 4) the preheating time will be max. 52
seconds, with +5°C the minimum
time will be 38 seconds.
With a coolant temperature of -30°C
the after-heating time will be max.
180 seconds, with +25°C the mini-
mum time will be 35 seconds.
12 Volt
approx. 2000 Watt
approx. 167 A
approx. 0.07 Ohm

1 (Fig. 5) S30 Battery disconnecting switch 250 Amp. permanent current

2500 Amp. 5 sec. long
2 (Fig. 5)) A13 Heating control unit 12 Volt
3 (Fig. 5) K14 Heating relay 12 Volt

1 (Fig. 6) B53 Temperature sensor for heating approx. 2 Ohm at 20°C

flange control (A13)
2 (Fig. 6) B152 Coolant temperature switch Contact switches at approx. 110° C
to ground

Fig. 7 Heating flange function diagram

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

198 BOMAG 008 911 17

Checking the heating flange control 8.36
8.36 Checking the heating flange perature sensor is pulled off (simulated sensor fail-
ure), a coolant temperature of 0° C is assumed.
control
l Start the heating process.

Depending on the coolant temperature the control

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

Rated current: 165 Amp +- 10 Amp.

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

Fig. 2 Monitoring module, new design (A15)

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

Sensor failure: Either short circuit or cable break-

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

Heating flange failure: Either short circuit or cable

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

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

008 911 17 BOMAG 199

8.37 Engine monitoring

8.37 Engine monitoring

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

Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time

10 sec. 2 min.
a H49, control light en- red, flashing X X Run the engine with idle
gine overheating Low-active speed or shut it down if
necessary, clean engine
oil cooler and radiator, if
necessary repair engine.
b H09, engine oil pres- red, flashing X X Check the engine oil lev-
sure control light Low-active el, if necessary repair the
engine.
c H15, engine air filter yellow, lights If necessary clean or re-
control light Low-active place engine air filter
d H08, charge control yellow, lights Check V-belt, if neces-
light High-active sary repair the generator
i H70, control light, yellow, lights Check, clean the water
water in diesel filter separator
k H52, pre-heating yellow, lights
control light yellow, flashes see chapter "Check heat-
in case of fault ing flange control"
Low-active
j Option red, flashing X Option Fill up coolant
H73, coolant level Low-active

200 BOMAG 008 911 17

Engine monitoring 8.37

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

Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time

10 sec. 2 min.
i H49, control light en- red, flashing X X Run the engine with idle
gine overheating Low-active speed or shut it down if
necessary, clean engine
oil cooler and radiator, if
necessary repair engine.
e H09, engine oil pres- red, flashing X X Check the engine oil lev-
sure control light Low-active el, if necessary repair the
engine.
h H15, engine air filter not used
control light Low-active
g H08, charge control yellow, lights Check V-belt, if neces-
light High-active sary repair the generator
b H70, control light, wa- yellow, lights Check, clean the water
ter in diesel filter separator
c H52, pre-heating con- yellow, lights see chapter "Check heat-
trol light yellow, flash- ing flange control"
es in case of
fault
Low-active
f Option red, flashing X Option Fill up coolant
H73, coolant level Low-active

008 911 17 BOMAG 201

8.37 Engine monitoring

Checking the engine monitoring system i Note

The following control lights and shut-down functions Control light i(Fig. 1), b(Fig. 2) lights up.
can be checked with the engine running: l
Push the plug back together, the plug interlock
Air filter clicks into place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.

Engine oil pressure

Fig. 3 Differential pressure switch

l Press on the locking wire and pull the plug off the
differential pressure switch 1 (Fig. 3).
l Bridge both contacts on the plug of the wiring loom. Fig. 5 Oil pressure switch
l
Press on the locking wire and pull off the plug 1 (Fig.
i Note 5).
Control light c(Fig. 1), h(Fig. 2) lights up. No audible l Apply the contact to engine ground.
will sound and the engine will not be shut down.
l Push the plug back on, the plug interlock clicks into i Note
place.
The control light b(Fig. 1), e(Fig. 2) flashes. An audible
l Check the plug interlock by lightly pulling on the wir- warning will sound and the engine is shut down after
ing loom. 10 seconds.
Water separator l
Push the plug back on, the plug interlock clicks into
place.
l
Check the plug interlock by lightly pulling on the wir-
ing loom.

Fig. 4 Sensor plug on water separator

l
Press the plug interlock and disconnect the plug
(Deutsch plug).
l Bridge both contacts on the plug of the wiring loom.

202 BOMAG 008 911 17

Engine monitoring 8.37
Engine overheating

Fig. 6 Coolant temperature switch

l Press on the locking wire (Fig. 6) and pull off the
plug.
l Bridge both contacts on the plug of the wiring loom.

i Note
Control light a(Fig. 1), i(Fig. 2) flashes. An audible
warning will sound and the engine is shut down after
2 minutes.
l
Push the plug back on, the plug interlock clicks into
place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.

Emergency stop switch

Fig. 7 Emergency stop switch

l Press the emergency stop switch (Fig. 7). The en-
gine should stop immediately.

008 911 17 BOMAG 203

8.38 Engine

8.38 Engine

Faults Possible cause Remedy

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

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

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

Fuel lines leaking Check all line connections for leakages

and tighten the fittings.

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

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

tive

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

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

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

Injection lines leaking Check the lines for leakages

Turbo charger defective Have examined by a specialist

Dry air filter dirty clean, replace if necessary

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

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

Exhaust gas turbo-charger defective Have examined by a specialist

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

Incorrect valve clearance Adjust the valve clearance

204 BOMAG 008 911 17

Engine 8.38
Faults Possible cause Remedy

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

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

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

correctly adjusted

Cooling air flow restricted Clean the cooling air duct

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

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

Dry air filter dirty clean, change if necessary

Exhaust gas turbo-charger defective Have examined by a specialist

Charge air hose leaking Check fastening and connections

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

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

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

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

008 911 17 BOMAG 205

8.39 Special tools, Deutz engine (BFM 2012)

8.39 Special tools, Deutz engine

(BFM 2012)

Deutsch English Français Español No.

Druckpumpe für Kühlmitteldichtheitsprüfung 8002

057 250 66
Pressure pump for coolant leakage test.

Pompe refoulante pour contrôle de l’étanchéité du

liquide refroidisseur

Bomba de presión para pruebas de estanqueidad

sistema de líquido refrigerante

35409 ©

Kompressionsdruckprüfer 8005
057 250 67
Compression tester

Compressiomètre

Compresímetro

35410 ©

Düsenprüfgerät 8008

Nozzle tester

Pompe d’essai d’injecteurs

Comprobador para inyectores

35411 ©

Stecknuss SW 15, lange Ausführung für Einspritz- 8012

ventil. (Überwurfmutter)

Socket a/flats 15, long version for injector

(cap nut)

Douille de 15, version longue pour injecteur

(écrou-raccord).

Llave de vaso de 15, versión larga, para inyector

(tuerca de unión)
35412 ©

206 BOMAG 008 911 17

Special tools, Deutz engine (BFM 2012) 8.39

008 911 17 BOMAG 207

8.39 Special tools, Deutz engine (BFM 2012)

057 250 78

208 BOMAG 008 911 17

Special tools, Deutz engine (BFM 2012) 8.39

Deutsch English Français Español No.

Anschlußstück für Kompressionsdruckprüfer 100 110

Connector for compression tester

Raccord pour compressiomètre

Pieza de empalme para el compresímetro

35421 ©

Durchdrehvorrichtung 100 320

057 250 80
Turning gear

Dispositif vireur

Dispositivo de viraje

35422 ©

Durchdrehvorrichtung 100 330

079 947 19
Turning gear

Dispositif vireur

Dispositivo de viraje

35423 ©

Messuhr M2T mit Feststellring. 100 400

057 250 81
Dial gauge M2T with locking ring

Comparateur M2T avec bague

d’immobilisation

Comparador M2T con anillo exterior

de bloqueo

35424 ©

008 911 17 BOMAG 209

8.39 Special tools, Deutz engine (BFM 2012)

No. Deutsch English Français Español

100 750 Messbalken mit Abstandsblättchen zum Messen

057 250 83 des OT und des Kolbenüberstandes.

Measuring bar with spacers for gauging

TDC and piston projection

Barre de mesure avec plaquettes d’écartement

pour mesurer le PMH et la cote de dépassement du
piston

Barra de medición con plaquitas distanciadoras

35425 © para la medición del PMS y saliente de pistón

100 800 Messgerät zum Messen und Blockieren der

Regelstange.

Measuring device for measuring and

locking control rod

Appareil de mesure et de blocage de la

crémaillère.

Equipo de medición y de bloqueo de la cremallera

35426 ©

100 810 Einstellbolzen für MAG-Wellen.

Adjusting pin for mass balancing shafts

Pige de calage pour arbres à masses d’équilibrage

(MAG)

Pernos de ajuste para ejes equilibradores

de masa „MAG".

35427 ©

100 830 Andrückvorrichtung für Regelstange

Press-on device for control rod

Dispositif de montage de cremaillère

Dispositivo de presión para la cremallera

35428 ©

210 BOMAG 008 911 17

Special tools, Deutz engine (BFM 2012) 8.39

Deutsch English Français Español No.

Messvorrichtung für Grundkreismessung 100 890

„Einspritzpumpe und Förderbeginn“.

Measuring device for base circle measurement

Dispositif de mesure du cercle de base

Dispositivo de medición del círculo base

“bomba de inyección y comienzo de alimentación“

35429 ©

Gradscheibe 360° mit Befestigung an der 101 020

Schwungscheibe für OT und FB Einstellung.

Graduated disc 360° with device for fastening

to flywheel for TDC and COD setting

Disque gradué 360° avec fixation sur volant moteur

pour réglage du PMH et point de calage du début
d’injection

Disco graduado 360° con fijación en el volante,

para ajuste del PMS y comienzo de alimentación 35430 ©

Adapter für Gradscheibe. 101 030

Adapter for graduated disc

Adaptateur pour disque gradué

Adaptador para el disco graduado

35431 ©

Zeiger für Gradscheibe. 101 300

Pointer for graduated disc

Index pour disque gradué

Indicador para el disco graduado

35432 ©

008 911 17 BOMAG 211

8.39 Special tools, Deutz engine (BFM 2012)

212 BOMAG 008 911 17

Special tools, Deutz engine (BFM 2012) 8.39

Deutsch English Français Español No.

Spezialschlüssel für Einspritzleitung 110 500

057 250 86
Special wrench for injection line

Clé spéciale pour conduite d’injection

Llave especial para tubería de inyección

35436 ©

Ausziehvorrichtung für den Dichtring unter 120 680

dem Einspritzventil.

Extractor for sealing ring beneath injector

Outil d’extraction pour le joint de l’injecteur

Dispositivo de extracción para el anillo de

junta del inyector

35437 ©

Aufspannbock für Zylinderkopf. 120 900 057 250 90

Clamping stand for cylinder head

Chevalet d’ablocage pour culasse

Caballete de sujeción para culata

35438 ©

Aufspannplatte für 120 900. 120 910

Clamping plate for 120 900

057 250 91

Plaque d’ablocage pour 120 900

Placa de sujeción para 120 900

35439 ©

008 911 17 BOMAG 213

8.39 Special tools, Deutz engine (BFM 2012)

No. Deutsch English Français Español

121 410 Montagewerkzeug für Ventilschaftabdichtung

Sleeve for fitting valve stem seal

Outil de montage pour joint de tige de soupape

Util de montaje para juntas de vástago de válvula

35440 ©

130 300 Kolbenring-Auflegezange

Piston ring pliers

Pince à monter les segments de piston

Alicates para colocar aros de pistón

35441 ©

130 440 Trapeznut-Verschleißlehre

Trapezoidal groove wear gauge

Jauge d’usure pour gorge trapézoïdale

Calibre de desgaste para ranura trapezoidal

35442 ©

130 660 Kolbenringspannband Ø 98 mm

057 250 97
Piston ring compressor

Collier à segments de piston de Ø 98 mm

Compresor de aros de pistón, Ø 98 mm

35443 ©

214 BOMAG 008 911 17

Special tools, Deutz engine (BFM 2012) 8.39

Deutsch English Français Español No.

Kolbenringspannband Ø 101 mm 130 670

057 250 98
Piston ring compressor

Collier à segments de piston de Ø 101 mm

Compresor de aros de pistón, Ø 101 mm

35443 ©

Montagewerkzeug für Kurbelwellendichtring vorn. 142 670

Assembly tool for front crankshaft seal

079 947 26
Outil de montage de bague d’étanchéité de
vilebrequin AV

Herramienta de montaje para el retén delantero del

cigüeñal

35445 ©

Montagewerkzeug für Kurbelwellendichtring hinten. 142 830

079 947 27
Assembly tool for rear crankshaft seal

Outil de montage de bague d’étanchéité de

vilebrequin AR

Herramienta de montaje para el retén trasero del

cigüeñal

35446 ©

Montagewerkzeug für MAG-Buchsen. 143 780

Assembly tool for engine balancer bushes

Outil de montage de douilles d’arbres à masses

d’équilibrage

Herramienta de montaje para casquillos de ejes

equilibradores

35447 ©

008 911 17 BOMAG 215

8.39 Special tools, Deutz engine (BFM 2012)

057 250 99

079 947 18

216 BOMAG 008 911 17

Special tools, Deutz engine (BFM 2012) 8.39

Deutsch English Français Español No.

Maul-Steckaufsatz für Drehmomentschlüssel 160 340

(mit großem Vierkant 14 x 18 mm) für Lüfter (Ein- /
Ausbau) - Zentralmutter
Open jawed wrench socket for torque wrench
(large square wrench 14 x 18 mm) for fan
(assembly and removal) – center nut
Embout à mâchoire pour clé dynamométrique
(à grand quatre-pans 14 x 18 mm) pour ventilateur
(démontage/remontage) – écrou central
Boca enchufable para llave dinamométrica
(con macho cuadrado grande 14 x 18 mm) para
(montaje/desmontaje) tuerca central del ventilador 35455 ©

Gegenhalter für Zahnrad Luftpresser 170 630

Dolly for air compressor gear

Dispositif de maintien pour pignon de compresseur

d’air

Dispositivo de retención para rueda dentada

compresor de aire

35450 ©

Motormontagebock für doppelseitige Auf- 6066

spannung

Engine assembly stand for double-sided

chucking

Chevalet de montage moteur avec double

ablocage

Caballete de montaje para sujeción bilateral 079 947 30

del motor
35451 ©

1 Satz Aufspannwinkel für doppelseitige Auf 6066/158

spannung.

1 Set of angled clamping plates for

double-sided chucking

1 jeu d’équerre de fixation pour double ablocage

1 juego de angulares para sujeción bilateral 079 947 31

35452 ©

008 911 17 BOMAG 217

8.39 Special tools, Deutz engine (BFM 2012)

218 BOMAG 008 911 17

9 Front axle

008 911 17 BOMAG 219

9.1 Repair overview for front axle

9.1 Repair overview for front axle

Fig. 1 6 Tie rods

1 Joint carrier 7 Rotation joint
2 Body bolster 8 Steering axle
3 Steering leg 9 Joint bolt with bearing
4 Wheel bearing 10 Wheel discs
5 Steering cylinder 11 Bearing bushes for steering axle

220 BOMAG 008 911 17

Dismantling the front axle 9.2
9.2 Dismantling the front axle
!Danger
Danger of squashing!
Do not stand or work under suspended loads!
1. Disassemble the front axle.
2. Attach the lifting tackle to the front axle (Fig. 1).

Fig. 1
3. Place the front axle with the top side down safely
on a assembly trestle (Fig. 2).

Fig. 2
4. Remove the locking plates from the steering arms
(Fig. 3).
5. Drive bolt (1) out with a suitable drift punch and
pull out the tie rods (2).

Fig. 3
Disassembly of wheel bearing units
6. Remove the wheel discs (Fig. 4).

Fig. 4

008 911 17 BOMAG 221

9.2 Dismantling the front axle

7. Remove the rear bearing cover (Fig. 5).

8. Disassemble the front bearing cover with Bel-
leville springs, shims and backing discs.

Fig. 5
9. Attach the lifting tackle to the wheel bearing unit.
10. Turn impact puller 1 (Fig. 6) into the thread (M24)
and extract the bearing bolt with the bearing.

iNote
Remove also the joint bolt from the opposite side.

Fig. 6
11. Lift the bearing unit out of the body bolster (Fig.
7).

Fig. 7
12. Bend the lug if the locking plate open and un-
screw the grooved nut 1 (Fig. 8).

Fig. 8

222 BOMAG 008 911 17

Dismantling the front axle 9.2
13. Take off the locking plate (Fig. 9).

Fig. 9
14. Take off the shim (Fig. 10).
15. Extract the wheel bearing using a suitable puller.

Fig. 10
Disassembling the steering arm
16. Disassemble the left hand holding plate (Fig. 11).
17. Disassemble the right hand holding plate .
18. Attach the lifting tackle to the body bolster.

Fig. 11
19. Lift both steering arms out of the steering axles
(Fig. 12).
20. Unscrew the steering cylinder fastening screws
and disassemble the steering cylinder (1).

Fig. 12

008 911 17 BOMAG 223

9.2 Dismantling the front axle

21. Lay the steering arms on the workbench (Fig. 13).

Fig. 13
22. Knock out the bearing bushings 1 (Fig. 14).

Fig. 14
Disassembling the body bolster
23. Attach the lifting tackle to the body bolster.
24. Remove the rear bearing cover (Fig. 15).
25. Disassemble the front bearing cover with Bel-
leville springs, shims and backing discs.

Fig. 15
26. Press the body bolster against the joint recepta-
cle to the stop (Fig. 16).

i Note
The outer race (1) of the rocker bearing is thereby
stripped off.
If the outer race is not stripped off completely, it
may need to be destroyed.
It may be helpful to weld a flat steel bar to the out-
er race so that it can be pulled off with a puller.

Fig. 16

224 BOMAG 008 911 17

Dismantling the front axle 9.2
27. Force inner race 1 (Fig. 17) of the rocker bearing
off the bolt.

i Note
If the inner race cannot be levered off, it may
need to be destroyed.
It may be helpful to weld a flat steel bar to the in-
ner race so that it can be pulled out with a puller.

28. Remove backing disc (2).

Fig. 17
29. Unscrew the socket head cap screws (Fig. 18).

Fig. 18
30. Turn in the forcing screws and force the joint bolt
out of the body bolster (Fig. 19).

Fig. 19
31. Take the joint bolts out of the body bolster (Fig.
20).

Fig. 20

008 911 17 BOMAG 225

9.2 Dismantling the front axle

32. Press the body bolster against the joint recepta-

cle to the stop (Fig. 21).

i Note
The outer race (1) of the rocker bearing is thereby
stripped off.
If the outer race is not stripped off completely, it
may need to be destroyed.
It may be helpful to weld a flat steel bar to the out-
er race so that it can be pulled off with a puller.

Fig. 21
33. Force inner race 1 (Fig. 22) of the rocker bearing
off the bolt.

i Note
If the inner race cannot be levered off, it may
need to be destroyed.
It may be helpful to weld a flat steel bar to the in-
ner race so that it can be pulled out with a puller.

34. Remove backing disc (2).

Fig. 22
35. Unscrew the socket head cap screws (Fig. 23).

Fig. 23
36. Turn in the forcing screws and force the joint bolt
out of the body bolster (Fig. 24).

Fig. 24

226 BOMAG 008 911 17

Dismantling the front axle 9.2
37. Take the joint bolts out of the body bolster (Fig.
25).

Fig. 25
38. Take the joint receptacle out of the body bolster
and lay it safely to the side (Fig. 26).

Fig. 26
Disassembling the steering axles

i Note
The steering axles 1 (Fig. 27) cannot be disas-
sembled without being destroyed.
The steering axles were assembled with the help
of liquid oxygen at -20°C.

Fig. 27

008 911 17 BOMAG 227

9.3 Assembling the front axle

9.3 Assembling the front axle

! Caution
Ensure strict cleanliness.

! Danger

Danger of squashing!
Do not stand or work under suspended loads!
1. Lay the body bolster with the top side down on the
assembly trestle (Fig. 1).

Fig. 1
Assembling the steering axles
2. Spray the receiving bores with sliding lacquer
OKS 571 to ease assembly (Fig. 2).

Fig. 2

! Danger

Persons handling liquid oxygen must learn

the following safety instructions:
Safety instructions, handling low temperature
liquid gases
Safety instructions, lack of oxygen.
Safety instructions, oxygen enrichment.
Safety instructions, frost bites and congela-
tion.
3. Cool the steering axles down to at least -20°C
with liquid oxygen.
Fig. 3 4. Press the steering axles 1 (Fig. 3) into the body
bolster until they bottom.

i Note
The steering axles must slide into the body bol-
ster.

228 BOMAG 008 911 17

Assembling the front axle 9.3
Assembling the joint receptacle
5. Lay the joint receptacle 1 (Fig. 4) on the assembly
trestle.

! Caution
Do not apply any load to the steering axles be-
fore the bottom section is free of ice.
6. Attach lifting tackle to steering axles with body
bolster (2).

Fig. 4
7. Assemble new seal rings (Fig. 5).
8. Oil the seal rings.

Fig. 5
9. Oil the receiving bores for the joint bolts (Fig. 6).

Fig. 6
10. Insert the body bolster into the joint receptacle
(Fig. 7).

Fig. 7

008 911 17 BOMAG 229

9.3 Assembling the front axle

Assembling the joint bolts

11. Screw in the front guide pins (M10) (Fig. 8).
12. Screw in the rear guide pins (M10) .

Fig. 8
13. Oil and attach the front and rear joints bolts (Fig.
9).

! Caution
Avoid skewing of the joint bolts.
14. Attach the assembly tool (1).

Fig. 9
15. Pull both joint bolts in against the stop (Fig. 10).
16. Remove the assembly tool.

Fig. 10
17. Remove the guide pins (Fig. 11).

Fig. 11

230 BOMAG 008 911 17

Assembling the front axle 9.3
18. Screw in the socket head cap screws from both
sides (Fig. 12) and........

Fig. 12
19. ..... tighten (Fig. 13).

Fig. 13
Assembling the rocker bearings
20. Assemble the front backing disc (Fig. 14).
21. Assemble the rear backing disc.

Fig. 14
22. Spray the bearing seats and the inner bearing
races with sliding lacquer OKS 571 to ease as-
sembly (Fig. 15).

! Caution
Do not use any grease.

Fig. 15

008 911 17 BOMAG 231

9.3 Assembling the front axle

23. Attach the inner rocker bearing races with the

wide outer rim forward (Fig. 16) and.....

! Caution
Do not skew.

Fig. 16
24. .... drive in with a suitable mandrel (Fig. 17)

Fig. 17
25. Spray the bearing seats and the outer bearing
races with sliding lacquer OKS 571 to ease as-
sembly (Fig. 18).

! Caution
Do not use any grease.

Fig. 18
26. Attach the outer bearing races with the wide outer
rim facing outside and drive them in with a plastic
hammer (Fig. 19).

! Caution
Do not skew.

Fig. 19

232 BOMAG 008 911 17

Assembling the front axle 9.3
27. Assemble the rear bearing cover.
28. Tighten the hexagon screws (Fig. 20) cross-wise.

Fig. 20
Adjusting the bearing preload

! Caution
The bearings must be fully pressed in!
29. Insert backing disc 1 (Fig. 21) and Belleville
springs (2) into the front cover.

i Note
Lay the Belleville springs into the cover with the
curvature pointing down.

Fig. 21
30. Attach the front bearing cover with backing disc
and Belleville springs and locate the assembly
with two fastening screws (Fig. 22).

! Caution
Adjust the bearing preload with an axial
preload of 40KN.
With threaded rod M12-8.8 = 77 Nm tightening
torque
With threaded rod M16-8.8 = 90 Nm tightening
torque.
31. Push the threaded rod through joint receptacle
Fig. 22
and body bolster.
32. Tighten the threaded rod with the specified torque
(Fig. 23).

Fig. 23

008 911 17 BOMAG 233

9.3 Assembling the front axle

33. Measure the gap (measurement „Y“) between

cover and joint receptacle with a feeler gauge
(Fig. 24).

i Note
Shim thickness "S" = 3.4 mm - "Y"
34. Remove the cover again.

Fig. 24
35. Insert shim 2 (Fig. 25) of appropriate thickness
and backing disc (1) into the cover.

Fig. 25
36. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 26).

Fig. 26
37. Assemble the cover (Fig. 27) with Belleville
springs, shims and backing disc.
38. Turn in and tighten the fastening screws.

Fig. 27

234 BOMAG 008 911 17

Assembling the front axle 9.3
39. Turn in protection plug 1 (Fig. 28).

Assembling the steering cylinders

40. Insert the steering cylinder with fastening clamps
into the grooves (2) in the body bolster.
41. Turn in and tighten the screws.

Fig. 28
Steering arm

i Note
The work steps (Fig. 29) to (Fig. 45) apply for both
body bolsters.
42. Lay the steering arm on the workbench (Fig. 29).

Fig. 29
43. Attach the bottom bearing bushing (Fig. 30).

Fig. 30
44. Attach the top bearing bushing (Fig. 31).

Fig. 31

008 911 17 BOMAG 235

9.3 Assembling the front axle

45. Attach the assembly tool 1 (Fig. 32).

46. Pull both bearing bushings fully in with the as-
sembly tool.

Fig. 32
47. Assemble new seals and apply a thin coat of oil
(Fig. 33).

Fig. 33
48. Apply some grease to the friction disc contact
surface (Fig. 34).

Fig. 34
49. Assemble the friction disc (Fig. 35).

Fig. 35

236 BOMAG 008 911 17

Assembling the front axle 9.3
50. Apply some grease to the friction disc seal ring
(Fig. 36).

Fig. 36
51. Assemble and grease the seal (Fig. 37).

Fig. 37
52. Clean the steering axle (Fig. 38).

Fig. 38
53. Spray the steering axle with sliding agent OKS
571 (Fig. 39).

Fig. 39

008 911 17 BOMAG 237

9.3 Assembling the front axle

54. Apply some grease to the body bolster contact

surface (Fig. 40).

Fig. 40
55. Attach the lifting tackle to the body bolster (Fig.
41).

Fig. 41
56. Fit body bolster and steering axle together (Fig.
42).

Fig. 42
57. Assemble the holding plate (Fig. 43).

Fig. 43

238 BOMAG 008 911 17

Assembling the front axle 9.3
58. Tighten the screw (Fig. 44).

Fig. 44
59. Oil the receiving bores for the bearing bolts (Fig.
45).

Fig. 45
Assembling the wheel bearings

i Note
The work steps (Fig. 46) to (Fig. 53) apply for both
bearing shafts.
60. Attach lifting tackle to the bearing shaft (Fig. 46)
and..........

Fig. 46
61. ......... stand the shaft in a hydraulic press (Fig.
47).
62. Assemble spacer (1).
63. Spray the bearing mounting surfaces with sliding
agent OKS 571 .

Fig. 47

008 911 17 BOMAG 239

9.3 Assembling the front axle

64. Press the wheel bearing in until it bottoms (Fig.

48).

Fig. 48
65. Turn the bearing shaft by 180° (Fig. 49).
66. Assemble spacer (1).
67. Spray the bearing mounting surfaces with sliding
agent OKS 571 .

Fig. 49
68. Press the wheel bearing in until it bottoms (Fig.
50).

Fig. 50
69. Attach shim and locking plate (Fig. 51).

Fig. 51

240 BOMAG 008 911 17

Assembling the front axle 9.3
70. Attach the grooved nut with the bevelled side
down and tighten it hand tight with a sickle span-
ner (Fig. 52).

Fig. 52
71. If necessary loosen the grooved nut again, until a
lug of the locking plate matches a groove in the
grooved nut (Fig. 53).
72. Bend the lug down.
73. Perform the work steps (Fig. 51), (Fig. 52) and
(Fig. 53) on both sides of the wheel bearing unit.

Fig. 53
Assembling the wheel bearing units

i Note
The work steps (Fig. 54) to (Fig. 70) apply for both
bearing units.
74. Attach the lifting tackle to the wheel bearing unit
(Fig. 54).
75. Oil the receiving bores for the bearing bolts.

Fig. 54
76. Fit wheel bearing unit and body bolster together
(Fig. 55).

Fig. 55

008 911 17 BOMAG 241

9.3 Assembling the front axle

77. Oil and attach the front and rear joints bolts (Fig.
56).

! Caution
Avoid skewing of the joint bolts.
78. Attach the assembly tool (1).

Fig. 56
79. Pull both joint bolts in against the stop (Fig. 57).
80. Remove the assembly tool.

Fig. 57
81. Assemble the backing discs on both sides (Fig.
58).

Fig. 58
82. Spray the bearing seats and the inner bearing
races with sliding lacquer OKS 571 to ease as-
sembly (Fig. 59).

! Caution
Do not use any grease.

Fig. 59

242 BOMAG 008 911 17

Assembling the front axle 9.3
83. Attach the inner rocker bearing races with the
wide outer rim forward (Fig. 60) and.....

! Caution
Do not skew.
84. ...... drive in with a suitable mandrel.

Fig. 60
85. Spray the bearing seats and the outer bearing
races with sliding lacquer OKS 571 to ease as-
sembly (Fig. 61).

! Caution
Do not use any grease.

Fig. 61
86. Attach the outer bearing races with the wide outer
rim facing outside and drive them in with a plastic
hammer (Fig. 62).

! Caution
Do not skew.

Fig. 62
87. Assemble the rear bearing cover (Fig. 63).
88. Tighten the hexagon screws cross-wise.

Fig. 63

008 911 17 BOMAG 243

9.3 Assembling the front axle

Adjusting the bearing preload

! Caution
Bearings and bearing bolts must be fully
pressed in!
89. Insert backing disc 1 (Fig. 64) and Belleville
springs (2) into the front cover.

i Note
Lay the Belleville springs into the cover with the
curvature pointing down.
Fig. 64
90. Attach the front bearing cover with backing disc
and Belleville springs and locate the assembly
with two fastening screws (Fig. 65).
91. Push the threaded rod through joint receptacle
and body bolster.

! Caution
Adjust the bearing preload with an axial
preload of 40KN.
With threaded rod M12-8.8 = 77 Nm tightening
torque
With threaded rod M16-8.8 = 90 Nm tightening
Fig. 65
torque.
92. Tighten the threaded rod with the specified
torque.
93. Measure the gap (measurement „Y“) between
cover and joint receptacle with a feeler gauge
(Fig. 66).

i Note
Shim thickness "S" = 3,2 mm - "Y"
94. Remove the cover again.

Fig. 66

244 BOMAG 008 911 17

Assembling the front axle 9.3
95. Insert shim 2 (Fig. 67) of appropriate thickness
and backing disc (1) into the cover.

Fig. 67
96. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 68).

Fig. 68
97. Assemble the cover (Fig. 69) with Belleville
springs, shims and backing disc.
98. Turn in and tighten the fastening screws.
99. Press in the protection plug (1).

Fig. 69
100. Assemble the wheel discs (Fig. 70).

Fig. 70

008 911 17 BOMAG 245

9.3 Assembling the front axle

Assembling the tie rods

i Note
Perform work steps (Fig. 71) to (Fig. 74) on the
left and right hand steering arms.
101. Spray the mating surfaces with sliding lacquer
OKS 571 to ease assembly (Fig. 71).
102. Drive the bearing into the tie rod with a suitable
drift punch.

Fig. 71
103. Apply both tie rod seals 2 (Fig. 72).
104. Slide tie rod (1) and seals (2) into the receptacle
on the steering arm.

Fig. 72
105. Spray the bolts with sliding lacquer OKS 571 to
ease assembly (Fig. 73).

i Note
Insert the bolt so that groove (2) is in line with
tapped bores (1).
106. Knock the bolt in with a plastic hammer.

Fig. 73
107. Fasten the locking plate (Fig. 74).

Fig. 74

246 BOMAG 008 911 17

Assembling the front axle 9.3
Adjusting the toe-in

i Note
Toe-in occurs when the front ends of the wheels
are closer together than the rear ends. With toe-
in the right hand wheel steers slightly to the left,
while the left hand wheel steers slightly to the
right (Fig. 75).

Fig. 75
108. Align both steering arms to each other (Fig. 76).

Fig. 76
109. Apply both tie rod seals 4 (Fig. 77).
110. Slide both tie rods (1) with seals (4) into the fork
heads (2) of the steering cylinder (5).
111. Insert a special tool (3, bolt with undersize) into
the fork heads of the cylinder.

Fig. 77
112. Measure the distance of the outer wheel discs at
the front (Fig. 78).
113. Measure the distance of the outer wheel discs at
the rear.

i Note
Nominal value for toe-in: 2 +/- 1 mm.

Fig. 78

008 911 17 BOMAG 247

9.3 Assembling the front axle

i Note
The toe-in is adjusted by turning the fork head (2)
accordingly. Adjust the left and right hand fork
heads as uniformly as possible.
114. Remove the special tool 3 (Fig. 79).
115. Pull the tie rods (1) out of the fork heads (2).
116. Turn the fork heads (2) into or out of the cylinder
(5).

i Note
Turning the for heads out reduces the toe-in.
Fig. 79
117. Slide both tie rods (1) with seals (4) into the fork
heads (2) of the steering cylinder (5) again.
118. Assemble the special tool (3) again.
119. Repeat the measurement (Fig. 80).

i Note
Repeat work steps (Fig. 79) and (Fig. 80), until
the toe-in is correctly adjusted.

Fig. 80
Assembling the steering bolts
120. Remove the special tool (Fig. 81).

Fig. 81

248 BOMAG 008 911 17

Assembling the front axle 9.3
i Note
Perform work steps (Fig. 82) to (Fig. 84) on the
left and right hand fork heads.
121. Spray the bolts with sliding lacquer OKS 571 to
ease assembly.

i Note
Insert the bolt so that groove (2) is in line with
tapped bores (1).
122. Drive the bolts (2) in with a plastic hammer.

Fig. 82
123. Fasten the locking plate 2 (Fig. 83).
124. Push the screws 1 through the fork head and turn
on the nuts.

Fig. 83
125. Tighten the fork head (Fig. 84).

Fig. 84
Turning the front axle around
126. Attach the lifting tackle to the front axle (Fig. 85).

Fig. 85

008 911 17 BOMAG 249

9.3 Assembling the front axle

127. Lay the front axle safely in front of the machine

(Fig. 86).
128. Assemble the front axle.

Fig. 86

250 BOMAG 008 911 17

10 Service Training

008 911 17 BOMAG 251

252 BOMAG 008 911 17
10.1 Service Training Hydraulics

008 911 17 BOMAG 253

10.1 Service Training Hydraulics

254 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Hydraulics and Pneumatics

Rubber Tire Rollers

BW 24 RH
BW 27 RH

12/2006

008 911 17 BOMAG 255

10.1 Service Training Hydraulics

Service Training
Table of contents

Hydraulic system D
Travel drive D
Travel pump E
Travel motors F
Travel gear G

Brake system H

Pneumatic system J
Compressed air brake J
Tire inflation system J

Steering K

BW 24/27 RH

256 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
General
The rubber tire rollers of series BW 24/27 RH are high performance machines for the extremely difficult
use in asphalt compaction and earth work.
Due to their kneading and fulling effect these rubber tire rollers achieve an excellent surface sealing
effect.

The machines of this series are powered by engine oil cooled Deutz diesel engines of series BF4M 2012
and 2012 C.

The new rubber tired rollers from BOMAG have modern HYDROSTATIC DRIVES.
The hydrostatic drive works with a travel pump (DA-controlled) and two compact travel systems
consisting of bent axle variable displacement motors and travel gear units on the rear axle. Apart from
extreme inclinations or declines these rubber tire rollers can comfortably work in one speed range.

The rubber tire rollers are designed with three travel speed ranges.

The new rubber tire rollers from BOMAG are designed with a HYDRO-DYNAMIC SERVICE BRAKE
with so-called wet discs. The new brake system is maintenance free and offers higher safety reserves,
than conventional drum brakes.. The brake is pneumatically supported.

By standard the rubber tire rollers are equipped with pressure sprinkling system and lighting according
to STVZO.

The pneumatic system is supplied by a diesel engine driven compressor.

The air pressure in the pneumatic system supports the brake system and is also used for the tire inflation
system.

BW 24/27 RH -A3-

008 911 17 BOMAG 257

10.1 Service Training Hydraulics

Service Training
Hydraulic system
Travel system and steering on the new rubber tire rollers from BOMAG work with hydraulically drives.

This enables low loss transmission of engine output power to all drives.

The pumps for the respective drives are driven by the engine and convert the mechanical energy
provided by the engine into hydraulic energy.

Since the medium oil is used for this power transfer the appearing power losses are only minimal.

Hydraulic oil filters protect the hydraulic circuits against contamination.

Temperature control valve and and hydraulic oil cooler ensure optimal temperature in the hydraulic
system.

Safety elements in pumps and hydraulic control elements protect the hydraulic system and the engine
against overloads and other damage.

Special features of the new BOMAG rubber tire rollers are:

the hydrostatic travel drive and
the hydrodynamic service brake

BW 24/27 RH -D1-

258 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Travel system
The new rubber tire rollers all have hydrostatic travel drives.

The speed dependent drive regulation (DA) is a purely hydro-mechanical regulation for travel drives in
closed hydraulic systems.
The travel drive regulation enables travel comfort similar to motor vehicles with automatic gearbox: The
more the throttle pedal is kicked down, the bigger the swashing angle and the flow volume from the
travel pump and the higher the travel speed.
With any occurring overload the maximum load control will reduce the flow volume from the pump to a
value that prevents the diesel engine from being extremely overloaded.
The DA-control also makes sure that the DA-pump will adapt the power take-off to the power provided
by the diesel engine.

The travel drive is a closed hydraulic circuit. One talks about a closed hydraulic system, when the
hydraulic oil flows from the consumer directly back to the pump. The closed circuit consists of a high
and a low pressure side, depending on the load direction (take-off moment on the consumer).
The fluid remains in the closed circuit, only the leakages in pump and motor must be replenished.

The hydrostatic travel system primarily consists of:

a travel pump (DA-control pump)

two travel motors (bent axle variable displacement motors)

and two travel gears with brakes (reduction gear)

BW 24/27 RH -D2-

008 911 17 BOMAG 259

10.1 Service Training Hydraulics

Service Training
Travel drive schematics

Brake pedal Travel direction

Throttle pedal Travel speed range selector switch
switch

back forw.

Signal
Inching valve forward

Engine Travel pump 2 travel motors

Diesel engine DA-pump parallel 2 travel gears
with brake

BW 24/27 RH -D3-

260 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Operator’s stand

1 1

3 2

3
2

1) Travel direction switch (electrically forward-reverse)

2) Throttle pedal and travel speed via control cable

3) Brake pedal via compressed air

BW 24/27 RH -D4-

008 911 17 BOMAG 261

10.1 Service Training Hydraulics

Service Training
Travel pump

The DA-control uses a variable displacement pump which is controlled by means of a speed dependent
hydraulic control. This pump is referred to as DA-pump.
The DA-pump is operated hydraulically in dependence on the rotational speed. For this purpose the
system is equipped with a charge pump and a DA-control valve to generate the pilot pressure in
dependence on the speed of the diesel engine.

4
1

4 5
8

Fig. 1 Hydraulic diagram Bosch/Rexroth travel pump A4VG105DA

1 Charge pump
2 4/3-way valve (control unit for travel direction)
3 Inching valve
4 High pressure relief valve with boost check valve
5 Charge pressure relief valve
6 DA-control valve
7 Charge pressure filter
8 Pressure override

BW 24/27 RH -E1-

262 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
9 Travel pump

The pump flow is determined by the displacement and the actual rotary speed of the pump. It is
proportional to the drive speed and the displacement. Due to the possibility of an infinite adjustment of
the swash plate the pump flow rate and therefore the travel speed can also be infinitely changed within
the pre-selected travel speed range.

The pump is equipped with all control and safety elements needed for operation in a closed hydraulic
circuit.

Inching valve
/ control

Fig. 2 Side view of pump

BW 24/27 RH -E2-

008 911 17 BOMAG 263

10.1 Service Training Hydraulics

Service Training

Pressure override

DA-control valve / DA-control cartridge

High pressure relief valves

Charge pressure relief valve

Fig. 3 Connecting plate

Inching valve
with inching valve

Fig. 4 Control

BW 24/27 RH -E3-

264 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Pump control

Fig. 5 Travel pump control

1 DA-control cartridge 5 4/3-way valve (travel direction)

2 Charge pressure relief valve 6 Discharge orifice
3 Pressure override 7 Supply orifice (8mm)
4 Control 8 Charge pump
A High pressure port B High pressure port

BW 24/27 RH -E4-

008 911 17 BOMAG 265

10.1 Service Training Hydraulics

Service Training

Fig. 6 DA-control valve

1 Charge pump 12 Circlip

2 Circlip 13 Threaded pin
3 Control tube 14 Control screw
4 Stepped piston 15 Locking nut
5 Ring 16 Charge pressure relief valve
6 Circlip 17 Housing channel
7 Nut 18 Pilot pressure channel
8 Washer 19 Control edge
9 Pressure spring 20 Control edge
10 O-ring 21 Measuring orifice (8mm)
11 Spring plate 22 Bore

BW 24/27 RH -E5-

266 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Pilot pressure is used to control the pump is infinitely from neutral position to the desired direction of oil
flow and to the desired displacement.

The necessary pilot pressure for the pump is supplied by the charge pump (auxiliary pump) and flows
through the DA-control valve cartridge to the control.

At an engine speed between low idle speed and control start (approx. 1100 rpm), the pump flow rate
of the charge pump is so low, that almost all of the oil can pass through the inside of the control valve
and flow to the charge ports in the travel pump. The static pressure in front of the orifice (ø 8 mm) in the
control valve cartridge is not yet high enough to move the inside spool against the spring.

When accelerating the engine to a speed higher than the control start (1100 rpm or HD=50bar), the
flow rate from the charge pump will increase accordingly. This higher oil flow rate causes a higher
pressure drop across the orifice and pushes the inside spool against the spring. This opens four bores,
which are arranged in a ring around the circumference of the spool and provides a connection to the
proportional 4/3-way solenoid valve on the pump control. The opening cross-section of these bores
around the circumference depends on the pressure drop across the inlet orifice of the control valve
cartridge and therefore on the speed of the diesel engine. It enlarges with increasing engine speed or
with increasing pump flow rate respectively.

At the control end these bores are fully open.

Since the bores have a considerable restricting effect, even when they are fully open, the pilot pressure
may be a lot lower than the charge pressure.

At control start (bores start to open) the pilot pressure is approx. 6 bar.

If the solenoid valve has been switched to a certain travel direction, the available pilot pressure is high
enough to actuate the pump slowly out of neutral position. The pump starts to deliver hydraulic oil to the
corresponding travel motors.

Raising the diesel engine speed also increases the pump flow rate of the charge pump, opens the bores
(orifice) around the circumference of the control valve spool and the pilot pressure increases gradually.
The pump changes to a higher displacement and delivers a higher amount of oil per unit of time to the
motors. The machine drives faster.

The rest of the oil flow passes through the DA-control valve cartridge to the charge pressure relief valves
in the travel pump.

Control start of the travel pump should be at an engine speed of 1100 rpm and a high pressure
(travel pump) of approx. 50 bar!

BW 24/27 RH -E6-

008 911 17 BOMAG 267

10.1 Service Training Hydraulics

Service Training

Fig. 7 Valve arrangement

1 DA-control cartridge 7 Supply orifice (8mm)

2 Charge pressure relief valve 8 Charge pump
3 High pressure relief valve 9 Travel pump
4 Pressure override A High pressure port
5 Travel direction valve B High pressure port
6 High pressure relief valve

The charge circuit is needed for the compensation of leaks and flushing quantities in a closed hydraulic
circuit and to accommodate controlling of the pump.

BW 24/27 RH -E7-

268 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training

Pressure override
in function

Fig. 8 Pressure override

1 Valve piston 8 Pressure spring

2 Bore 9 Adjustment screw
3 Valve seat 10 Pilot pressure channel
4 Piston 11 Housing channel
5 Valve bush 12 High pressure circuit
6 Control piston 13 High pressure circuit
7 Spring cup 14 Valve seat

BW 24/27 RH -E8-

008 911 17 BOMAG 269

10.1 Service Training Hydraulics

Service Training
High pressure relief valves with bypass to tow the machine

BW 24/27 RH -E9-

270 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Inching valve

The inching valve is attached to the travel pump between control unit and pump housing.
The inching valve works in connection with the service brake.
The inching function supports the service brake.
In case of soft braking (up to 20 bar braking pressure) only the hydrostatic drive will brake using the
inching function.
When applying high braking pressure, both the hydraulic system and the service brake will work
simultaneously. The pump control unit is in this case directly linked with the service brake circuit.
Increasing pressure in the brake system causes a reduction in pilot pressure and thus a reduction of the
travel pump swashing angle.

Compressed air Travel

direction Travel speed range selecto
Throttle (pneumatic)
pedal Brake pedal

Brake
cylinder
to the
Brake

inching valve

BW 24/27 RH - E 10 -

008 911 17 BOMAG 271

10.1 Service Training Hydraulics

Service Training
Components and test ports

2
3

Travel pump

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

diagram
1 Travel pump 9
2 High pressure port, forward 9 max. 455 bar
3 High pressure port, reverse 9 max. 455 bar
4 Pressure test port - charge pressure 9 25 bar
5 Suction connection for internal 9 Q=25.1ccm
charge pump

BW 24/27 RH - E 11 -

272 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Travel pump

1 4
3
2

5 6 7

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

diagram
1 Pressure test port, travel pressure 9 max. 455 bar
reverse
2 Charge pressure relief valve 9 25 bar
3 DA-control valve 9
4 Pressure test port, travel pressure 9 max. 455 bar
forward
5 Pressure reducing valve 15 Setting 21 bar
6 Brake valve Y 04, sheet 003 14 12 V brake open
7 Brake releasing valve 12

BW 24/27 RH - E 12 -

008 911 17 BOMAG 273

10.1 Service Training Hydraulics

Service Training
Travel pump control

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

diagram
1 Travel direction solenoid, reverse Y17, sheet 009 9 switched 12 V
2 Travel direction solenoid, reverse Y16, sheet 009 9 switched 12 V
3 Pressure override 9 Setting 430 bar

BW 24/27 RH - E 13 -

274 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
inching valve

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

diagram
1 inching valve 9
2 Ventilation 9
3 Connection - inching pressure from 9 0 - 81 bar
brake cylinder

BW 24/27 RH - E 14 -

008 911 17 BOMAG 275

10.1 Service Training Hydraulics

Service Training
Filter

3 1

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

diagram
1 charge oil filter 7
2 Pressure differential switch B21, sheet 004 7 Switching point at
a pressure
differential of 3.5
bar
3 Return flow filter from brake housing 19
cross-flushing

BW 24/27 RH - E 15 -

276 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Travel motors

The rubber tire rollers are equipped with two drive axles which drive one wheel pair each. The drive
axles consists of two travel motors and two travel gears with brake and are located in the rear area of
the machine.
The motors are Bosch/Rexroth bent axle motors with variable displacement A6VM 107 HA2R.
With a solenoid valve the motors can be electrically controlled from minimum displacement Qmin (high
speed and low torque) to maximum displacement Qmax (low speed and high torque). Whereby the
motor automatically changes from Qmin towards Qmax when an operating pressure (high pressure) of
approx. 215 bar is reached. The motors can thus be operated in different travel speed ranges, as
desired.
The machines are designed with 3 speed ranges.

1. Travel speed range

Both motors are switched and remain in Qmax position (low speed and high torque).

2. Travel speed range

In this cased only one motor is switched to Qmax. In this case only the right hand motor in travel
direction will be at Qmax.

3. Travel speed range

Both motors are not switched and remain in Qmin position (high speed and low torque), until an
operating pressure (high pressure in travel circuit) of approx..215 bar is reached. Then the motors swing
automatically towards Qmax.

The pressure range and the speed with which the motors swing from Qmin to Qmax is determined by
the internal pressure increase spring.

The control start of the motor is the point at which the motor starts to swing from Qmin to Qmax.

The control end of the motor is reached when the motor has reached Qmax position.

In zero position or without pressure the motor is

always in Vgmin or Qmin position

Important motor adjustment data

The control start of the travel motors is 125 bar.
The value of the pressure increase spring is 100 bar.
The control end of the motors is approx. 315 bar
All pressures are operating pressures (high pressure), measured in the travel circuit and related to a
charge pressure of 25 bar.

These values are factory default values and should not be changed.

BW 24/27 RH -F1-

008 911 17 BOMAG 277

10.1 Service Training Hydraulics

Service Training
Cross-section of bent axle motor A6VM HA2R with flushing valve

Port M
Pilot pressure Flushing valve

Qmin
Stop screw

Drive shaft

Valve plate

Piston

Qmax
Stop screw

Port G
High pressure
H Control start
Setscrew
Qmax
solenoid
Travel direction
solenoid

BW 24/27 RH -F2-

278 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Variable displacement motor A6VM 107 HA2R

Working principle:

High pressure oil is fed through the inlet port. The pistons perform an axial stroke movement, which is
then transferred to the drive shaft by the piston joints, whereby the axial movement is converted to a
rotary movement of the shaft. The cylinder is driven by the pistons. The out flowing hydraulic oil flows
back to the pump.
When the volume flow rises to high pressure, the axial piston movement will become faster. This
increases also the output speed.
In a variable displacement motor this angle can be infinitely adjusted within certain limits. The change
in swashing angle causes a difference in stroke length and thus a change in displacement. The output
speed is proportional to the supplied fluid volume and the swashing angle. The available motor torque
increases with the pressure drop between high and low pressure side.
The swashing angle is hydraulically changed by the control piston. The hydraulic section with the valve
plate is thereby displaced and hydraulically held in position.

An increasing angle results in higher displacement and torque, but in a lower output speed. Reducing
the swashing angle reduces also displacement and torque, but increases the output speed. In
combination with the DA-control in the pump the variable displacement motor A6VM can be used. This
motor can be regulated in various ways.

In combination with DA-pumps the high pressure dependent control HA is of relevance for the variable
displacement motor.

In speed range 3 the displacement changes in dependence on the operating pressure (high pressure).
The control unit measures the internal operating pressure at port A or B on the hydraulic motor (no pilot
line required) and swashes from minimum displacement (Vg min to maximum displacement Vg max
when the nominal pressure (pressure increase spring) set on the controller is reached.
With the high pressure dependent control the control start takes place at Vg min (min. torque, max.
speed) and the control end at Vg max. (max. torque, min. speed).

Vgmin or Qmin is 36.5 qcm per revolution.

Vgmax or Qmax is 107 qcm per revolution.

In zero position or without pressure the motor always

is in position Vgmin or Qmin

BW 24/27 RH -F3-

008 911 17 BOMAG 279

10.1 Service Training Hydraulics

Service Training
Travel direction solenoid valve

The travel direction valve ensures that, when changing the high pressure side
(e.g. travel drive when driving downhill), the pre-selected pressure side of the motor will always regulate
the swashing angle and an undesired swashing of the variable displacement motor (travel motor) to
higher displacement is avoided.
On the rubber tire rollers the travel direction valve is always energized (12V) in forward travel.

Qmax solenoid valve (1st speed range)

The high pressure dependent control of the travel motor is overridden by an electrical signal applied to
the switching solenoid (Qmax solenoid). This causes the variable displacement motor (travel motor) to
swash to maximum swashing angle (Qmax) and speed range 1 is activated.

Flushing valve

The flushing and flushing pressure relief valve has the function of dissipating heat from the closed circuit
and flushing the housing.
Hot pressure fluid is discharged from the corresponding low pressure side into the motor housing. This
fluid is returned to the tank, together with the leak oil.
Any pressure fluid removed from the closed circuit must be replaced by cool oil from the charge pump.
The valve is flanged to the variable displacement motor.
Various flushing quantities can be adjusted by means of orifices.

The flushing pressure relief valve is a safety valve. It has the function of limiting the flushing pressure,
so that the charge pressure is maintained.

BW 24/27 RH -F4-

280 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Description and testing the motor control start

Control start from Vgmin to Vgmax

BW 24/27 RH -F5-

008 911 17 BOMAG 281

10.1 Service Training Hydraulics

Service Training
Hydraulic diagram travel motor driving to the right

1 2

Qmax

Qmin 4

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

diagram
11 Travel motor right 11
1 Travel direction valve Y 164, sheet 009 11 switched 12 V
Y 163 left motor
2 Qmax valve (1st speed range) Y 130, sheet 009 11 switched 12 V
Y 03 left motor
3 Flushing valve with flushing 11 16 bar
limitation valve
4 Control 11 Zero position
Qmin

BW 24/27 RH -F6-

282 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Components and test ports

5
1 4

Travel motor left

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

diagram
1 Travel motor left 10
2 High pressure ports forw./rev. 10 max. 455 bar
3 Travel direction solenoid valve Y 163, sheet 009 10 switched 12 V
(Y164 right motor)
4 Speed range solenoid, Qmax. Y 03, sheet 009 10 switched 12 V
(Y130 right motor)
5 Flushing valve 10
6 Pressure test port M1, pilot pressure 10 approx. 1/2 high
pressure

BW 24/27 RH -F7-

008 911 17 BOMAG 283

10.1 Service Training Hydraulics

Service Training
Travel motor left

2
3
1
4
5

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

diagram
1 Travel motor left 10
2 High pressure ports forw./rev. 10 max. 455 bar
3 Travel direction solenoid valve Y 163, sheet 009 10 switched 12 V
(Y164 right motor)
4 Speed range solenoid, Qmax. Y 03, sheet 009 10 switched 12 V
(Y130 right motor)
5 Leak oil port 10

BW 24/27 RH -F8-

284 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Travel gear with brake

The travel gear in the rubber tire roller is a reduction gear from Bonfiglioli with a transmission ratio of
i=32,2.

The gearbox inlet carries the travel motor and the hydro-dynamic multi-disc brake.
This brake is statically released and applied via the brake valve.
Another brake port serves the purpose of hydro-dynamic braking. This brake pressure is applied by a
brake cylinder and closes the brake with the brake valve opening pressure of 21 bar.

The brake housing is cross-flushed in order to avoid premature wear of brake discs.
These two ports are also located on the brake housing.

The two rubber wheels are mounted to the power take-off of the gearbox.

BW 24/27 RH -G1-

008 911 17 BOMAG 285

10.1 Service Training Hydraulics

Service Training
Travel gear with brake

T1

T2
P1

Hydraulic diagram of travel gear

P1) Brake releasing pressure from brake valve

P2) Brake pressure from brake cylinder
T1) Cross-flushing brake housing inlet
T2) Cross-flushing of brake housing outlet

BW 24/27 RH -G2-

286 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Gearbox inlet

Gearbox outlet

BW 24/27 RH -G3-

008 911 17 BOMAG 287

10.1 Service Training Hydraulics

Service Training
Travel gear unit with travel motor

BW 24/27 RH -G4-

288 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training

BW 24/27 RH -G5-

008 911 17 BOMAG 289

10.1 Service Training Hydraulics

Service Training
Brake system
The new rubber tire rollers are equipped with two brake systems.

A conventional static multi-disc brake, also referred to as parking brake, which is released via a brake
valve with charge pressure (pressure reducing valve 21 bar) and is closed when no pressure is
available.

The second brake is the hydro-dynamic multi-disc brake, which is pneumatically operates a
compressed air brake pedal with a brake cylinder which then acts on the brake piston with boosted
hydraulic pressure (1:10) and closes the brake.
At a brake pressure of up to 20 bar an inching valve only reduces the swashing angle in the travel pump.
If the brake pressure increases over 21 bar, the brake will close immediately, even if it is opened by
charge pressure (pressure reducing valve 21 bar).
The brake pressure from the brake valve can be up to 80 bar.

BW 24/27 RH -H1-

290 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
The brake housing is cross-flushed to avoid premature wear of the brake discs. Cross-flushing is
accomplished by the steering pump and it is described in detail in the corresponding chapter.

from / to Flushing of brake housing

Brake valve

Hydraulic diagram

Brake
housing

Oil supply
from
Hydraulic oil tank

from brake pedal

Brake cylinder

Return flow to filter and tank

BW 24/27 RH -H2-

008 911 17 BOMAG 291

10.1 Service Training Hydraulics

Service Training

BW 24/27 RH -H3-

292 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training

BW 24/27 RH -H4-

008 911 17 BOMAG 293

10.1 Service Training Hydraulics

Service Training
Cross-section of brake housing

BW 24/27 RH -H5-

294 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Components and test ports

Compressed air port

from brake pedal

The hydraulic brake pressure is 10 times higher than the pneumatic pilot pressure

i.e. the pneumatic pilot pressure = max. 8 bar, hydraulic brake pressure = max. 80 bar

BW 24/27 RH -H6-

008 911 17 BOMAG 295

10.1 Service Training Hydraulics

Service Training

BW 24/27 RH -H7-

296 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training

BW 24/27 RH -H8-

008 911 17 BOMAG 297

10.1 Service Training Hydraulics

Service Training

BW 24/27 RH -H9-

298 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training

BW 24/27 RH - H 10 -

008 911 17 BOMAG 299

10.1 Service Training Hydraulics

Service Training
Ventilation

Important:

The brake system must be thoroughly bled after any work in the hydraulic system of the
machine.

Ventilation
Brake cylinder

Ventilation
inching valve

BW 24/27 RH - H 11 -

300 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training

Ventilation
Brake housing

BW 24/27 RH - H 12 -

008 911 17 BOMAG 301

10.1 Service Training Hydraulics

Service Training
Pneumatic system
The rubber tire rollers are equipped with a compressed air system.
This compressed air system serves two on-board systems.

1. The compressed air brake system

2. The tire inflation system (option)

The compressor is directly mounted to the engine and takes in air through the air filter.

After the compressor this hot pressurized air is supplied through a cooling spiral to the air drier,
regeneration tank and air tank..

The system pressure is 8.1 bar

At an air pressure under 5.7 bar the pressure switch (B12, sheet 4, electric wiring diagram) will
switch, the control light (brake system) will light up and the warning buzzer will sound.

Pressure to the brake system always has priority.

At a system pressure lower than 6.5 bar no air pressure will be available for the tire inflation system.

Each of the eight rubber wheels is fitted with a pressure retaining valve. This valve is set to a residual
pressure of 2 bar and thus prevents exhaustive emptying of the tires.

BW 24/27 RH -J1-

302 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training

BW 24/27 RH -J2-

008 911 17 BOMAG 303

10.1 Service Training Hydraulics

Service Training

BW 24/27 RH -J3-

304 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training

BW 24/27 RH -J4-

008 911 17 BOMAG 305

10.1 Service Training Hydraulics

Service Training

BW 24/27 RH -J5-

306 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Components and test ports

Compressor and regeneration tank

1 5 4

Pos. Designation Pos. in wiring diagram Pos. in pneumatic Measuring values

diagram
1 Compressor 1
2 Air intake 1
3 Pressure line 1
4 Cooler - cooling spiral 4
5 Regeneration tank 19

BW 24/27 RH -J6-

008 911 17 BOMAG 307

10.1 Service Training Hydraulics

Service Training
Air drier

3 2

Pos. Designation Pos. in wiring diagram Pos. in pneumatic Measuring values

diagram
1 Air drier 5
2 DBV pneumatic system 5 Setting 8,1 bar
3 Input 5
4 output 5

BW 24/27 RH -J7-

308 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Air tank

3
1

Pos. Designation Pos. in wiring diagram Pos. in pneumatic Measuring values

diagram
1 Air tank 6
2 Pressure switch B12, Page 004 7 Switching pnt. 5.7
bar
3 Output, brake pedal 6
4 Tire inflation system 6
5 Overflow valve 11 Setting 6.3 bar
6 Pressure test port, pneumatic 6 max. 8.1 bar
system

BW 24/27 RH -J8-

008 911 17 BOMAG 309

10.1 Service Training Hydraulics

Service Training
Pos. Designation Pos. in wiring diagram Pos. in pneumatic Measuring values
diagram
7 Brake cylinder input, pressure from 18 max. 8.1 bar
brake pedal

BW 24/27 RH -J9-

310 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Brake pedal

Pos. Designation Pos. in wiring diagram Pos. in pneumatic Measuring values

diagram
1 Brake pedal 8 and 9
2 Compressed air inlet 8 and 9
3 Output to brake cylinder 8 and 9

BW 24/27 RH - J 10 -

008 911 17 BOMAG 311

10.1 Service Training Hydraulics

Service Training
Tire inflation system

Air-ON Air-OFF

BW 24/27 RH - J 11 -

312 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Tire pressure retaining valve

1
2

Pos. Designation Pos. in wiring diagram Pos. in pneumatic Measuring values

diagram
1 Pressure retaining valve 16 Setting 2 bar
2 Rotary joint 17

BW 24/27 RH - J 12 -

008 911 17 BOMAG 313

10.1 Service Training Hydraulics

Service Training
Steering
The new rubber tire rollers from BOMAG are equipped with a hydraulically operated steering system.

30

30

Hydraulic diagram steering system

1 Steering/flushing pump 8 Safety check valve
3 Steering valve 19 Return flow filter with pressure switch B22
5 Steering cylinder 20 Temperature switch B148
6 Priority valve 30 Gearbox brake housing right and left

BW 24/27 RH -K1-

314 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
The steering system consists mainly of:

• the steering pump,

• the priority valve,

• the steering valve,

• the steering cylinder and

• the pressure resistant connecting hoses

Since the steering pump besides its function of supplying the steering system also serves the purpose
of cross-flushing the brake, the system is equipped with a priority valve. The priority valve ensures that
the steering will always be prioritized under any condition. The priority valve is triggered by the steering
valve through the LS-line. This valve restricts the oil flow to the brake housing whenever oil is needed
for the steering. The gear pump delivers the hydraulic oil out of the hydraulic oil tank to the priority valve.
When the steering is not operated, the complete oil flow will flow to both brake housings for cross-
flushing. After the brake housings the oil flows are united and passed through a filter back into the tank.
This cross-flushing is protected by a 6 bar check valve.

When operating the steering the steering valve will generate a load signal "LS", informing the priority
valve that more oil should be directed to the steering.

When turning the steering wheel the distributor valve guides the oil flow to the corresponding steering
cylinder sides.

The steering cylinder displaces the front steering bolster (steering axle) of the machine.

The steering valve contains also a pressure relief valve. This valve limits the steering pressure to 170
bar.

Suddenly occurring pressure peaks, which may be caused by e.g. external influences like driving
against a curb stone, are compensated by two shock valves (setting 235 bar), which are integrated in
the steering valve.

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

BW 24/27 RH -K2-

008 911 17 BOMAG 315

10.1 Service Training Hydraulics

Service Training
Steering pump

The steering/charge pump is a tandem gear pump with fixed displacement. The pump is designed with
a displacement of 16 ccm/rev. and supplies steering and brake housing.

The pump is driven by the diesel engine and draws the hydraulic oil directly out of the oil tank. The oil
then flows to the priority valve and from there to the steering valve or the brake housings.

9 9 6 1 7

3
8
2

4 5

Steering pump
1 Housing 4, 5 Bearing plates 9 Seals
2 Flange 6 Cover
3 Shaft 7, 8 Pinions

Function of the gear pump

The drive pinion of the steering pump is driven by the auxiliary drive of the engine. Drive gear and driven
gear are positioned by a bearing plate in such a way, that the teeth of both gears mesh with minimum
clearance when rotating.
The displacement chambers are formed between the tooth flanks, the inside wall of the housing and the
faces of the bearing plates. The chambers transport the hydraulic oil from the suction side to the
pressure side. This generates a vacuum in the suction line, which draws the hydraulic oil out of the tank.
These tooth chambers transport the hydraulic oil along the inside wall of the housing from the suction
side to the pressure side, from where it is pressed to the consumers. To ensure a safe function of the
pump the tooth chambers must be so tightly sealed that the hydraulic fluid can be transported from the
suction side to the pressure side without any losses.
Outer gear pumps are fitted with gap seals. This results in pressure level dependent fluid losses from
the pressure side to the suction side. An axial pressure field presses the bearing plate on the cover side
against the front face of the gears, making sure that only a very little quantity of oil will leak from the
pressure side to the suction side when the pressure increases during operation.
The pressure field is always under system pressure.

BW 24/27 RH -K3-

316 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Priority valve

Since the pressure oil from the steering pump is also needed for cross-flushing the brake housings, the
machine is fitted with a priority valve. This valve ensures that the steering will always be prioritized under
any condition. The priority valve guides the oil to the following consumers:

• to the steering valve (port CF)

• to the brake housings (port EF)

Priority valve

Distribution of the oil is determined by the switching position of the valve spool.
This position depends on the following values:

• the requirements caused by the steering load (LS-signal) arriving from the steering valve

• the load (pressure) in the steering system (max. 176 bar)

The load signal (LS) from the steering valve controls the position of the valve spool in such a way, that
the oil flow is at any time determined by the steering speed.

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

BW 24/27 RH -K4-

008 911 17 BOMAG 317

10.1 Service Training Hydraulics

Service Training
Steering valve

The steering valve consists mainly of:

• the distributor valve,

• the rating pump,

• the steering pressure relief valve and

• the shock valves.

1
2

9
3

8
6

Steering unit
1 Neutral setting springs 6 Ring gear
2 Housing 7 Gear
3 Inner spool 8 Check valve
4 Outer spool 9 Pressure relief valve
5 Universal shaft

BW 24/27 RH -K5-

318 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
When turning the steering wheel the oil flow from the pump is guided through the distributor valve to the
rating pump and from there to the respective sides of the steering cylinders.

The rating pump determines the exact oil quantity in dependence on the turning angle of the steering
wheel.

The high pressure relief valve in the steering unit limits the pressure in the steering system to 170 bar.

The steering unit is equipped with so-called shock valves. These valves are adjusted to 235 bar. They
compensate extreme pressure peaks, which can be introduced from outside, e.g. when driving over
obstacles. The system is thereby protected against overloads.

Each of these shock valves is fitted with an additional anti-cavitation valve. These anti-cavitation valves
protect the system against cavitation which could be caused by the reaction of the shock valves.

A check valve inside the steering unit makes sure that the hydraulic oil cannot flow to the steering pump
if forces are introduced from outside. In such a case the steering cylinders would act as pumps and
press the oil back to the pump.

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

BW 24/27 RH -K6-

008 911 17 BOMAG 319

10.1 Service Training Hydraulics

Service Training
Components and test ports

4
5
1
1

3 2 2

Steering pump and return flow filter

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

diagram
1 Steering pump 16ccm 1
2 Steering pressure test port 1 max.170 + 6 bar
3 Return flow filter - flushing of brake 19
housings
4 Pressure differential switch B22, Page 004 19 Δp 3,5 bar
5 Temperature switch B148, Page 004 20 Switching point
120°C

BW 24/27 RH -K7-

320 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Steering valve

3 2
9
5
6
4 3

4 2 1
5

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

diagram
1 Steering valve 3 Pressure relief
valve setting 170
bar
2 LS-port to priority valve 3
3 L-port to steering valve 3
4 R-port to steering cylinder 3
5 Port P from priority valve 3
6 Port T to charge system 3

BW 24/27 RH -K8-

008 911 17 BOMAG 321

10.1 Service Training Hydraulics

Service Training
Priority valve

2 1

Priority valve

BW 24/27 RH -K9-

322 BOMAG 008 911 17

Service Training Hydraulics 10.1

Service Training
Check valve in hydraulic tank inlet

BW 24/27 RH K 10 -

008 911 17 BOMAG 323

10.1 Service Training Hydraulics

324 BOMAG 008 911 17

11 Air conditioning system

008 911 17 BOMAG 325

326 BOMAG 008 911 17
Physical basics 11.1
11.1 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.

008 911 17 BOMAG 327

11.1 Physical basics

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.

328 BOMAG 008 911 17

Physical basics 11.1
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

008 911 17 BOMAG 329

11.2 Refrigerant R134a

11.2 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

330 BOMAG 008 911 17

Compressor oil / refrigeration oil 11.3
liquid container has absorbed approx. 8 gr. of water, 11.3 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.

008 911 17 BOMAG 331

11.4 Working principle of the air conditioning system

11.4 Working principle of the air 11.5 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.

332 BOMAG 008 911 17

Description of components 11.6
Monitoring chain 11.6 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.

008 911 17 BOMAG 333

11.6 Description of components

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-
ant.
The quantity depends on the amount of oil that
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 When replacing a heat exchanger, e.g. evaporator
100 gr. 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.

334 BOMAG 008 911 17

Description of components 11.6
Dryer / filter / fluid container / inspection Safety valve
glass

Fig. 2

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

Opening 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.

008 911 17 BOMAG 335

11.6 Description of components

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.+

336 BOMAG 008 911 17

Description of components 11.6
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.

008 911 17 BOMAG 337

11.6 Description of components

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

338 BOMAG 008 911 17

Checking the compressor oil level 11.7
11.7 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.

008 911 17 BOMAG 339

11.8 Checking the magnetic clutch

11.8 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).

340 BOMAG 008 911 17

Inspection and maintenance work 11.9
11.9 Inspection and maintenance 11.10Checking, 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

008 911 17 BOMAG 341

11.11 Service the air conditioning

Press the compressor in direction of arrow, until the

11.11Service 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 Clean the condenser fins with compressed air or
cold water (Fig. 6).

Checking the refrigerant level

l Start the engine.

1 Optional equipment

342 BOMAG 008 911 17

Service the air conditioning 11.11

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.

008 911 17 BOMAG 343

11.11 Service the air conditioning

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.
blue = drying agent o.k.
purple = 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.

344 BOMAG 008 911 17

Drying and evacuation 11.12
11.12Drying and evacuation 11.13Emptying 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.

008 911 17 BOMAG 345

11.14 Leak test

11.14Leak 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.

346 BOMAG 008 911 17

Filling instructions 11.15
11.15Filling 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.

008 911 17 BOMAG 347

11.15 Filling instructions

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

348 BOMAG 008 911 17

Filling instructions 11.15
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.

008 911 17 BOMAG 349

11.16 Trouble shooting in refrigerant circuit, basic principles

11.16Trouble 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)

350 BOMAG 008 911 17

Trouble shooting in refrigerant circuit, basic principles 11.16
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

008 911 17 BOMAG 351

11.16 Trouble shooting in refrigerant circuit, basic principles

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"

352 BOMAG 008 911 17

Trouble shooting in refrigerant circuit, basic principles 11.16

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

008 911 17 BOMAG 353

11.17 Trouble shooting, refrigerant circuit diagram

11.17Trouble 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

354 BOMAG 008 911 17

Trouble shooting procedure 11.18
11.18Trouble 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.

008 911 17 BOMAG 355

11.18 Trouble shooting procedure

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

356 BOMAG 008 911 17

Trouble shooting procedure 11.18
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

008 911 17 BOMAG 357

11.18 Trouble shooting procedure

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

358 BOMAG 008 911 17

Trouble shooting procedure 11.18
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

008 911 17 BOMAG 359

11.18 Trouble shooting procedure

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

360 BOMAG 008 911 17

Trouble shooting procedure 11.18
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

008 911 17 BOMAG 361

11.18 Trouble shooting procedure

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

362 BOMAG 008 911 17

Trouble shooting procedure 11.18
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

008 911 17 BOMAG 363

11.18 Trouble shooting procedure

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

364 BOMAG 008 911 17

Steam table for R134a 11.19

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

008 911 17 BOMAG 365

11.19 Steam table for R134a

366 BOMAG 008 911 17

Steam table for R134a 11.19

008 911 17 BOMAG 367

11.19 Steam table for R134a

368 BOMAG 008 911 17

Steam table for R134a 11.19

008 911 17 BOMAG 369

11.19 Steam table for R134a

370 BOMAG 008 911 17

11.20Heating control / air conditioning control

008 911 17 BOMAG 371

11.20 Heating control / air conditioning control

372 BOMAG 008 911 17

Heating control / air conditioning control 11.20

008 911 17 BOMAG 373

11.20 Heating control / air conditioning control

374 BOMAG 008 911 17

Heating control / air conditioning control 11.20

008 911 17 BOMAG 375

11.20 Heating control / air conditioning control

376 BOMAG 008 911 17

12 Replacing the cab window panes

008 911 17 BOMAG 377

12.1 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

378 BOMAG 008 911 17

Special tools 12.2
12.2 Special tools
1. Locking handle for fastening element

BOMAG part-no.: 055 705 84

Fig. 1
2. Suction lifter

commercial

Fig. 2

008 911 17 BOMAG 379

12.3 Auxiliary materials

12.3 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

380 BOMAG 008 911 17

Auxiliary materials 12.3
6. Silicone sealant

BOMAG part-no.: 009 700 36

Fig. 4

008 911 17 BOMAG 381

12.4 Removing and installing the window pane

12.4 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

382 BOMAG 008 911 17

Removing and installing the window pane 12.4
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 17 BOMAG 383

12.4 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

384 BOMAG 008 911 17

Removing and installing the window pane 12.4
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 17 BOMAG 385

12.4 Removing and installing the window pane

386 BOMAG 008 911 17

13 Suppliers documentation

008 911 17 BOMAG 387

388 BOMAG 008 911 17
13.1 Travel pump A4VG 71 ... 180

008 911 17 BOMAG 389

13.1 Travel pump A4VG 71 ... 180

390 BOMAG 008 911 17

Travel pump A4VG 71 ... 180 13.1
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 92 003-02-R/03.03
Verstellpumpe A4VG 71-180 ersetzt/replaces 01.02

Variable Pump A4VG 71-180

Baureihe/Series 32

Reparaturanleitung / Repair Instructions

008 911 17 BOMAG 391

13.1 Bosch Rexroth AG | Mobile Hydraulics
2 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Hinweis / Inhalt
Notice / Contents

HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.

INHALT CONTENTS
Seite/
Page

A4VG A4VG

Schnittbild 3-4 Sectional view

Allgemeine Reparaturhinweise 5 General repair instructions
Dichtsätze und Baugruppen 6-9 Seal kits and sub assembly groups
Triebwelle abdichten 10 Sealing of the drive shaft
Hilfspumpe abdichten 11 Sealing of the boost pump
Stellkolbendeckel abdichten 12-13 Sealing of the control piston cover
Speisedruckventil abdichten 14 Sealing of the boost pressure valve
Druckbegrenzungsventil abdichten 15 Sealing of the pressure relief valve HD
Druckabschneidung abdichten 16 Sealing of the pressure cut-off valve
Ansteuergerät abdichten 17 Sealing of the control device
Ansteuergerät HW 18 Control device HW
Ansteuergeräte EP - HD 19-22 Control devices EP - HD
4/3 Wegeventil DA 23 Control device DA
Regelventil abdichten / überprüfen 24 Sealing of the regulator valve
Pumpe demontieren 25-29 Pump disassembly
Verstellung demontieren 30-31 Dismantling of the control
Zylinder demontieren 32 Dismantling of the cylinder
Überprüfungshinweise 33-34 Inspection notes
Stellkolben, Triebwerk montieren 35-37 Positioning piston, rotary group assembly
Triebwerk einbauen 38-41 Installation of the rotary group
Pumpe montieren 42-44 Assembly of the pump
Montageanweisung für Anziehdrehmomente 45-48 Assembly guidelines for tightening torques
Sicherheitsbestimmungen 49-50 Safety regulations
Einstellhinweise 51-57 Adjustment instructions

392 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.13
Schnittbild
Sectional view

HW/D

EP/D HD/D

008 911 17 BOMAG 393

13.1 Bosch Rexroth AG | Mobile Hydraulics
4 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Schnittbild
Sectional view

DA/D

394 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.15
Allgemeine Reparaturhinweise
General repair instructions

Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!

Attention!
Observe the following notices when carrying
out repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.

Fill the hydraulic units with the operating medium

before commissioning.

008 911 17 BOMAG 395

13.1 Bosch Rexroth AG | Mobile Hydraulics
6 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

Peripheral seal kit.

Triebwerk komplett.

Complete rotary group.

Stellkolben

Positioning piston

396 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.17
Stellkolben - Turcon-Glyd-Ring Dichtung
Positioning piston - Turcon-Glyd-ring seal

Deckel Stelldruck

Führungsbuchse
Stellzylinder
Turcon-Glyd-Ring
Lecköl
Pumpengehäuse

Bei den Verstellpumpen A4VG erfolgt zur Zeit die Umstellung At present the change of the control into Turcon seal is made
der Verstellung auf Turcon-Dichtungen. for A4VG.
Die Stückliste der kompletten Einheit erhält dabei eine neue The parts list of the complete unit will receive a new identification
Ident.- Nummer. number.
Typenschlüssel, Typnummer und Außenabmeßungen bleiben Type reference and outside dimensions remain unchanged
dabei unverändert. (Pumpengehäuse ändert sich nur im Bereich (pump housing will change at the area of the positioning piston.
vom Stellkolben. Stellkolben ändert sich in eine angefaste Positioning piston will change into chamfering design).
Ausführung).

Pumpengehäuse / Pump housing Pumpengehäuse / Pump housing

mit Lagerbuchse / with bush ALT / OLD mit Turcon-Dichtung / with Turcon seal NEU / NEW

* *

Die Umstellung der Verstellung auf Turcon-Dichtung ist The change of the control into Turcon seal design
im allgemeinen mit einer Funktionsverbesserung improves in general the function (DA-behaviour, lower
verbunden (DA-Verhalten, geringerer Temperatureinfluß temperature-influence on control times).
auf Stellzeiten).

Bei gleicher Düsenbestückung können sich die Stellzeiten The control times will slightly change with the same throttle
geringfügig verändern. sections. Therefore our customers have to be informed
about this change.

008 911 17 BOMAG 397

13.1 Bosch Rexroth AG | Mobile Hydraulics
8 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Baugruppen
Sub assemblies

Anschlußplatte

Valve plate

Ansteuergerät HW
Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.

Control device HW
Note:
Size 71 control device as size 40 - 56 with flat seal.

alt / old Ansteuergerät HD

Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.

Control device HD
Note:
neu / new Size 71 control device as size 40 - 56 with flat seal.

Ansteuergerät EP
Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.

alt / old Control device EP

Note:
Size 71 control device as size 40 - 56 with flat seal.

neu / new

4/3 Wegeventil DA
Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.
alt / old
Control device DA
Note:
neu / new Size 71 control device as size 40 - 56 with flat seal.

398 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.19
Baugruppen
Sub assemblies

Hilfspumpe

Boost pump

Regelventil

Control valve

HD - Ventil

High pressure valve

ND - Ventil

Low pressure valve

Druckabschneidung

Pressure cut-off

008 911 17 BOMAG 399

13.1 Bosch Rexroth AG | Mobile Hydraulics
10 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Triebwelle abdichten
Sealing of the drive shaft

Triebwelle abkleben.
Sicherungsring ausbauen.

Protecting the drive shaft.

Remove retaining ring.

Blechschraube in die mit Gummi gefüllten

Löcher eindrehen.
Mit Zange WDR herausziehen.

Screw in sheet metal screw into the holes fitted

with rubber.
Pull out shaft seal with pliers.

Wellendichtring mit Buchse auf Anschlag

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
leicht einfetten.

Press-in shaft seal with bush to stop.

Lightly grease the seal, dust lips and shaft seal ring.

400 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
11

Hilfspumpe abdichten
Sealing of the boost pump

*
*
Achtung!
* Angefaste "Seite" zum Deckel montieren.

Note!
* Mount chamfered side facing cover.

Lage kennzeichnen,
Befestigungsschrauben ausbauen.

Mark position,
remove fixing screws.

Deckel abdrücken.

Pry-off cover.

Kontrolle:
O-Ring, Nut, Lauffläche, Anschlußplatte.

Check:
O-ring, groove, gliding surface, connection plate.

008 911 17 BOMAG 401

13.1 Bosch Rexroth AG | Mobile Hydraulics
12 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Stellkolbendeckel abdichten
Sealing of the control piston cover

Achtung!
Korrekt mechanische 0-Lageneinstellung
überprüfen

Attention!
Check correct mechanical 0-position.

Lage kennzeichnen.

Mark position.

Deckel verdrehen und mit leichten

Hammerschlägen lösen.

Rotate cover and release by tapping gently

with hammer.

402 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
13

Stellkolbendeckel abdichten
Sealing of the control piston cover

Deckel kennzeichnen. Maß X festhalten, Konter-

mutter lösen, Stellschraube gegenhalten.

Mark cover. Must be fixed, loosen counter nut,

hold adjustment screw.
X

Deckel demontieren.

Remove cover.

Deckel von Stellschraube "abschrauben".

Lift off by turning the setting screw.

Kontrolle!
O-Ring (1), Nut (2), Gehäuse (3).

Check!
O-ring (1), groove (2), housing (3).

Achtung!
Korrekte mechanische Nullageneinstellung muß
nach Einbau im Gerät bzw. Prüfstand erfolgen.
(siehe Einstellhinweise Seite 54)

Attention!
Adjustment of the correct zero position to be carried
out after installation into the machine or on the test
bench.
(see adjustment instructions on page 54)

008 911 17 BOMAG 403

13.1 Bosch Rexroth AG | Mobile Hydraulics
14 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Speisedruckventil abdichten
Sealing of the boost pressure valve

Ventil komplett ausbauen.

Hinweis:
Einstellschraube nicht verändern.
Achtung!
Nach Einbau Ventileinstellung überprüfen!

Remove valve completely:

Note:
Do not change adjustment screw.
Attention!
Check valve setting after installation.

404 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
15

Druckbegrenzungsventil abdichten
Sealing of the pressure relief valve HD

Ventil komplett ausbauen.

Kontrolle: O-Ring, Gehäuse.
Wechsel der Dichtmutter - Einstellmaß (*)
festhalten.
Achtung!
Nach Einbau "Ventileinstellung" überprüfen.

Remove valve completely.

Control: O-ring, housing.
Replacement of the tightening nut, record
measure (*).
Attention!
After assembly check "valve setting".
*

008 911 17 BOMAG 405

13.1 Bosch Rexroth AG | Mobile Hydraulics
16 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Druckabschneidung abdichten
Sealing of the pressure cut-off valve

Einstellteil komplett ausschrauben.

Kontrolle: O-Ring, Gehäuse.
Wechsel der Dichtmutter - Einstellmaß (*)
festhalten.
Achtung!
Nach Einbau "Ventileinstellung" überprüfen.

Unscrew setting cartridge completely.

Control: O-ring, housing.
Replacement of the tightening nut, record
measure (*).
Attention!
After assembly check "valve setting".

406 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
17

Ansteuergerät abdichten
Sealing of the control device

DA
DA alt / old
HD
alt / old

DA
neu / new
HD
neu / new EP
alt / old

HW

EP
neu / new
NG 71 ... 125

NG 180

Ansteuergerät abbauen. Remove control device.

NG 71: Abdichtung der Ansteuergeräte wie NG 40 - 56 Size 71: Sealing of control device as size 40 - 56
mit Flachdichtung. with flat seal.
Achtung! Korrekte hydraulische Nullageneinstellung überprüfen. Attention! Check correct hydraulic 0-position.

Befestigungsschrauben demontieren.

Remove fixing screws.

Ansteuergerät abdrücken.

Pry-off the control unit.

Kontrolle
Dichtfläche (1), Flachdichtung (2), O-Ringe (3).

Check
Sealing surface (1), gasket (2), O-rings (3).

008 911 17 BOMAG 407

13.1 Bosch Rexroth AG | Mobile Hydraulics
18 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Ansteuergerät HW
Control device HW

NG 90-180
Size 90-180

Kontrolle:
O-Ringe und Dichtung.

Check:
O-rings, gasket.

408 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
19

Ansteuergeräte EP - HD
EP - HD Control devices

Ansteuergerät HD - EP alt (NG 90 - 180)

HD - EP (Size 90 - 180) control unit old

HD alt / old

EP alt / old HD alt / old

EP alt / old

Neues Ansteuergerät HD - EP (NG 71)

New HD - EP (Size 71) control unit alt / old

131,0 mm
neu / new

77,4 mm
202,0 mm

alt / old
214,4 mm

neu / new

008 911 17 BOMAG 409

13.1 Bosch Rexroth AG | Mobile Hydraulics
20 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Ansteuergeräte EP - HD
EP - HD Control devices

Ansteuergerät HD neu (NG 90 - 180)

HD - control unit new (Size 90 - 180)

Ansteuergerät EP neu (NG 90 - 180)

EP - control unit new (Size 90 - 180)

410 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
21

Ansteuergeräte EP - HD
EP - HD Control devices

* Markierung Montageposition HD *
* Marking the assembly position HD
*

* *

* Markierung
Montageposition HD * Assembly position marker HD

Wird von EP- auf HD-Ausführung umgebaut - Is converted from EP into the HD version -
Deckelposition beachten siehe Markierung take note of the cover position, see marker

Leckölkanal offen wird geschlossen. The open leakage port is plugged

Zugfeder tauschen! Exchange the tension spring!

008 911 17 BOMAG 411

13.1 Bosch Rexroth AG | Mobile Hydraulics
22 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Ansteuergeräte EP - HD
EP - HD Control devices

Markierung Montageposition EP Die neuen Proportionalmagnete müssen bei der Inbe-

Assembly position marker EP triebnahme entlüftet werden. Wird die Luft nicht aus
* dem Ankerraum entfernt, kann es zum Schwingen der
Hydraulische Nullage
Ansteuerung kommen.
Hydraulic zero position
Zum Entlüften ist am Ende des Magneten, im Messing-
Klemmschraube teil, ein kleiner Gewindestift M4, SW 2 vorhanden.
Clamping screw Dieser Gewindestift ist max. 2 Umdrehungen heraus-
* zudrehen und nach dem Entlüften mit 1 Nm wieder
festzuziehen.
Bei der Ausführung mit Nothand mit Federrückzug muß
zum Entlüften die Kunststoffmutter mit Gummibalg
entfernt und nach dem Entlüften mit 5+1 Nm wieder
angeschraubt werden.

Entlüftungsschraube * max. 2 Umdrehungen herausdrehen. The new proportional solenoids must be bled during
Bleed screw *. Unscrew by commissioning. If the air is not removed from the
a max. of 2 turns armature chamber oscillations at the control can occur.
* For bleeding purposes there is, on the end of the sole-
* noid, in the brass component a small set screw M4,
2A/F. This can be unscrewed by a maximum of 2 turns
and then after completion of the bleeding tightened to
a maximum of 2 Nm.
For the version with hand override and spring return
the plastic nut with rubber coating has to be removed
for bleeding. After bleeding it has to be replaced and
tightened with 5+1 Nm.

Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm

* *
Markierung
Klemmschraube 6,1 Nm Anziehmoment 5+1 Nm
Montageposition EP
Clamping screw 6,1 Nm Steckschlüssel SW 26
Assembly position
marker EP Tightening torque 5+1 Nm
26 A/F socket spanner
Hydraulische Nullage
Exzenterstift
Hydraulic
zero point
Eccentric pin
Beim Lösen der Klemmschraube
Exzenterstift - Hydraulische Nullage festhalten.

When loosening the clamping screw

Hold the eccentric pin - hydraulic zero point

412 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
23

4/3 Wegeventil DA
Control device DA

4/3 Wegeventil DA alt (NG 90 - 180)

DA - control unit old (Size 90 - 180)

Ablaufdrossel

4/3 Wegeventil DA neu (NG 90 - 180)

DA - control unit new (Size 90 - 180)

Anziehmoment 5+1 Nm
Steckschlüssel SW 26
Tightening torque 5+1 Nm
26 A/F socket spanner

Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm

008 911 17 BOMAG 413

13.1 Bosch Rexroth AG | Mobile Hydraulics
24 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Regelventil abdichten/überprüfen
Sealing of the regulator valve

Blende überprüfen.
Keine Beschädigung.

Inspect orifice.
No damage.

Gewinde abkleben.
O-Ring einsetzen.

Cover threads.
Insert O-ring.

414 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
25

Pumpe demontieren
Removing of the pump

EP, HD, HW
Verschlußschraube / Stift
Locking screw / pin

DA
Verdrillschraube /
Timing adjustment screw

Ansteuergerät abbauen.

Remove control device.

Hilfspumpe ausbauen.
Hinweis:
Einbaulage kennzeichnen.

Remove auxiliary pump.

Note:
Mark assembly position previously.

008 911 17 BOMAG 415

13.1 Bosch Rexroth AG | Mobile Hydraulics
26 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Pumpe demontieren
Removing of the pump

Anschlußplatte mit Hilfspumpe

Achtung: Drehrichtung wird immer mit Blick

auf die Triebwelle angegeben.

Port plate with auxiliary pump

Attention: Direction of rotation is always

indicated with view on the drive shaft.

z.B. Drehrichtung "Rechts"

e.g. "clockwise" direction of rotation

Drehrichtung "rechts"
2 1
Breite Seite zur Sichel "rechts".

1. O-Ring,
2. Entlastungskanal

Direction of rotation "clockwise"

2
Broadside to the crescent "clockwise"

1. O-ring
2. Discharge channel

416 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
27

Pumpe demontieren
Removing of the pump

Drehrichtung "links"

"Counterclockwise" direction of rotation

2 1 1. O-Ring,
2. Entlastungskanal

1. O-ring
2. Discharge channel

Verschleißplatte 71 - 180

Wear plate 71 - 180

008 911 17 BOMAG 417

13.1 Bosch Rexroth AG | Mobile Hydraulics
28 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Pumpe demontieren
Pump disassembly

Lage der Verdrillschraube markieren (1).

Einstellmaß festhalten.
Verdrillschraube auf Demontageposition stellen (2).

Mark the position of the indexing screw (1).

Record setting measure.
Set the indexing screw to disassembly position (2).
X

Lage der Hilfspumpe und Anschlußplatte

markieren.
Anschlußplattenbefestigung lösen.

Mark position of the connection plate.

Loosen connection plate fixation.

Anschlußplatte und Steuerplatte abheben.

Lift off port plate and control plate.

1. Zylinder nach unten drücken, nicht beschädigen.

2. Verdrillschraube herausdrehen.

1. Press the cylinder to the bottom, do not damage.

2. Remove fixing indexing screw.

Zylinder komplett mit Kolben und

Rückzugeinrichtung ausbauen.

Push off hydraulic section of rotary group.

418 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
29

Pumpe demontieren
Pump disassembly

WDR / Sicherungsring ausbauen.

Remove radial seal ring and retaining ring.

Triebwelle mit leichten Hammerschlägen austreiben.

Remove drive shaft with slide hammer strokes.

Schwenkwiege / Lager komplett ausbauen.

Remove swash plate / bearing cups.

Gelenkstift ausbauen.

Remove joint pin.

008 911 17 BOMAG 419

13.1 Bosch Rexroth AG | Mobile Hydraulics
30 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Verstellung demontieren
Dismantling of the control

Alt / Old
Neu / New

Alt / Old

Neu / New

Lage vom Deckel markieren, Maß "Nullage" fest-

halten - Mutter lösen.

Mark position of the cover, note measure of

"zero position" - loosen nut.

Deckel abdrehen.

Remove cover.

420 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
31

Verstellung demontieren
Dismantling of the control

Lage des Deckels markieren.

Befestigungsschrauben lösen, abbauen.

Mark position of the cover.

Loosen locking screw, remove cover.

Stellzylinder ausbauen.

Remove positioning ring.

Vorrichtung aufsetzen und Feder vorspannen.

Aufnahmering ausbauen.

Fit tool device and preload spring.

Remove take-off ring.

Ringe ausbauen.
Sicherungsring ausbauen.
Achtung: Teile stehen unter Federvorspannung.

Remove rings.
Remove safety ring.
Attention: Parts are under spring load.

008 911 17 BOMAG 421

13.1 Bosch Rexroth AG | Mobile Hydraulics
32 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Zylinder demontieren
Dismantling of the cylinder

Kolben mit Rückzugeinrichtung ausbauen.

Tragkugel mit Tellerfedersäule abheben.

Remove piston with retaining plate.

Remove retaining ball with spring cup assembly.

Sicherungsring ausbauen.

Remove safety ring.

Scheibe 1, 2

Disc 1, 2

1 2

422 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
33

Überprüfungshinweise
Inspection notes

Lager Lagerschalen Kontrolle!

Bearing Bearing cup Käfig-Paar (1),
Lagerschalenpaar (2).
2
Check!
Cage set (1),
Bearing cup set (2).

Kontrolle!
Lagerbahnen (1)

Check!
Bearing surfaces (1)

Kontrolle!
Gleitfläche riefenfrei.

Check!
Sliding surface free from scoring.

Kontrolle!
Rückzugeinrichtung riefenfrei.

Check!
Check that return device is free of scoring.

Kontrolle!
1 1. Verzahnung "ausgeschlagen", Passungsrost.
2 2. Laufflächen.
1 3. Lauffläche - Wellendichtring.
3
1
Check!
1. Splines for damage or fretting.
2. Running surfaces.
3. Groove cut by shaft seal.

008 911 17 BOMAG 423

13.1 Bosch Rexroth AG | Mobile Hydraulics
34 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Überprüfungshinweise
Inspection notes

Kontrolle!
Lauffläche (1) keine Kratzer, keine Metall-
einlagerungen, kein Axialspiel (2), (Kolben nur
satzweise tauschen).

Check!
Check that there are no scratches or metal deposits
on sliding surface (1), and there is no axial play (2),
(otherwise: pistons must be replaced in sets).

Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).

Check!
Cylinder bores (1), splines (2).

Kontrolle!
Zylindergleitfläche (1) riefenfrei.
Steuerplatte (2) nicht riefig.

Check!
Cylinder surface (1) free of scoring.
Control plate (2) without scoring.

Kontrolle!
Stellkolben - Schwenkwiegenverbindung
Gleitstein (1), Nut im Stellkolben (2), Stellkolben.

Check!
Positioning piston - cradle linkage
Gliding stone (1), groove at the positioning piston
(2).
Positioning piston.

424 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
35

Stellkolben, Triebwerk montieren

Positioning piston, rotary group assembly

Stellkolben montieren.
Hinweis:
Auf korrekten Sitz der geteilten Ringe "achten".

Assemble positioning piston.

Instruction:
Observe correct fit of the divided rings.

Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring

Hilfswerkzeuge / Auxiliary tools:
Montagezange / Assembly pliers: B+S x M22

Montage / Assembly A4VG

2
3

3
2
Pos. / Pos. / Pos. / Pos. /
1
Item 1 Item 2 / 3 Item 2 / 3 Item 1

Pos. / Item 1: Stangenführungsring montieren.

Install barguide ring.

Pos. / Item 3: O-Ring montieren.

Install O-ring.

008 911 17 BOMAG 425

13.1 Bosch Rexroth AG | Mobile Hydraulics
36 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Stellkolben, Triebwerk montieren

Positioning piston, rotary group assembly

Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring

Dichtring (Pos. 2) in die Montagezange einlegen.

Fit the seal ring (Item 2) into the assembly tool.

Dichtring mit Zangenschenkel nierenförmig zu-

sammendrücken. Die Verformung von Turcon-Dich-
tungen ist sorgfältig vorzunehmen, damit die Dicht-
kanten nicht beschädigt werden.

Press the seal ring into the kidney shape using the
assembly tool. The deformation of the Turcon seal
has to be done with care so as not to damage the
sealing edges.

Dichtring ins Gehäuse einführen und in der

Aufnahmenut plazieren. Dann Spannung lösen und
Montagezange herausziehen. Lage des Dicht-
ringes prüfen - eventuell mit dem Finger
egalisieren.

Position the seal ring into the housing and place it

into the groove. Release the tension and withdraw
the assembly tool.
Check the position of the seal ring if necessary
straighten using a finger.

Führungsdorn in Stellkolben einbauen.

Insert guide thorn into the positioning piston.

Führungsdorn / A4VG28 I: 277 5 017

Guide thorn: A4VG40 I: 277 5 017
A4VG56 I: 277 5 018
A4VG71 I: 277 5 019
A4VG90 I: 277 5 020
A4VG125 I: 277 5 021
A4VG180 I: 277 5 022
A4VG250 I: 277 5 023

Führungsdorn leicht einfetten.

Stellkolben mit Führungsdorn einbauen.

Grease slightly guide thorn.

Install positioning piston with guide thorn.

426 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
37

Stellkolben, Triebwerk montieren

Positioning piston, rotary group assembly

Stellkolben ins Gehäuse einsetzen.

Hinweis:
Stellkolben vor Einbau einölen.

Insert positioning piston into the housing.

Instruction:
Oil positioning piston before assembly.

Stellkolben mit Hebel (Id.Nr. 2774491) ausrichten.

* Führung für Gleitstein - Schwenkwiege

Position stroke piston with lever (Id.No. 2774491).

* Sliding stone guidance in the piston.

Lagerschalenpaar einsetzen.

Insert bearing cup set.

Lager, Draht, Gleitstein und Gelenkstift montieren.

Montagehilfe: z.B. - Klammer / Gummiringe / Fett

Assemble bearing, wire, gliding stone and

articulating pin.
Assistance: Devices e.g. - Clamp / rubber rings /
grease

Schwenkwiege komplett ins Gehäuse einsetzen.

Auf korrekten Sitz der Schwenklager im Gehäuse
"achten".
Montagehilfe ausbauen.

Insert completely swivel cradle into the housing.

Pay attention for correct seat of the swivel cradle in
the housing.
Remove auxiliary device.

008 911 17 BOMAG 427

13.1 Bosch Rexroth AG | Mobile Hydraulics
38 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Triebwerk einbauen
Installation of the rotary group

Kontrolle: Sitz der Schwenklager in der

Lagerbahn.
Schwenkwiege mittig stellen mit Meßvorrichtung
(Uhr oder Tiefenmaß)
Punkt 1 und 2 kontrollieren - gleiches Maß.

Check: Location of the swivel-bearing

in the bearing.
Centralise by using a measuring device (dial gauge
or depth measurement).
Check points 1 and 2 - they should have the same
dimension.

Gelenkstift montieren.

Fit joint pin.

428 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
39

Triebwerk einbauen
Installation of the rotary group

Haltevorrichtung montieren.
Mit Gewindestift Schwenkwiege festhalten.
Keine Gewaltanwendung.

Fit holding device.

Hold swash plate in position utilising the set screw.
Do not use force.

Haltevorrichtung "Schwenkwiege" A4V

Holding device "swivel cradle" A4V

Teil/Part 3 Teil/Part 4

∅ ∅
6, 7, 8, 9
∅ ∅
3, 4, 5

∅ ∅

Teil/Part 5
∅
2
∅
1

Pos./Item Benennung/Designation Stck./Qty.

1 Winkel/Angle 2
2 Gewindestift/Threaded pin 2
3 Scheibe/Shim 2
4 Scheibe/Shim 2
5 Scheibe/Shim 2
6 Zyl. Schraube/Cyl. screw M12 x 25 DIN 912 2
7 Zyl. Schraube/Cyl. screw M14 x 25 DIN 912 2
8 Zyl. Schraube/Cyl. screw M16 x 30 DIN 912 2
9 Zyl. Schraube/Cyl. screw M20 x 35 DIN 912 2

008 911 17 BOMAG 429

13.1 Bosch Rexroth AG | Mobile Hydraulics
40 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Triebwerk einbauen
Installation of the rotary group

Neue Montageposition!
Triebwelle mit Lager und Wellendichtring
einbauen (siehe Seite 10).

Assemble drive shaft with bearings and radial

seal rings (see at page 10).

Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note:
Oil piston and piston pad.

430 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
41

Triebwerk einbauen
Installation of the rotary group

Vorrichtung ausbauen.
Zylinder mit Kolben und Rückzugeinrichtung
einbauen.

Remove holding device.

Fit cylinder complete with pistons and retaining device.

Montagehilfe:
Mit O-Ring Kolben festhalten.

Assembly aid:
Hold the pistons by using an O-ring.

008 911 17 BOMAG 431

13.1 Bosch Rexroth AG | Mobile Hydraulics
42 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Triebwerk montieren DA
Assembly of the rotary group DA

Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung! Geräuschkerben sind drehrichtungs-
bezogen eingeschliffen.

Control plate clockwise rotation - indexed in the

R direction of rotation.
Note! Noise grooves are machined - in based on
directionof rotation.

Steuerplatte Linkslauf - in Drehrichtung verdreht.

Achtung! Geräuschkerben sind drehrichtungs-
bezogen eingeschliffen.
L
Control plate counter clockwise rotation - indexed
in the direction of rotation.
Note! Noise grooves are machined - in based on
direction of rotation.

Bei Ausführung mit Verdrillschraube:

Zylinder nach unten drücken - Verdrillschraube
auf Maß x einschrauben.
* Kerbe in Montageposition.

For the version with eccentric screw:

Push the cylinder down - screw in the eccentric
screw in the eccentric screw until dimension x is
reached.
* groove in assembled position.

Maß X mit Vorrichtung neu ermitteln.

Zylinder mit Vorrichtung nach unten drücken.
Verdrillschraube bis Anschlag einschrauben -
Maß X - Kerbe in Montageposition drehen.

Re-identify dimension X with device.

Push cylinder down with device.
Screw in eccentric screw till stop - Dimension X -
Turn groove in assembly position.

Hilfsvorrichtung: / A4VG71 I: 277 5 088

X Auxiliary device: A4VG90 I: 277 5 089
A4VG125 I: 277 5 090
A4VG180 I: 277 5 091
A4VG250 I: 277 5 092

Steuerplatte einsetzen - Rechtslauf.

Insert the control plate - clockwise rotation.

432 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
43

Triebwerk montieren DA
Assembly of the rotary group DA

Steuerplatte einsetzen - Linkslauf.

Insert the control plate - Counter- clockwise

rotation.

Anschlußplatte aufbauen.
Achtung! Federvorspannung!
Mit zwei Befestigungsschrauben überkreuz An-
schlußplatte in Gehäuseführung einsetzen -
Fertigmontage!

Assemble connection plate.

Attention! Spring preloaded!
Insert control plate into housing, guidance with two
locking screws crossing over -Finish assembly!

Verdrillschraube - Nach Markierung ausrichten.

Locking screw - Observe adjusting measure.

1. Deckel montieren.
2. Nullage nach Maß einstellen.

1. Assemble cover
2. Adjust zero position according to measure.

008 911 17 BOMAG 433

13.1 Bosch Rexroth AG | Mobile Hydraulics
44 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Triebwerk montieren EP, HD, HW

Assembly of the rotary group EP, HD, HW

Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung! Pos.1 Fixierstift
Geräuschkerben sind drehrichtungsbezogen
eingeschliffen.

Control plate clockwise rotation - indexed in the

direction of rotation.
R Pos.1
Note! Pos.1 Fixing pin
Noise grooves are machined - in based on direction
of rotation.

Steuerplatte Linkslauf - in Drehrichtung verdreht.

Achtung! Pos.1 Fixierstift
Geräuschkerben sind drehrichtungsbezogen
eingeschliffen.

Control plate counter clockwise rotation - indexed

L Pos.1
in the direction of rotation.
Note! Pos.1 Fixing pin
Noise grooves are machined - in based on direction
of rotation.

Zylinderflächen und DU-Lager einölen, neue

O-Ringe mit Fett einreiben und einsetzen.

Oil the running surfaces of the cylinder barrel and

the DU- bearing. Grease the O-rings and insert
in grooves.

Verschlußschraube

Plug

434 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
45

Triebwerk montieren EP, HD, HW

Assembly of the rotary group EP, HD, HW

Verschlußschraube einbauen.

Screw in the plug.

Anschlußplatte mit Steuerplatte lagerichtig aufset-

zen.
Hinweis:
EP, HD, HW -Steuerplatte mit Fett einsetzen.

Place port block with control plate in correct

position.
Note:
EP, HD, HW - Put control plate with grease.

1. Deckel montieren.
2. Nullage nach Maß einstellen.

1. Assemble cover
2. Adjust zero position according to measure.

008 911 17 BOMAG 435

13.1 Bosch Rexroth AG | Mobile Hydraulics
46 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Pumpe montieren
Assembly of the pump

Achtung!
Korrekte mechanische Nullageneinstellung muß nach
Einbau im Gerät bzw. Prüfstand erfolgen.

Attention!
Adjustments of the correct zero position to be carried out
after installation into the machine or on the bench test.

Hilfspumpe montieren.
Hinweis: Drehrichtung beachten. (Siehe Seite 26, 27)

Assemble auxiliary pump.

Note: Take care of direction of rotation. (See page 26, 27)

Dichtung mit zwei Befestigungschrauben zentrieren und

NG 71 Ansteuergerät einbauen.
Alle vier Schrauben mit halbem Drehmoment anziehen.

Centre the seal using two fixing screws and fit

the control unit.
Tighten all four screws to half of specified torque.

Fünfte Schraube einsetzen und mit Drehmoment = 10,4 Nm

festziehen.
Restliche vier Schrauben nach Drehmoment festziehen.

Fit the fifth screw and tighten to a torque of 10,4 Nm.

Then tighten the other four screws to there correct torque.

Ansteuergerät montieren.

Assemble control device.

436 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
47

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metrischem The values stated are valid for bolts with metric ISO threads
ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflagemaßen to DIN 13 part 13, as well as head areas to DIN 912 socked
nach DIN 912 Zylinderschrauben, head cap screws,
DIN 931 Sechskantschrauben mit Schaft bzw. DIN 931 hexagon bolt or
DIN 933 Sechskantschrauben mit Gewinde bis Kopf. DIN 933 hexagon bolts with threads up to the head.

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240

008 911 17 BOMAG 437

13.1 Bosch Rexroth AG | Mobile Hydraulics
48 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

438 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
49

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

5. Verschlußschrauben mit Innensechskant, O-Ring und 5. Plugs with internal hexagon, O-ring and UNF-,
UNF-, UN-Gewinde nach SAE J 514 (nach N 02.106) UN- threads to SAE J 514 (nach N 02.106)

G
O-Ring / O-ring seal
Dichtung / Thread

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 10
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 35
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390

6. SEAL-LOCK-Dichtmuttern (nach N 02.100) 6. SEAL-LOCK - sealing nuts (to N 02.100)

Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

008 911 17 BOMAG 439

13.1 Bosch Rexroth AG | Mobile Hydraulics
50 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A4V - Düsen / orifices

Gewinde / Anziehdremomente Nm /
Thread Tightening torques Nm
bisher / up to neu / new
M6 6,5 3
M10 28 12

440 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
51

Sicherheitsbestimmungen
Safety regulations

Allgemein General advice

● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.

Vor dem Start Before starting

● Beachten Sie die Bedienungshinweise vor dem Starten. ● Observe the operating instructions before starting.
● Prüfen Sie die Maschine auf auffällige Fehler. ● Check the machine for remarkable faults.
● Fahren Sie die Maschine nicht mit defekten Instrumenten, ● Do not operate the machine with defective instruments,
Kontrolleuchten oder Steuerorganen. warning lights or control elements.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. ● All safety devices must be in a secure position.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen ● Do not carry with you movable objects or secure them to the
Sie diese an der Maschine. machine.
● Halten Sie die Maschine von öligem und zündfähigem ● Keep oily and inflammable material away from the machine.
Material frei. ● Before entering thc driver s cabin, check if personsor
● Prüfen Sie vor dem Besteigen der Maschine, ob sich obstacles are beside or beneath the machine.
Personen oder Hindernisse neben oder unter der Maschine ● Be careful when entering the driver s cabin, use stairs and
befinden. handles.
● Vorsicht beim Besteigen der Maschine, benützen Sie ● Adjust your seat before starting.
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.

008 911 17 BOMAG 441

13.1 Bosch Rexroth AG | Mobile Hydraulics
52 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Sicherheitsbestimmungen
Safety regulations

Starten Start
● Beim Starten müssen alle Bedienhebel in “Neutralstellung” ● When starting all operating levers must be in “neutral position”.
stehen. ● Only start the machine from the driver s seat.
● Die Maschine nur vom Fahrersitz aus Starten. ● Check the indicating instruments after start to assure that all
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um functions are in order.
sicher zu gehen, daß alles ordnungsgemäß funktioniert. ● Do not leave the machine unobserved when the motor is
● Lassen Sie die Maschine nicht unbewacht, während running.
der Motor läuft. ● When starting with battery connection cables connect plus
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus with plus and minus with minus. Always connect mass cable
mit Plus und Minus mit Minus. Massekabel (Minus) immer (minus) at last and cut off at first.
zuletzt anschliesen und zuerst abtrennen.

Vorsicht Attention
● Auspuffgase sind lebensgefährlich. Bei Start in ● Exhaust gas is dangerous. Assure sufficient fresh air when
geschlossenen Räumen für ausreichende Luftzufuhr starting in closed rooms!
sorgen!

Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck- Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. Daher heavy injuries. Therefore immediately consult a doctor as
sofort einen Arzt aufsuchen, da anderenfalls schwere otherwise heavy infections can be caused.
Infektionen entstehen können! 2. When searching leakages use appropriate auxiliary devices
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr because of the danger of accidents.
geeignete Hilfsmittel verwenden! 3. Before working at the hydraulic equipment, lower pressure
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt to zero and lower working arms of the rnachine.
drucklos machen und angebaute Geräte absenken! 4. When working at the hydraulic equipment, absolutely stop
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor motor and secure tractor against rolling away (parking brake,
abstellen und Traktor gegen Wegrollen sichern shim)!
(Feststellbremse, Unterlegkeil)! 5. When connecting hydraulic cylinders and motor pay attention
5. Beim Anschließen von Hydraulikzylindern und -motoren ist to correct connection of hydraulic flexible hoses.
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu 6. In case of exchanging the ports, the tunctions are vice versa
achten! (f. ex. lift-up/lower) - danger of accidents!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen 7. Check hydraulic flexible hoses regularly and replace them in
(z.B. Heben/Senken) - Unfallgefahr! case of dammage or wear! The new hose pipes must comply
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei with the technical requirements of the machine manufacturer!
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen Orderly disposal or recycling of oil, fuel and
des Geräteherstellers entsprechen! filters!

Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!

442 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
53

Einstellhinweise - ND-Ventil (Speisedruck)

Adjustment instructions - Low pressure valve (Boost pressure)

Achtung! Attention!
Sicherheitsbestimmungen beachten! Observe safety regulations!

Hinweis: Note:
Nachjustierung nur bei Betriebstemperatur. Readjusting only at operating temperature.

Manometer an "G" anschließen. Connect pressure gauge to "G".

Achtung! Attention!
* Speisedruckeinstellung! * Boost pressure setting!
Nenndruck pH - 20 bar Nominal pressure pH - 20 bar
Höchstdruck pH - 40 bar Peak pressure pH - 40 bar
Bei Max.-Drehzahl. at max. speed.

Hinweis: Note:
Einstelldaten nach Werksauftrag. Setting data is in accordance to the works order.

* bei DA-Ausführung * with the DA version

"G"

008 911 17 BOMAG 443

13.1 Bosch Rexroth AG | Mobile Hydraulics
54 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Einstellhinweise - Mechanische "Nullage"

Adjustment instructions - Mechanical "zero position"

HW HD EP DA

Achtung!
Sicherheitsbestimmungen beachten!
Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignal
aus hydraulischer Nullage.
Manometer an MA und MB anschließen.
Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Totband der Nullage - vermitteln.

Attention!
Observe safety regulations!
Connect both control chambers with a nominal size
6 hose. Avoidance of residual signals from hydraulic
zero position.
Connect pressure gauges to MA and MB. Adjust
the zero position so that with at blocked drive both
pressure gauges indicate the same pressure valve.
Note:
Ascertain the zero position dead band.

444 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
55

Einstellhinweise - Hydraulische "Nullage"

Adjustment instructions - Hydraulic "zero position"

* *
*

HW HD EP
Achtung!
Sicherheitsbestimmungen beachten!

Attention!
Observe safety regulations!

Manometer an X1 und X2 anschließen.

* Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Excenterjustierung - nicht über ± 90° verdrehen.

Connect pressure gauges to X1 and X2.

Adjust the zero position so that with a block drive
both pressure gauges indicate the same pressure
value.
Note:
Eccentric adjusting - Do not turn more than ± 90°.

008 911 17 BOMAG 445

13.1 Bosch Rexroth AG | Mobile Hydraulics
56 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung

Adjustment instructions - HP- valves (High pressure) and pressure cut-off

Druckabschneidung Achtung!
Pressure cut-off Sicherheitsbestimmungen beachten!
HD-Ventil ohne Bypass
1. HD-Ventile sind immer 10% höher eingestellt als die
Druckabschneidung.
Bei Veränderung eines Einstellwertes immer beide
kontrollieren.
2. Nachjustierung nur bei Betriebstemperatur
Manometer an MA und MB anschließen.
Druckabschneidung: Maß X Einstellschrauben notieren!
Einstellschraube auf Block drehen.
HD-Ventile: Mit geringer Pumpenmenge über Ventile fahren.
Einstellwert kontrollieren.
(Nur kurzzeitig "Temperatur“.)
Drucklos "Einstellwert“ verändern - Kontrolle
Druckabschneidung:
Einstellschraube auf Maß (*) zurückdrehen.
Druckwert kontrollieren bzw. nachjustieren.
Achtung! Differenz von 10% HD-Ventile und
Druckabschneidung beachten!
Hinweis: Einstelldaten nach Werksauftrag.
Zum Blockieren der Druckabschneidung beim Überprüfen
der Hochdruckventile die Einstellschraube Pos. 1 mit gelöster Pos.1
Kontermutter Pos. 2 bis zum Anschlag mit Item 1
max. 2 Nm im drucklosen Zustand eindrehen!
Bei größerem Kraftaufwand als 2 Nm werden sonst Federteller
und Feder verbogen. Druckabschneidungseinstellung ist nicht Pos.2
mehr gewährleistet. Item 2

To block the pressure cut-off when testing the high pressure

valves, the adjustment screw (item 1), with the lock-nut (item 2)
loosened, has to be screwed in
with a max. torque of 2 Nm in the depressurised condition
until the end stop is reached. Attention!
Forces larger than 2 Nm bends the spring and spring plate. Observe safety regulations.
The pressure cut-off setting can then no longer be guaranteed. HP valve without bypass-function
1. HP valves are always adjusted 10% higher than the
pressure cut-off.
If one setting value is changed, always check both values.
2. Readjusting only at operating temperature.
HD- Ventile Connect pressure gauge MA and MB.
HP- valves Pressure cut-off: Note measurement X for setting screw!
Turn setting screw to the blocked position.

HP valves: Operate the valves with small pump flow over the
valves.
Check setting value. (only for a short time "temperature“).
Change zero pressure "setting value“ - then check.

Pressure cut-off:
Turn back setting screw to measurement (*).
Check pressure value and readjust if necessary.
Attention! Observe the 10% pressure difference
between the HP valves and the pressure cut-off!
Note: Setting data is in accordance with the works order.

446 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
57

Einstellhinweise - Bypassventil
Adjustment instructions - Bypass valve

A4VG 71 - 90 Pos.1
ca. 2 Umdrehungen
10 Nm

Pos.1
Anziehdrehmoment /
Tightening torque
20 Nm

150 Nm

100 Nm

Pos.1 Neu / New Alt / Old

Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit Vehicle with hydrostatic transmission and gear shift without idling
hydrostatischem Fahrantrieb und Schaltgetriebe ohne Leerlauf- setting position (free wheeling).
stellung (Freilauf).

Hydrostatischer Antrieb / Bypaß-Schaltung Hydrostatic transmission / Bypass-switching

In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. In this case the travel transmission is switched on to free
Zu diesem Zweck haben die in der Verstellpumpe integrierten wheeling.For this purpose the variable displacement pump has
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion. incorporated high pressure relief valves with bypass function.
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird The screw (item 1) is unscrewed to such an extent, that the valve
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich cartridge is released and free oil circulation is possible.
ist.

A4VG 125 - 250

Bypass-Schaltung
ca. 2 Umdrehungen
Pos.1 200 ± 10 Nm

008 911 17 BOMAG 447

13.1 Bosch Rexroth AG | Mobile Hydraulics
58 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

Achtung!
Sicherheitsbestimmungen beachten!

Überprüfung der Einstelldaten

Betriebstemperatur soll während des Über-
prüfungsvorgangs weitgehend konstant
gehalten werden.
Antriebsmotor starten, Leerlaufdrehzahl

Blockzustand
Fahrtrichtungsschalter "0“
Motordrehzahl langsam steigern bis zur max.
Motordrehzahl, dabei Meßgeräte beobachten.
Speisedruck:
Leerlaufdrehzahl
Psp = ca. 15-20 bar
max. Motordrehzahl
Psp = . . . . . . . . bar*

Blockzustand
Fahrtrichtungsschalter - vorwärts
(Straßengang und Festgebremst)

Einstelldaten Pumpe A4V/DA überprüfen

Regelbeginn
HD 40 - 50 bar
Motordrehzahl . min.1 * Psp . . . . . bar*
HD . . . . . . bar
Nachjustierung - Regelbeginnschraube
Verdrillung
Regelende
Regelbeginn HD . . . . . bar*
Motordrehzahl . . . . . min.1 * Psp . . . . . bar*
Nachjustierung - Verdrillschraube

Hinweis:
Excenterjustierung - Drehrichtung beachten

Hinweis: * Einstelldaten nach Werksauftrag!

448 BOMAG 008 911 17

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.1
59

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

Attention!
Observe safety regulations!

Check setting data.

Operating temperature should be kept largely
constant during the check procedure.
Start prime mover, idle speed.

Block position
Drive direction switch - "0“.
Slowly increase motor speed up to the max.
motor speed and thereby observe measuring
instruments.

Boost pressure:
Idle speed of prime mover
Psp = approx. 15 - 20 bar
max. motor speed
Psp = . . . . . . . . . bar*

Block position
Drive direction switch - forward
(Road gear and fully applied brake)

Check setting data pump A4VIDA

Begin of control:
Timing HD 40 - 50 bar
adjustment screw
Motor speed . . . . . rpm* Psp . . . . . . . bar*
HD . . . . . . . bar*
Begin of control Readjusting - control start screw

End of control
HD . . . . . . . . bar
Motor speed . . . . . . rpm* Psp . . . . . . . bar*
Readjusting timing adjustment screw

Note:
Eccentric adjusting - observe direction of
rotation

* Setting data according to order!

008 911 17 BOMAG 449

13.1 Travel pump A4VG 71 ... 180

Brueninghaus Hydromatik GmbH

Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
[email protected]
www.boschrexroth.com/brm

© 2003 by Brueninghaus Hydromatik © 2003 by Brueninghaus Hydromatik

GmbH, 89275 Elchingen GmbH, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Brueninghaus Hydromatik GmbH
any form or by any means, without the reproduziert oder unter Verwendung
prior written authorization of Bosch elektronischer Systeme gespeichert,
Rexroth AG. In the event of verarbeitet, vervielfältigt oder verbreitet
contravention of the above provisions, werden. Zuwiderhandlungen
the contravening party is obliged to verpflichten zu Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist zu
remembered that our products are beachten, dass unsere Produkte einem
subject to a natural process of wear natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.

Printed in Germany
RDE 92 003-02-R/03.03

450 BOMAG 008 911 17

13.2 Travel motor A6VM/VE

008 911 17 BOMAG 451

13.2 Travel motor A6VM/VE

This repair manual describes the fixed displacement motor A6VM, which is identical with the
travel motor A6VE, which differs only by a different housing design.

452 BOMAG 008 911 17

Travel motor A6VM/VE 13.2
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 91 604-01-R/03.03
Verstellmotor A6VM 28...200 ersetzt/replaces 08.01

Variable Displ. Motor A6VM 28...200

Reparaturanleitung / Repair Instructions

008 911 17 BOMAG 453

13.2 Bosch Rexroth AG | Mobile Hydraulics
2 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Typschlüssel
Typschlüssel A6V M / 6 3 W
Axialkolbenmaschine
Schrägachsenbauart, verstellbar A6V
Betriebsart
Motor (Einschubmotor A6VE siehe RD 91606) M
Nenngröße
≅ Schluckvolumen Vg max (cm3) 28 55 80 107 140 160 200
NG 28...200: Fertigung Werk Elchingen
Regel- und Verstelleinrichtung 28 55 80 107 140 160 200
Hydraulische Verstellung Steuerdruckanstieg 10 bar HD1 HD1 *
steuerdruckabhängig 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulische Zweipunktverstellung HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Elektrische Verstellung, Steuerspannung 12 V EP1 EP1 *
mit Proportionalmagnet 24 V EP2 EP2 *
Elektrische Steuerspannung 12 V EZ1 – – – EZ1 *
Zweipunktverstellung, 24 V EZ2 – – – EZ2 *
mit Schaltmagnet 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatische Verstellung, ohne Druckanstieg HA1 HA1 *
hochdruckabhängig mit Druckanstieg Δp = 100 bar HA2 HA2 *
Hydraulische Verstellung, drehzahlabhängig DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulisches Fahrtrichtungsventil DA1 DA1 *
elektrisches Fahrtrichtungsventil 12 V DA2 DA2 *
+ elektrische Vg max-Schaltung 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulisches Fahrtrichtungsventil DA4 DA4 *
elektrisches Fahrtrichtungsventil 12 V DA5 DA5 *
+ elektrische Vg max-Schaltung 24 V DA6 DA6 *
Druckregelung (nur für HD, EP) 28 55 80 107 140 160 200
ohne Druckregelung (kein Zeichen)
Druckregelung, direktgesteuert D
direktgesteuert, mit 2. Druckeinstellung E
fernsteuerbar – – – – – – – G
Übersteuerung der HA-Verstellung (nur für HA1, HA2)
ohne Übersteuerung (kein Zeichen)
hydraulische Übersteuerung T
elektrische Übersteuerung Steuerspannung 12 V U1
24 V U2
elektrische Übersteuerung Steuerspannung 12 V R1
+ elektrisches Fahrtrichtungsventil 24 V R2

* Differentialkolben Gleichgangkolben

454 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.23
Type code
Type code A6V M / 6 3 W
Axial piston unit
Bent axis design, variable displacement A6V
Mode of operation
Motor (plug-in motor A6VE see RE 91606) M
Size
≅ Displacement Vg max (cm3) 28 55 80 107 140 160 200
Sizes 28...200: production plant Elchingen
Control device 28 55 80 107 140 160 200
Hydraulic control pilot pressure increase 10 bar HD1 HD1 *
pilot pressure related 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulic two-position control HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Electrical control, control voltage 12 V EP1 EP1 *
with proportional solenoid 24 V EP2 EP2 *
Electrical control voltage 12 V EZ1 – – – EZ1 *
two-position control, 24 V EZ2 – – – EZ2 *
with switching solenoid 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatic control, without pressure increase HA1 HA1 *
high pressure related with pressure increase Δp = 100 bar HA2 HA2 *
Hydraulic control, speed related DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulic valve for travel direction DA1 DA1 *
electrical valve for travel direction 12 V DA2 DA2 *
+ electrical Vg max-switch 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulic valve for travel direction DA4 DA4 *
electrical valve for travel direction 12 V DA5 DA5 *
+ electrical Vg max-switch 24 V DA6 DA6 *
Pressure control (only for HD, EP) 28 55 80 107 140 160 200
without pressure control (no code)
Pressure control, direct control D
direct control, with 2nd pressure setting E
remote control – – – – – – – G
Override of HA-control (only for HA1, HA2)
without override (no code)
Hydraulic override T
Electrical override control voltage 12 V U1
24 V U2
Electrical override control voltage 12 V R1
+ el. valve for travel direction 24 V R2

* Differential piston Synchronizing piston

008 911 17 BOMAG 455

13.2 Travel motor A6VM/VE

456 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.25
Schnittbild
Sectional drawing

A6VM 55-107 HZ3

A B

max. min.

X T

A6VM 55-107 EZ3

A B

max. min.

A6VM 55-107 HA3

A B

max. min.

A6VM 55-107 HA3U

A B

max. min.

008 911 17 BOMAG 457

13.2 Bosch Rexroth AG | Mobile Hydraulics
6 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Schnittbild
Sectional drawing

A6VM 28-200 HD

A B

max min

X
G

M1 T(T1)

A6VM 28-200 HD
mit Spülventil / with flushing valve

A B

max min

M1 T(T1)

A6VM 28-200 HD1D

mit Druckregelventil / with pressure
control valve

A B

max min

X
G

M1 T(T1)

458 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.27
Schnittbild
Sectional drawing

A6VM 28-200 EP

A B

max min

M1 T(T1)

A6VM 28-200 EP./..A

A B

max min

T(T1) M1

A6VM 28-200 EP./..A

A B

max min

Sa

T(T1) M1

008 911 17 BOMAG 459

13.2 Bosch Rexroth AG | Mobile Hydraulics
8 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Schnittbild
Sectional drawing

A6VM ... DA1

A B X1 X2

max min
G
X3

M1 T(T1)

A6VM ... DA3 A B

X1

X3
max min
G

M1 T(T1)

460 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.29
Schnittbild
Sectional drawing

A6VM 28-200 HA2U

mit Bremsventil / with braking valve

A
S

max min

T(T1) M1

A6VM 28-200 HA1R

mit Spülventil / with flushing valve

A B

max min

T(T1) M1

A6VM ... HA1U

mit Spülventil / with flushing valve

A B

max min

T(T1) M1

008 911 17 BOMAG 461

13.2 Bosch Rexroth AG | Mobile Hydraulics
10 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Allgemeine Reparaturhinweise
General repair instructions

Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!

Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.

Fill up hydraulic aggregates with medium

before start- up.

462 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
11

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

External seal kit.

Gehäuse

Housing

Triebwerk komplett
Hinweis: Pos. 1 - Für Anschlußplatte mit
Pos. 2 Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben

Complete rotary group

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston
Pos. 1

Pos. 1 Pos. 2 Anschlußplatte mit Stellkolben

Hinweis: Pos. 1 - Für Anschlußplatte mit
Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben

Port plate with control piston

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston

008 911 17 BOMAG 463

13.2 Bosch Rexroth AG | Mobile Hydraulics
12 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Schaltmagnet / Proportionalmagnet

Solenoid

Deckel mit * Drosselstift.

* Drosselstift "Auftragsbezogen".
* Cover with * throttle pin.
* Throttle pin "as to order requirement".
*
*

*
*
Deckel mit Spül- und Speisedruckventil
* und * Drosselstift
* Drosselstift "Auftragsbezogen".
Cover with flushing and boost pressure valve
and * throttle pin.
* Throttle pin "as to order requirement".

464 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
13

Baugruppen / Steuerteile
Component groups / Control components

z. B. HA EP

HA2
Auftrags-
bezogen *
"as to order
DA
requirement".

HD

008 911 17 BOMAG 465

13.2 Bosch Rexroth AG | Mobile Hydraulics
14 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Baugruppen / Steuerteile
Component groups / Control components

z. B. HZ3 / EZ3

HA3 / HA3U

466 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
15

Dichtmutter austauschen
Replace seal nut

Dichtmutter austauschen.
Zuerst Maß X messen und festhalten.

Replace seal nut.

First measure and record setting height.

Maß X

Beim Anziehen Einstellschraube gegenhalten,

anschließend Einstellhöhe kontrollieren.

When tightening, counterhold setting screw, then

check setting height.

008 911 17 BOMAG 467

13.2 Bosch Rexroth AG | Mobile Hydraulics
16 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwelle abdichten
Sealing of the drive shaft

Triebwelle abkleben.
Sicherungsring und Scheibe ausbauen.

Protecting the drive shaft.

Remove retaining ring and shim.

Blechschraube in die mit Gummi gefüllten

Löcher eindrehen.
Mit Zange WDR herausziehen.

Screw in sheet metal screw into the holes

fitted with rubber.
Pull out seal with pliers.

Wellendichtring und Scheibe mit Montagehülse

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
* leicht einfetten
Einpresstiefe beachten! * Marke für Einpresstiefe.
Sicherungsring einbauen.

Press in shaft seal ring and shim with bush to stop.

Take note of press-in depth!
Lightly grease the seal, dust lips and shaft seal ring.
Install * mark for press-in depth of safety ring.

468 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
17

Steuerteile abdichten
Sealing of the control parts

Achtung!
Federvorspannung

1 Attention!
Spring load

1. Deckel / Cover
2. Steuerteil / Control part
1
Kontrolle
Bohrung im Gehäuse, O-Ring, Nut.

Inspect
Drilling in housing, O-ring, groove.

Einstellschraube nicht ausbauen.

2 Kontrolle
O-Ring, O-Ring-Nut, Gehäuse

Do not remove adjustment screw.

Inspect
O-ring, O-ring groove, housing

Montagehilfe
Stift mit Fett einkleben.

2 Assembly aid
Insert pin with grease.

008 911 17 BOMAG 469

13.2 Bosch Rexroth AG | Mobile Hydraulics
18 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Verstellung abdichten
Sealing the hydraulic control

Beispiel: A6VM ... HD Verstellung

Demontageposition:
Deckel Pos. 1 abbauen.

Example: A6VM ... HD control

Pos.1 Disassembly position:
Remove cover pos. 1

1
1. O-Ring
2
2. Stellölzulauf
3. Drosselstift
Einbaulage je nach Steuerteil verschieden.

1. O-ring
2. Input flow of oil control
3. Throttle pin
Installation position differs according to the
3 control components

1
5
1. Stellölzulauf / Input flow of oil control
2 3 2. Hochdruck bzw. Niederdruck / High pressure /
low pressure
3. Hochdruck bzw. Niederdruck / High pressure /
low pressure
4. Lecköl / Leckage oil
4 5. Stellkolben / Control piston

470 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
19

Verstellung abdichten
Sealing the hydraulic control

Pos. 2

Beispiel: A6VM ... Verstellung - Differentialkolben

Demontageposition: Deckel Pos. 2 abbauen.
Achtung! Federvorspannung.
Maß x: Maß festhalten (Regelbeginn).
x
Example: A6VM... control - differential piston
Disassembly position: Remove cover pos. 2.
Attention! Spring load.
Dimension x: Note dimension (begin of regulation).

1. O-Ring Kontrolle

1. Check of O-ring

1
2 1. Hochdruck - kleine Stellkolbenseite
* 2. Stelldruck
3. Hochdruck - Rückschlagventil
4. Hochdruck - Rückschlagventil
* siehe Serviceinfo

1. High pressure - small control piston side

2. Control pressure
3
4 3. High pressure - check valve
4. High pressure - check valve
* see serviceinfo

008 911 17 BOMAG 471

13.2 Bosch Rexroth AG | Mobile Hydraulics
20 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Abschlußplatte demontieren
Disassembly of the port plate

x Differentialkolben:
Maß X festhalten.

Differential piston:
Note dimension x

Bei "Demontage" der Anschlußplatte

"Triebwerk" immer auf Null schwenken.
Kolbenringe hängen aus der Zylinder-
bohrung aus.

For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.
Qmin-Schraube
Qmin-screw

Qmin-Schraube ausbauen.
Triebwerk auf 0o schwenken.

Remove Qmin-screw.
Swivel rotary group to 0o.

472 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
21

Abschlußplatte demontieren
Disassembly of the port plate

x Gleichgangkolben:
Maß X festhalten.

Synchronizing piston:
Note dimension x.

Bei "Demontage" der Anschlußplatte "Triebwerk"

immer auf Null schwenken.
* Kolbenringe hängen sonst aus der Zylinder-
bohrung aus.
Qmin-Schraube
For disassembly of the port plate, swivel always
Qmin-screw
rotary group to zero position.
* Piston rings to hang out of the cylinder boring.

Qmin-Schraube und Verschlußschraube ausbauen.

Remove Qmin-screw and plug.

Mit Schraube Qmin Triebwerk auf 0o schwenken.

Swivel rotary group to zero position with screw Qmin

.

008 911 17 BOMAG 473

13.2 Bosch Rexroth AG | Mobile Hydraulics
22 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Abschlußplatte demontieren
Disassembly of the port plate

Anschlußplatte
Lage markieren. Schrauben lösen.
Abbauen

Port plate
Mark position. Loosen screws.
Removal

O-Ring austauschen.
Neuer O-Ring mit etwas Fett einkleben.
Triebwerk nicht ausschwenken.
Kolbenringe hängen aus der Zylinderbohrung aus.

Check O-ring.
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring.

Steuerlinse in Gleitbahn mit Fett einkleben.

Fertigmontage in umgekehrter Reihenfolge.
Anschlußplatte aufsetzen.
Triebwerk senkrecht.

Stick control lens in sliding surface with grease.

Assembly in reversal order.
Mount port plate.
Rotary group vertical.

474 BOMAG 008 911 17

Travel motor A6VM/VE 13.2

008 911 17 BOMAG 475

13.2 Travel motor A6VM/VE

476 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
25

Triebwerk ausbauen
Remove rotary group

Gewindestift in Mittelzapfen einschrauben,

mit Schutzscheibe und Mutter Zylinder befestigen.
Qmax - Anschlagschraube ausbauen.

Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
Remove Qmax -stop screw.

Nenngröße / Size 28 : M4 x 60 mm
55 : M5 x 80 mm
80 : M6 x 90 mm
107 : M6 x 100 mm
140 : M8 x 110 mm
160 : M8 x 110 mm
200 : M8 x 110 mm

Triebwerk auspressen!
Bei Wiederverwendung der Lager nicht schlagen.

Press out rotary group!

If the bearings are used again do not hit on the drive
shaft.

008 911 17 BOMAG 477

13.2 Bosch Rexroth AG | Mobile Hydraulics
26 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwerk ausbauen
Remove rotary group

Oder mit Abziehvorrichtung ausdrücken.

Or press-out with extraction device.

478 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
27

Triebwerk austauschen
Exchanging of the rotary group

eingepresst
pressed in
Triebwerk komplett
Abstimmung hydraulischer
Teil notwendig.

Complete rotary group

Setting of hydraulic part
necessary.

Triebwerk Baugruppe
1.Mechanischer Teil: Triebwelle mit Lager abgestimmt.
2.Hydraulischer Teil: Abstimmung notwendig *.

Rotary group
1. Mechanical part: Adjust drive shaft with bearing.
2. Hydraulic part: Adjustment necessary *.

Triebwerk: Alle Bauteile

* Abstimmung
Abstimmwerte, Drehmomente siehe Serviceinfo.

Rotary group: All parts

* Setting
Setting value, torque see service information.

008 911 17 BOMAG 479

13.2 Bosch Rexroth AG | Mobile Hydraulics
28 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwerk austauschen
Exchanging of the rotary group

Befestigungsschraube (Zylinder) ausbauen.

Zylinder abheben.

Remove fixing screw (cylinder).

Remove cylinder.

Rückzugplatte demontieren.
Schrauben sind eingeklebt. Nach Erwärmen auf
max 120o C mit Torx-Werkzeug demontieren.

Disassemble retaining plate.

Screws are glued. Warm it up to max. 120o C
and remove with Torx-tools.

480 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
29

Überprüfungshinweise
Inspection notes

Kein Passungsrost, nicht ausgeschlagen.

Free of corrosion, erosion or fretting;

no damage to splines or keyways.

Kolben
Riefenfrei und keine Pittings.

Pistons
No scoring and no pittings.

1 2

Mittelzapfen
Riefenfrei und keine Pittings.

Center pin
No scoring and no pittings.

Rückzugplatte
Riefenfrei und keine Ausbrüche.

Retaining plate
No scoring and no evidence of wear

Zylinder / Steuerlinse
1 Bohrungen riefenfrei, nicht ausgelaufen.
2 Gleichmäßiges Tragbild, riß- und riefenfrei.

Cylinder block / control lens

1 Bores free of scoring, no evidence of wear.
2 Faces smooth and even, free of cracks
and scoring.

008 911 17 BOMAG 481

13.2 Bosch Rexroth AG | Mobile Hydraulics
30 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Überprüfungshinweise
Inspection notes

Reglergehäuse
Gleitbahn und Seitenführung riefenfrei,
nicht ausgelaufen.

Control housing
Sliding surface and side guides free of scoring
and no wear.

Sichtkontrolle:
Im Lagerbereich riefenfrei und keine Einlaufspuren.

Visual check:
Bearing areas free of scoring and no evidence
of wear.

482 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
31

Triebwerk montieren / siehe Serviceinformation

Rotary group assembly / see service information

Triebwelle: mechanischer Teil

Rotary group: mechanical part

1 Abstimmung Maß * und Lagerdrehmomente

siehe Serviceinfo.

2
* Adjustment dimension * and bearing torque
see service infoprmation.

Lager aufpressen.
Beim Aufpressen Lagerdrehmoment nicht
überschreiten.

Press on bearing.
Do not exeed bearing torque during press-on.

BOJH
GG
DRTT
GHE

000
000
BOJH
GG
DRTT
GHE

Lager mit Montagehülse vorspannen und laufende Drehmomentenkontrolle.

Preload bearing with assembly sleeve and steady control of the torque.

008 911 17 BOMAG 483

13.2 Bosch Rexroth AG | Mobile Hydraulics
32 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwerk montieren
Rotary group assembly

Sicherungsring 1 montieren.
Maß * für Abstimmscheibe mit Endmaß ermitteln
(überkreuz).
Abstimmscheibe einbauen.
Sicherungsring montieren.

1 Assemble safety ring.

Determine dimension * for adjustment disc with fi-
* nal dimensions (crossover)
Install adjustment shim.
Assemble safety ring.

Triebwelle einbaufertig.

Drive shaft ready for assembly.

484 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
33

Triebwerk montieren
Rotary group assembly

Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.
(Anziehdremoment siehe Seite 42).

Insert retaining plate with piston and center pin.

Use screw with Precote-coating.
(Tightening torque see page 42).

Auf richtige Schichtung aller Teile achten.

Make sure all parts are fitted in correctly.

Triebwerk auf Null schwenken und Zylinder mit

Gewindestift befestigen. (siehe Seite 25)

Swivel cylinder block to zero position and fix the

cylinder with a threaded pin (see page 25)

008 911 17 BOMAG 485

13.2 Bosch Rexroth AG | Mobile Hydraulics
34 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwerk montieren
Rotary group assembly

Triebwerk komplett zum Einbau fertig.

Rotary group completely assembled ready

for assembly.

Montagehülse montieren.

Place assembly sleeve.

Gehäuse auf 80oC erwärmen.

Warm up housing to 80oC.

486 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
35

Triebwerk montieren
Rotary group assembly

Triebwerk ins Gehäuse auf Anschlag einsetzen.

Insert rotary group into housing to seat position.

Nach Einbau des Triebwerks im Gehäuse ist die

Triebwelle bis auf Anschlag nach vorne zu ziehen.

Pull the drive shaft after rotary groupassembly into

housing to seat position.

2 1

Zylinder in Nullposition
ausrichten.
1. Zylinderbefestigungsschraube
demontieren.
2. O-Ring einsetzen.

Fix zero position of cylinder

with Qmax-screw.
1. Disassemble cylinder
fixing screw.
2. Insert O-ring.

008 911 17 BOMAG 487

13.2 Bosch Rexroth AG | Mobile Hydraulics
36 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwerksabstimmung (siehe Serviceinfo)

Rotary group adjustment (see service information)

Mit Schraube Zylinderausschwenkung

vermitteln.

Determine cylinder swivel range to

max. angle with screw.

* * Scheibe
* Disc

Zentrierscheibe aufsetzen.

Place centering disc.

Meßvorrichtung aufbauen.

Mount measuring device.

Maß X überprüfen.

Check dimension X.

488 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
37

Abschlußplatte montieren
Assembly of the port plate

1. Anschlußplatte mit Differential-

* kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf
Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.

1. Assemble port plate with

differential piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to
dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

Deckel montieren.

Assemble cover.

Steuerteil montieren.
x
Assemble control components.

008 911 17 BOMAG 489

13.2 Bosch Rexroth AG | Mobile Hydraulics
38 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Anschlußplatte montieren
Assembly of the port plate

1. Anschlußplatte mit Gleichgang-

kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
* Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.

1. Assemble port plate with

synchronizing piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

Wellendichtring, Scheiben und Sicherungsring

montieren.
Mit Montagehülse einpressen.
Dicht- und Staublippe, Wellendichtring leicht
einfetten.
Einpresstiefe beachten!

Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.
Lightly grease the seal, dust lips and shaft seal ring.
Take care of press-in depth.

490 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
39

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metrischen The values stated are valid for bolts with metric ISO threads
ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflage- to DIN 13 part 13, as well as head areas to DIN 912 socked
maßen nach DIN 912 Zylinderschrauben, DIN 931 head cap screws, DIN 931 hexagon bolt or
Sechskantschrauben mit Schaft bzw. DIN 933 hexagon bolts with threads up to the head.
DIN 933 Sechskantschrauben mit Gewinde bis Kopf.

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240

008 911 17 BOMAG 491

13.2 Bosch Rexroth AG | Mobile Hydraulics
40 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

492 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
41

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

5. Verschlußschrauben mit Innensechskant, 5. Plugs with internal hexagon, O-ring and UNF-,
O-Ring und UNF-, UN-Gewinde nach SAE J 514 UN- threads to SAE J 514 (nach N 02.106)
(nach N 02.106)

G
O-Ring / O-ring seal
Dichtung / Thread

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 20
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 90
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390

008 911 17 BOMAG 493

13.2 Bosch Rexroth AG | Mobile Hydraulics
42 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

6. Linsenschrauben mit Innen-TORX, Gewindevor- 6. Oval head screw with inner TORX, thread precoated with
beschichtung mit "precote" "precote"

precote 80 - Rot / Red

Standard / Standard

precote 86 - Blau / Blue

Variante / Variant
* * mit Unterkopfbeschichtung - farblos
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20
* with head bottom coating - colorless
siehe Stückliste / as to parts list

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7

7. SEAL-LOCK-Dichtmuttern (nach N 02.100) 7. SEAL-LOCK - sealing nuts (to N 02.100)

Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

494 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
43

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A6V - Stellkolben / positioning piston

für / for A6V / A7V / A7F / A8V)

Anziehdrehmoment MA für Gewindestift (1) / Anziehdrehmoment MA für Schraube (2) /

Tightening torque MA for threaded pin (1) Tightening torque MA for shaft bolts (2)
(Verbindung: Stellkolben und Stellzapfen / (Verbindung: Stellkolben und Stellzapfen für A6V
Connection: Positioning piston and positioning trunnion Connection: Positioning piston and piston for A6V

M6 : 8,5 Nm M14 x 1,5 : 120 Nm

M8 : 14,0 Nm
M10 : 30,0 Nm
M12 : 52,0 Nm

008 911 17 BOMAG 495

13.2 Bosch Rexroth AG | Mobile Hydraulics
44 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Sicherheitsbestimmungen
Safety regulations

Allgemein General advice

● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.

Vor dem Start Before starting

● Beachten Sie die Bedienungshinweise vor dem Starten. ● Observe the operating instructions before starting.
● Prüfen Sie die Maschine auf auffällige Fehler. ● Check the machine for remarkable faults.
● Fahren Sie die Maschine nicht mit defekten Instrumenten, ● Do not operate the machine with defective instruments,
Kontrolleuchten oder Steuerorganen. warning lights or control elements.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. ● All safety devices must be in a secure position.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen ● Do not carry with you movable objects or secure them to the
Sie diese an der Maschine. machine.
● Halten Sie die Maschine von öligem und zündfähigem ● Keep oily and inflammable material away from the machine.
Material frei. ● Before entering thc driver s cabin, check if personsor
● Prüfen Sie vor dem Besteigen der Maschine, ob sich obstacles are beside or beneath the machine.
Personen oder Hindernisse neben oder unter der Maschine ● Be careful when entering the driver s cabin, use stairs and
befinden. handles.
● Vorsicht beim Besteigen der Maschine, benützen Sie ● Adjust your seat before starting.
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.

496 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
45

Sicherheitsbestimmungen
Safety regulations

Starten Start
● Beim Starten müssen alle Bedienhebel in “Neutralstellung” ● When starting all operating levers must be in “neutral position”.
stehen. ● Only start the machine from the driver s seat.
● Die Maschine nur vom Fahrersitz aus Starten. ● Check the indicating instruments after start to assure that all
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um functions are in order.
sicher zu gehen, daß alles ordnungsgemäß funktioniert. ● Do not leave the machine unobserved when the motor is
● Lassen Sie die Maschine nicht unbewacht, während running.
der Motor läuft. ● When starting with battery connection cables connect plus
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus with plus and minus with minus. Always connect mass cable
mit Plus und Minus mit Minus. Massekabel (Minus) immer (minus) at last and cut off at first.
zuletzt anschliesen und zuerst abtrennen.

Vorsicht Attention
● Auspuffgase sind lebensgefährlich. Bei Start in ● Exhaust gas is dangerous. Assure sufficient fresh air when
geschlossenen Räumen für ausreichende Luftzufuhr starting in closed rooms!
sorgen!

Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck- Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. Daher heavy injuries. Therefore immediately consult a doctor as
sofort einen Arzt aufsuchen, da anderenfalls schwere otherwise heavy infections can be caused.
Infektionen entstehen können! 2. When searching leakages use appropriate auxiliary devices
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr because of the danger of accidents.
geeignete Hilfsmittel verwenden! 3. Before working at the hydraulic equipment, lower pressure
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt to zero and lower working arms of the rnachine.
drucklos machen und angebaute Geräte absenken! 4. When working at the hydraulic equipment, absolutely stop
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor motor and secure tractor against rolling away (parking brake,
abstellen und Traktor gegen Wegrollen sichern shim)!
(Feststellbremse, Unterlegkeil)! 5. When connecting hydraulic cylinders and motor pay attention
5. Beim Anschließen von Hydraulikzylindern und -motoren ist to correct connection of hydraulic flexible hoses.
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu 6. In case of exchanging the ports, the tunctions are vice versa
achten! (f. ex. lift-up/lower) - danger of accidents!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen 7. Check hydraulic flexible hoses regularly and replace them in
(z.B. Heben/Senken) - Unfallgefahr! case of dammage or wear! The new hose pipes must comply
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei with the technical requirements of the machine manufacturer!
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen Orderly disposal or recycling of oil, fuel and
des Geräteherstellers entsprechen! filters!

Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!

008 911 17 BOMAG 497

13.2 Bosch Rexroth AG | Mobile Hydraulics
46 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel HD e.g HD

X - 10 bar

Einstellschraube - Regelbeginn / P
Set screw - begin of control
Vg min

G
X
Betriebsdruck /
Operating
pressure

~ P/2

1:2

M1

Stelldruck /
Control pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).

A6VM - HD Vg max - Vg min A6VM - HD Vg max - Vg min

● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Manometer "X" = 60 bar ● Pressure gauge "X" = 60 bar

Regelbeginn / Einstellung Begin of regulation / Setting

Beispiel: 10 bar Steuerdruck an X Example: 10 bar pilot pressure at X

Manometer an M1 beachten! Observe pressure gauge at M1!

Druckwert an X erhöhen bis an M1 die Hälfte Increase pressure value at X till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation

Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später

498 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
47

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel EP e.g EP

Einstellschraube - Regelbeginn /
Set screw - Begin of control
P

Vg min

Betriebsdruck /
Operating pressure

~ P/2

1:2

M1

Stelldruck /
Control pressure

Sicherheitsbestimmungen beachten! Observe safety regulations!

Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).

A6VM - EP Vg max - Vg min A6VM - HD Vg max - Vg min

● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Magnet = Multimessgerät ● Solenoid = multi measuring device

Regelbeginn / Einstellung Begin of regulation / Setting

Beispiel: 200/400 mA Example: 200/400 mA

Manometer an M1 beachten! Observe pressure gauge at M1!

Strom erhöhen bis an M1 die Hälfte Increase current till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation

Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später

008 911 17 BOMAG 499

13.2 Bosch Rexroth AG | Mobile Hydraulics
48 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg min - Vg max ) (Begin of regulation of Vg min - Vg max )
z.Beispiel HA z.Beispiel HA

Vg min X M1

Stelldruck /
Control
pressure
1:2

Einstellschraube - Regelbeginn / G
Set screw - Begin of control Betriebsdruck /
Operating
pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake)
Manometer 600 bar an G und M1 anschließen. Connect pressure gauge 600 bar at G and M1
Beispiel 1: Example 1:
Regelbeginn 200 bar, Begin of regulation 200 bar
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge at
Stelldruck Manometer M1 G = 200 bar
1 /2 des Betriebsdruckes = ca. 100 bar Positioning pressure gauge M1
♦ Regelbeginn 1/2 of the sevice pressure = approx. 100 bar.
Nachjustierung des Stelldruckes an ♦ Begin of control
Einstellschraube - Regelbeginn Readjust positioning pressure at set screw - start of control
Hinweis: Note:
Drehen im Uhrzeigersinn - Regelbeginn früher. Clockwise turning - begin of regulation earlier
Drehen gegen Uhrzeigersinn - Regelbeginn später. Anti-clockwise turning - begin of regulation later
Beispiel 2: Example 2:
Bei Anlagen mit zwei oder mehr Motoren z. B. Raupenfahrzeuge In systems with two or more motors, e.g. tracked vehicles,
kann folgende Einstellung zusätzlich erfolgen. the following setting may be carried out additionally.
Kontermutter von Einstellschraube Vgmin lösen - Remove safety cap from the setscrew Vg min - do not disturb
Einstellschraube nicht verdrehen. Maß X festhalten. setscrew.
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge is indicating
anzeigt. 200 bar at G.
Kontrolle: Einstellschraube Vg min "fest" (Steuerlinse wird gegen Verification: Vg min "fixed" (lens plate is pressed against setscrew).
die Einstellschraube gedrückt). Up from 200 bar service pressure the screw is becoming
Ab 200 bar Betriebsdruck wird die Schraube "lose" "movable".
(Steuerlinse schwenkt Richtung Vg max). (lens plate is stroking to direction Vg max).
♦ Regelbeginn ♦ Begin of control
Achtung! Attention
Einstellwert Vg min -Schraube nicht verändern. Do not modify setting data of Vg min screw.
Hinweis: Nachjustierung an Einstellschraube- Regelbeginn Note: Readjustment at the set screw - begin of regulation

500 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
49

Inbetriebnahme
Operating instruction

Einstellüberprüfung (Regelbeginn) G1
DA1/4, DA2,3,4,5,6 X3 Einstellschraube - Regelbeginn
Vg min
5/8

100

1:2

M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Stelldruck

Beispiel: Betriebsdaten nach Geräteblatt

Verstellbeginn Vg min - Vg max bei 20 bar Steuerdruck X3
und 220 bar Betriebsdruck

● Manometer G = 600 bar Betriebsdruck

● Manometer X3 = 60 bar Steuerdruck
● Manometer M1 = 600 bar Stelldruck G
Fahrzeug beladen, Straßengang, Fahren (max. Geschwindigkeit
= max. Steuerdruck)
Manometer M1 beobachten, anbremsen für Druckaufbau an
"G", ab 220 bar Betriebsdruck baut sich Druck an M1 ab.
♦ Regelbeginn P/2.

DA1, DA2, DA3 PSt / PSt 5/100

X3 G M1 = 1/2 Betriebsdruck (Regelbeginn)

20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = Regelbeginn Vg min ♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Einstellschraube - Regelbeginn - Drehen im Uhrzeigersinn - Regelbeginn später

nur 1/8 Umdrehung verstellen ♦ kontrollieren

DA4, DA5, DA6 PSt / PSt 8/100

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ® Vg max
20 bar 225 bar 0 bar = Vg max Stelldruck

008 911 17 BOMAG 501

13.2 Bosch Rexroth AG | Mobile Hydraulics
50 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Inbetriebnahme
Operating instruction

Setting test (Begin of Regulation) G1

DA1/4, DA2,3,4,5,6 X3
Setscrew - Begin of control
Vg min
5/8

100

1:2

M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Control
pressure
X3
Example: Operation data as to machine specification sheet
Begin of regulation Vg min - Vg max at 20 bar pilot pressure
and 220 bar service pressure
G
● Pressure gauge G = 600 bar service pressure
● Pressure gauge X3 = 60 bar pilot pressure
● Pressure gauge M1 = 600 bar positioning pressure
Load vehicle, travel mode, travel (max. speed = max. pilot pressure
Observe pressure gauge M1, declarate at "G" for pressure generation,
up from 220 bar service pressure pressure at M1 is dropping.
♦ begin of regulation P/2.

DA1, DA2, DA3 PSt / PSt 5/100

X3 G M1 = 1/2 service pressure (begin of regulation)
20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = begin of regulation Vg min ♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Setscrew - begin of regulation - turn clockwise - begin of regulation later

displace by 1/8 turn only ♦ verification

DA4, DA5, DA6 PSt / PSt 8/100

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ♦ Vg max
20 bar 225 bar 0 bar = Vg max Control
pressure

502 BOMAG 008 911 17

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.2
51

008 911 17 BOMAG 503

13.2 Travel motor A6VM/VE

Brueninghaus Hydromatik GmbH

Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
[email protected]
www.boschrexroth.com/brm

© 2003 by Brueninghaus Hydromatik © 2003 by Brueninghaus Hydromatik

GmbH, 89275 Elchingen GmbH, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Brueninghaus Hydromatik GmbH
any form or by any means, without the reproduziert oder unter Verwendung
prior written authorization of Bosch elektronischer Systeme gespeichert,
Rexroth AG. In the event of verarbeitet, vervielfältigt oder verbreitet
contravention of the above provisions, werden. Zuwiderhandlungen
the contravening party is obliged to verpflichten zu Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist zu
remembered that our products are beachten, dass unsere Produkte einem
subject to a natural process of wear natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.

Printed in Germany
RDE 91 604-01-R/03.03

504 BOMAG 008 911 17

13.3 Travel gear

008 911 17 BOMAG 505

13.3 Travel gear

506 BOMAG 008 911 17

Travel gear 13.3

RIDUTTORE PER COMANDO RUOTA

WHEEL DRIVE

6 06 Y 3 LB S011 B 32 I3 5EW90-S02 VAM

CODICE
CODE 2T255608241A

Manuale di installazione, uso

e manutenzione

Installation, operation and maintenance

manual

Emissione:
02/2007
Issue:

Aggiornamento - data:
Revision - date: 0.0 - 14/02/2007

Compilatore:
Ufficio tecnico commerciale: Prepared by: .............................................................
Technical and commercial dept: Approvato da:
Approved by: ............................................................

008 911 17 BOMAG 507

13.3 Travel gear

-2-
508 BOMAG 008 911 17
Travel gear 13.3

INDICE INDEX

1. INFORMAZIONI GENERALI 1. GENERAL INFORMATIONS

1.1. Scopo del manuale ........................................... 2 1.1. Manual aim ...................................................... 2
1.2. Identificazione del prodotto ............................... 3 1.2. Product identification........................................ 3
1.3. Modalità di richiesta assistenza ........................ 3 1.3. Requesting assistance ..................................... 3
1.4. Informazioni sulla sicurezza.............................. 4 1.4. Informations on safety...................................... 4
1.5. Modalità di consegna ........................................ 5 1.5. Delivery methods ............................................. 5
1.6. Modalità di imballaggio ..................................... 5 1.6. Packaging methods ......................................... 5
1.7. Sollevamento e movimentazione ...................... 6 1.7. Lifting and handling ......................................... 6
1.8. Modalità di magazzinaggio ............................... 7 1.8. Storage methods.............................................. 7

2. INFORMAZIONI TECNICHE 2. TECHNICAL INFORMATIONS

2.1. Descrizione del prodotto ................................... 8 2.1. Product description .......................................... 8

3. INFORMAZIONI SULL’INSTALLAZIONE 3. INSTALLATION INFORMATIONS

3.1. Procedure per l’installazione........................... 11 3.1. Installation procedure..................................... 11
3.2. Installazione del motore idraulico.................... 12 3.2. Hydraulic motor installation ............................ 12
3.3. Installazione del motoriduttore 3.3. Installation of the wheel drive
sulla macchina 13 on the machine ............................................... 13
3.4. Fissaggio ruota al motoriduttore ..................... 13 3.4. Fixing of the wheel to the gearmotor.............. 13
3.5. Collegamento del freno................................... 14 3.5. Connecting the brake..................................... 14
3.6. Caratteristiche olio lubrificazione 3.6. Characteristics of oil forced
forzata freno 15 brake lubrication 15
3.7. Riempimento olio lubrificante del riduttore...... 16 3.7. Filling-up the gearbox with lubricating oil ....... 16
3.8. Prima messa in esercizio e rodaggio .............. 18 3.8. First start up and running in ........................... 18

4. INFORMAZIONI SULLA MANUTENZIONE 4. MAINTENANCE INFORMATIONS

4.1. Manutenzione periodica.................................. 19 4.1. Periodic maintenance .................................... 19
4.2. Sostituzione dell'olio lubrificante ..................... 20 4.2. Changing the lubricating oil............................ 20
4.3. Ricerca guasti ................................................. 21 4.3. Troubleshooting ............................................. 21
4.4. Smontaggio del motoriduttore......................... 22 4.4. Motorgearbox disassembly ............................ 22
4.5. Fasi di smontaggio.......................................... 25 4.5. Disassembling method................................... 25
4.6. Fasi di smontaggio riduttore............................ 25 4.6. Gearbox disassembly method ....................... 25
4.7. Fasi di smontaggio gruppo riduttore ............... 29 4.7. Gearbox kit disassembly method ................... 29
4.8. Fasi di smontaggio gruppo freno .................... 36 4.8. Brake kit disassembly method ....................... 36
4.9. Valutazione dei pezzi da sostituire.................. 41 4.9. Evaluating that pieces to replace ................... 41
4.10.Fasi di rimontaggio gruppo freno .................... 42 4.10.Brake kit reassembling method...................... 42
4.11.Fasi di rimontaggio gruppo riduttore ............... 48 4.11.Gearbox kit reassembling method ................. 48
4.12.Fasi di rimontaggio riduttore ........................... 57 4.12.Gearbox reassembling method ...................... 57
4.13.Controllo finale e reinstallazione ..................... 64 4.13.Final test and reinstallation ............................ 64
4.14.Dismissione e rottamazione del prodotto........ 65 4.14.Dismantling and destroying the product......... 65

INDICE -1- INDEX

008 911 17 BOMAG 509
13.3 Travel gear

1. INFORMAZIONI GENERALI 1. GENERAL INFORMATIONS

1.1. Scopo del manuale 1.1. Manual aim

Questo manuale è stato realizzato dal costruttore per This manual has been realized by the manufacturer to
fornire le informazioni necessarie a coloro che sono give necessary information to those authorised to work
autorizzati ad interagire con il prodotto: dai progettisti, on this product for example the design engineers,
agli installatori, manutentori e riparatori. installers, repair and maintenance technicians.
Oltre ad adottare le regole della buona tecnica di Besides helping one understand the rules of good
costruzione, le informazioni devono essere lette manufacturing techniques used, the information given
attentamente ed applicate in modo rigoroso. must be read attentively and strictly put into action.
La non osservanza di dette informazioni può essere Failure to observe this information may lead to health
causa di rischi per la salute e la sicurezza delle and safety risks to persons as well as economic loss.
persone e danni economici.
This information was compiled by the Italian
Queste informazioni sono state realizzate dal manufacturer in his original language (Italian) and can
costruttore nella propria lingua originale (italiano) e be translated into other languages to satisfy
possono essere tradotte in altre lingue per soddisfare commercial and/or legal needs.
le esigenze commerciali e/o legislative.

Informazioni Information
La completa e costante osservanza delle indicazioni A strict and consistent compliance with the
contenute nel presente manuale tecnico garantisce specifications of this technical manual ensure the
la migliore economia di esercizio ed una più lunga minimum operating costs and a longer unit life.
durata di funzionamento del motoriduttore.
La documentazione fotografica ed i disegni sono forniti Photographic documentation and drawings are
a scopo esplicativo, in modo da descrivere supplied for educational purposes, so as to safely and
esaurientemente le operazioni da eseguire sul riduttore. properly carry out maintenance operations.
Anche se il riduttore in vostro possesso si discostasse Minor deviations from pictures of this manual may
in parte dalle illustrazioni contenute in questo manuale appear on the actual gearbox. However, these
tecnico, le caratteristiche e la sequenza delle operazioni discrepancies are not relevant to the main parameters,
descritte sono sempre garantite. or maintenance functions.

INFORMAZIONI GENERALI -2- GENERAL INFORMATIONS

510 BOMAG 008 911 17
Travel gear 13.3

1.2. Identificazione del prodotto 1.2. Product identification

I dati per l'identificazione del prodotto sono riportati in The data to identify the product are shown on the
una targhetta applicata su di esso. identification plate attached to it.

Informazioni Information
Per la richiesta di informazioni, ricambi, For all enquiries regarding general information on
assistenza, ect, fornire sempre i dati identificativi. the product, spare parts, assistance etc, always
give the identification data stamped on the ID
plate.
La targhetta va mantenuta integra per tutta la vita del The plate must not be removed or damaged during the
prodotto. L'illustrazione evidenzia la disposizione dei life of the product. The following illustration shows how
dati. the data is set out.

Identificazione del Costruttore Codice del montatore

Manufacturer’s identification Assembler code

Designazione del prodotto: Rapporto di riduzione

composizione alfanumerica che Reduction ratio
consente di identificare il prodotto.
Product designation: Data di produzione
alphanumeric composition which Date of production
allows identification of the product.

Codice prodotto Codice del prodotto cliente

Trasmital Bonfiglioli Customer product code
Trasmital Bonfiglioli
product code Numero di matricola
Serial number
Codice a barre (tipo 39)
Bar code (type 39)
IDM-15220100300.tif

1.3. Modalità di richiesta assistenza 1.3. Requesting assistance

Per qualsiasi richiesta di assistenza rivolgersi For all requests for assistance please contact the
direttamente alla rete di vendita del costruttore manufacturers’ sales network, directly.

INFORMAZIONI GENERALI -3- GENERAL INFORMATIONS

008 911 17 BOMAG 511
13.3 Travel gear

1.4. Informazioni sulla sicurezza 1.4. Informations on safety

Leggere attentamente le istruzioni riportate in questo Carefully read the instructions given in this instruction
manuale e eventualmente quelle applicate manual as well as the ones attached to the product and
direttamente sul prodotto, in particolare rispettare make sure to follow the information concerning safety.
quelle riguardanti la sicurezza.
Personnel, which perform any type of work on the
Il personale che effettua qualsiasi tipo di intervento in product during its life span, must possess precise
tutto l’arco di vita del prodotto, deve possedere precise technical qualifications as well as recognised skills and
competenze tecniche, particolari capacità ed experience gained in the specific sector. Failure to do
esperienze acquisite e riconosciute nel settore so may lead to health and safety risks to persons.
specifico. La mancanza di questi requisiti può causare
It is recommended that when handling the product
danni alla sicurezza e alla salute delle persone.
attention is paid to the information given in this manual
Eseguire la movimentazione del prodotto rispettando and particularly in the sections: “Packaging Methods”
le informazioni riportate in questo manuale nei and “Lifting and handling” or simply follow the
paragrafi "Modalità di imballaggio" e "Sollevamento e instructions given on the packaging (if present).
movimentazione" oppure applicate direttamente
Utilise the product only for the use specified by the
sull’imballo (se presenti).
manufacturer. Improper use of the product could lead
Utilizzare il prodotto solo per gli usi previsti dal to health and safety risks to persons as well as
fabbricante. L’impiego del prodotto per usi impropri economic loss and furthermore will invalidate the
può recare rischi per la sicurezza e la salute delle guarantee given by the manufacturer.
persone e danni economici, nonché il decadere della
Keep the product in perfect working order by following
garanzia da parte del costruttore.
the scheduled maintenance procedure set out by the
Mantenere il prodotto in condizioni di massima manufacturer. Good maintenance will ensure the best
efficienza effettuando le operazioni di manutenzione performances, a longer period of operation and a
programmata previste dal costruttore. Una buona constant safeguard towards security requirements.
manutenzione consentirà di ottenere le migliori
To undertake maintenance procedures in areas which
prestazioni, una più lunga durata di esercizio e un
are hard to reach or otherwise dangerous it is
mantenimento costante dei requisiti di sicurezza.
important to follow adequate safety conditions for one
Per eseguire interventi di manutenzione in zone non self and for others in compliance with the rules and
facilmente accessibili o pericolose, predisporre regulations that govern safety in the workplace.
adeguate condizioni di sicurezza per sé stessi e per gli
When replacing worn parts, use original spare parts.
altri rispondenti alle leggi vigenti in materia di
Use oils and greases recommended by the
sicurezza sul lavoro.
manufacturer. Doing this, will ensure that the product
Sostituire i particolari usurati utilizzando i ricambi works properly and that the safety level is
originali. Usare gli oli e i grassi consigliati dal “acceptable”.
costruttore. Tutto questo potrà assicurare la
funzionalità del prodotto ed un livello di “sicurezza
accettabile”.

INFORMAZIONI GENERALI -4- GENERAL INFORMATIONS

512 BOMAG 008 911 17
Travel gear 13.3

1.5. Modalità di consegna 1.5. Delivery methods

I riduttori vengono forniti dalla BONFIGLIOLI Gearboxes are supplied by BONFIGLIOLI

TRASMITAL nelle seguenti condizioni standard: TRASMITAL at the following standard conditions:
– Già predisposti per essere installati nella posizione – Ready for installation in the mounting position
di montaggio come definito in fase d’ordine. specified when ordering.
– Le parti interne, per garantirne l’integrità, sono – To guarantee their reliability, the internal parts are
preventivamente lubrificate con un velo d’olio usato properly lubricated with a layer of oil, the same as
per il collaudo finale del riduttore. Non viene the one used in the final test of the gearbox.
eseguito il riempimento dell’olio lubrificante Lubricating oil has not been added (as shown on
(come segnalato da cartellino). the card).
– Le parti grezze e le superfici di accoppiamento – All unmachined parts and surfaces to be coupled
vengono opportunamente trattate con antiossidanti. are appropriately treated with antioxidants.
– Le superfici esterne sono protette con smalto di – External surfaces are protected with an antioxidant
fondo antiossidante all'acqua di colore grigio e water resistant grey color and painted with a grey
successivamente finite con smalto di colore grigio (i sinthetic finish coat (painting data are shown on the
dati di verniciatura sono riportati nel disegno di installation drawing). Machined surfaces are not
installazione). Le superfici di accoppiamento non painted. The breather plug must not be painted, if
sono verniciate. Il tappo di sfiato se presente, non available.
deve essere verniciato. – Tested to in-house specifications.
– Collaudati secondo specifiche interne. – Appropriately packaged to facilitate handling,
– Appositamente imballati per agevolarne la transport and storage.
movimentazione, il trasporto e lo stoccaggio.

IMBALLO SU PALLET CON TERMORETRAIBILE IMBALLO CON CASSA

PACKAGED ON A PALLET WITH PACKAGED IN A CASE
THERMOSHRINKING FILM

Cartellino che informa

“privo di lubrificante”
Card which states: “does not
contain lubricating oil”

IDM-15220600100.tif

1.6. Modalità di imballaggio 1.6. Packaging methods

Le illustrazioni raffigurano i tipi di imballo più frequenti. The illustrations show the more common types of
packaging.

Informazioni Information
Al ricevimento del prodotto, accertarsi che When the product arrives, ensure that it meets the
corrisponda alle specifiche di acquisto e che non information contained in the purchase agreement
presenti danni o anomalie. Per qualsiasi and that there are no damages or irregularities. If
inconveniente rivolgersi direttamente alla rete di there are any problems contact the manufacturers’
vendita del costruttore. sales network directly.

INFORMAZIONI GENERALI -5- GENERAL INFORMATIONS

008 911 17 BOMAG 513
13.3 Travel gear

1.7. Sollevamento e movimentazione 1.7. Lifting and handling

Se la movimentazione avviene quando il prodotto è If the handling occurs when the product is still
imballato, è sufficiente attenersi alle indicazioni packaged, simply follow the instructions given on the
applicate direttamente sull'imballo e/o comunque packaging and/or use normal hoisting means.
utilizzando i normali mezzi di sollevamento.

Cautela - Precauzione Caution

Considerando che la massa e la forma del prodotto Considering that the size and form of the product
non ne consentono lo spostamento a mano, in does not allow manual shifting, in particular
particolari movimentazioni (es: installazione), è handlings, (e.g. installation) it is necessary to use
necessario utilizzare accessori che consentono di accessories that guarantee human safety and
garantire la sicurezza delle persone ed evitare which also avoid damages to the product.
danni al prodotto.
Per sollevare e movimentare il prodotto, dopo aver To lift and handle the product, after having opened the
aperto l'imballo, attenersi alle seguenti indicazioni: packaging, follow the information given below:
1. Avvitare n° 2 golfari M20 UNI ISO 3266 nei fori 1. Tighten nos. 2 eyebolts M20 UNI ISO 3266 into the
filettati del corpo angolare. thread holes of the right angle housing.
2. Servendosi di un paranco sollevare e movimentare 2. By using a tackle lift and handle with care avoiding
con la massima cautela evitando gli urti. impacts.

Golfare M20 UNI

ISO 3266
Eyebolt M20 UNI
ISO 3266

IDM-15220600200.tif

INFORMAZIONI GENERALI -6- GENERAL INFORMATIONS

514 BOMAG 008 911 17
Travel gear 13.3

1.8. Modalità di magazzinaggio 1.8. Storage methods

In fase di magazzinaggio del prodotto adottare le In the storage process of the product follow the safety
precauzioni di seguito indicate. measures given below.
1. Evitare ambienti con eccessiva umidità ed esposti 1. Avoid environments with excessive humidity and
ad intemperie ed escludere aree all'aperto. exposed to changing weather conditions and make
sure that open areas are excluded.
2. Evitare il contatto diretto del prodotto con il suolo.
2. Make sure that the product does not lie directly on
3. Disporre il prodotto in modo che abbia una base di
the ground.
appoggio stabile e verificare che non sussistano
rischi di spostamenti imprevisti. 3. Make sure that the product is placed on a stable
base thereby avoiding that the product moves
4. Accatastare il prodotto imballato (se consentito)
about unexpectedly.
seguendo le indicazioni riportate sull'imballo stesso.
4. Stack the packaged product (if allowed) following
Per periodi di magazzinaggio previsti superiori a 6
the indications given on the packaging itself.
mesi, verificare ed eventualmente eseguire le seguenti
operazioni. For storing periods that go beyond 6 months, check
and consult the following procedures.
5. Per evitare ossidazioni, ricoprire tutte le parti
esterne lavorate con grasso. 5. To avoid oxidation, cover all the worked external
parts with grease.
6. Riempire completamente i riduttori di olio
lubrificante. 6. Fill completely the gearboxes with lubricant oil.

Informazioni Information
I riduttori, prima del loro utilizzo, dovranno essere Before use, the gearboxes should be filled with the
riempiti con la corretta quantità e tipo di proper amount of lubricant of the recommended
lubrificante previsto. type.

INFORMAZIONI GENERALI -7- GENERAL INFORMATIONS

008 911 17 BOMAG 515
13.3 Travel gear

2. INFORMAZIONI TECNICHE 2. TECHNICAL INFORMATIONS

2.1. Descrizione del prodotto 2.1. Product description

I riduttori BONFIGLIOLI TRASMITAL della serie The BONFIGLIOLI TRASMITAL gearboxes of the
descritta in questo manuale sono stati progettati e series described in this manual are designed and built
costruiti per essere applicati su rulli gommati per il for wheel drive of pneumatic tyred roller machines.
comando ruota.
An important piece of advice given is “to perfectly”
Una importante raccomandazione è di progettare “a design the main hydraulic system.
regola d’arte” l’impianto idraulico di comando.
The illustrations show the parts and the main functions
L’illustrazione mostra le parti e le principali funzioni di of the gearbox.
un riduttore.

Gruppo riduttore
Gearbox kit
Gruppo riduzioni
Reduction kit

Gruppo riduzione angolare

Right angle reduction kit

Gruppo riduzioni
Reduction kit

Gruppo freno
Brake kit

IDM-15220600600.tif

INFORMAZIONI TECNICHE -8- TECHNICAL INFORMATIONS

516 BOMAG 008 911 17
Travel gear 13.3

Gruppo riduzioni
Reduction kit

IDM-15220600700.tif

Gruppo freno
Brake kit

IDM-15220600800.tif

INFORMAZIONI TECNICHE -9- TECHNICAL INFORMATIONS

008 911 17 BOMAG 517
13.3 Travel gear

Posizione dei tappi olio sul riduttore/ Oil plugs position on the gearbox

IDM-15220600900.tif

Legenda: Legend:
1 1
M18x1,5 ......................................... Tappo carico olio M18x1,5 .............................................. Oil filling plug
2 2
M14x1,5 ......................................... Tappo livello olio M14x1,5 ............................................... Oil level plug
3 3
M18x1,5 ....................................... Tappo scarico olio M18x1,5 ......................................... Oil draining plug
4 4
M14x1,5 .............................................. Tappo chiuso M14x1,5 ................................................ Closed plug
5 5
G 1/4” (n° 2) ..................................... Comando freno G 1/4” (nos. 2) ............................. Brake release port
6 6
G 1/4” (n° 2) ........................ Comando azionamento G 1/4” (nos. 2) ............................. Dynamic operated
dinamico del freno brake port
7 7
G 3/4” .......... Entrata olio lubrificazione forzata freno G 3/4” ............. Forced oil brake lubrication inlet port
8 8
G 3/4” ............ Uscita olio lubrificazione forzata freno G 3/4” ........... Forced oil brake lubrication outlet port
9 9
G 3/8” .................................. Tappo scarico olio freno G 3/8” ................................... Oil brake draining plug

INFORMAZIONI TECNICHE - 10 - TECHNICAL INFORMATIONS

518 BOMAG 008 911 17
Travel gear 13.3

3. INFORMAZIONI SULL’INSTALLAZIONE 3. INSTALLATION INFORMATIONS

3.1. Procedure per l’installazione 3.1. Installation procedure

Prima dell'installazione eseguire le seguenti operazioni. Before proceeding with installation, follow the
instructions given below.
1. Pulire accuratamente il prodotto dai residui
dell'imballaggio e di protezione. 1. Properly clean the product removing packaging
and all remains of protection padding.
2. Predisporre le parti di accoppiamento facendo
riferimento al disegno di installazione. 2. Prepare the parts to be coupled using the
installation drawing as a guide.
Le fasi principali di installazione sono di seguito
elencate. Nei paragrafi successivi sono indicate, in The main installation processes are given below. In the
dettaglio, le operazioni da eseguire. following sections, the procedures to follow are given
– Installazione del motore idraulico (paragrafo 3.2.) in detail.
– Installazione del prodotto sulla macchina – Hydraulic motor installation (section 3.2.)
(paragrafo 3.3.) – Mounting the product to the machine (section 3.3.)
– Fissaggio ruota al motoriduttore (paragrafo 3.4.) – Fixing of the wheel to the gearmotor (section 3.4.)
– Collegamento del freno (paragrafo 3.5.) – Connecting the brake (section 3.5.)
– Riempimento e livello dell'olio lubrificante riduttore – Filling-up the gearmotor with lubricating oil and level
(paragrafo 3.7.). of oil to maintain in the gearbox (section 3.7.).

INFORMAZIONI SULL’INSTALLAZIONE - 11 - INSTALLATION INFORMATIONS

008 911 17 BOMAG 519
13.3 Travel gear

3.2. Installazione del motore idraulico 3.2. Hydraulic motor installation

Assicurarsi che le superfici di accoppiamento ed il The mating areas and the pilot diameter of the gearbox
centraggio dove va inserito il motore idraulico siano where the motor is to be mounted must be clean and
pulite ed esenti da bave. without burrs.

Informazioni Information
Prima di montare il motore idraulico, verificare, Before assembling the hydraulic motor, verify by a
con un calibro per interni, il corretto assemblaggio depth slide gauge the correct assembly of the unit
del riduttore controllando la quota assiale indicata checking the axial distance as shown in the
nello schema seguente. scheme below.
1. Montare la guarnizione O-ring (A) nella propria 1. Fit the O-ring seal (A) in its seat in the hydraulic
sede nel motore idraulico ed assemblare motor, and assemble it to the gearbox being
quest'ultimo al riduttore facendo attenzione a non careful not to damage the seal already fitted.
danneggiare la guarnizione precedentemente
2. Tighten the nos. 4 screws M16 (B), grade 8,8, by a
montata.
torque wrench at 215 Nm torque.
2. Serrare le n° 4 viti M16 (B), classe di resistenza
8,8, con una chiave dinamometrica alla coppia di
215 Nm.

Informazioni Information
Togliere i tappi in plastica a protezione degli Only when it is necessary to attach pipes, remove
attacchi solamente al momento del collegamento the plastic caps protecting the connections, this
dei tubi, per evitare l’immissione di qualsiasi corpo will ensure that no foreign body goes inside the
estraneo all’interno del motore idraulico. hydraulic motor.

B A

IDM-15220601000.tif

Legenda: Legend:
B B
n° 4 viti ...............................M16 classe 8,8 - 215 Nm n° 4 screws......................... M16 grade 8,8 - 215 Nm

INFORMAZIONI SULL’INSTALLAZIONE - 12 - INSTALLATION INFORMATIONS

520 BOMAG 008 911 17
Travel gear 13.3

3.3. Installazione del motoriduttore sulla macchina 3.3. Installation of the wheel drive on the machine

1. Spostare il motoriduttore nella zona di 1. Move the wheel drive in the mounting area
installazione sollevandolo come indicato nel applying lifting methods shown in section 1.7.
paragrafo 1.7.
2. Clean the mating surfaces from oils or paint and fit
2. Pulire le zone di accoppiamento da protettivi o the wheel drive on the machine frame (for the
vernice ed installare il motoriduttore sul telaio correct orientation refer to the installation drawing).
macchina (per il corretto orientamento fare 3. Fix the wheel drive to the machine frame by using
riferimento al disegno di installazione). nos. 8 screws M20 (C), grade 10,9, tightened by a
3. Fissare il motoriduttore al telaio macchina con n° 8 torque wrench at 585 Nm.
viti M20 (C), classe di resistenza 10,9, serrate con
una chiave dinamometrica alla coppia di 585 Nm.

3.4. Fissaggio ruota al motoriduttore 3.4. Fixing of the wheel to the gearmotor

1. Pulire le zone di accoppiamento da protettivi o 1. Clean the mating surfaces from oils or paint and
vernice ed assemblare la ruota al motoriduttore. assemble the wheel to the gearmotor.
2. Fissare le ruote al motoriduttore con n° 20 viti 2. Fix the wheels to the wheel drive by using nos. 20
M20x1,5 (D), classe minima di resistenza 10,9, screws M20x1,5 (D), grade 10,9, tightened by a
serrate con una chiave dinamometrica alla coppia torque wrench at 635 Nm.
di 635 Nm.

Telaio macchina
Machine frame
D
Ruota
C Wheel

IDM-15220601100.tif

Legenda: Legend:
C C
n° 8 viti .............................M20 classe 10,9 - 585 Nm n° 8 screws ...................... M20 grade 10,9 - 585 Nm
D D
n° 20 viti ....................M20x1,5 classe 10,9 - 635 Nm n° 20 screws ............. M20x1,5 grade 10,9 - 635 Nm

INFORMAZIONI SULL’INSTALLAZIONE - 13 - INSTALLATION INFORMATIONS

008 911 17 BOMAG 521
13.3 Travel gear

3.5. Collegamento del freno 3.5. Connecting the brake

Il riduttore è provvisto di un freno negativo a dischi The gearbox is fitted with a negative multi disk safety
multipli di sicurezza con sblocco a comando idraulico brake with hydraulic control release (parking brake).
(freno di stazionamento). For information regarding the characteristics of the
Per informazioni riguardanti le caratteristiche del freno, brake refer to the installation drawing.
fare riferimento al disegno di installazione.

DATI FRENO / BRAKE TECHNICAL DATA

Pressione minima di completa apertura/minimum brake release pressure (bar) 19

Pressione massima di comando freno/ Maximum operating pressure brake (bar) 50

Coppia frenante/ Braking torque (Nm) 900 ± 10%

Informazioni Information
Togliere i tappi in plastica a protezione degli Only when it is necessary to attach pipes, remove
attacchi solamente al momento del collegamento the plastic caps protecting the connections, this
dei tubi, per evitare l'immissione di qualsiasi corpo will ensure that no foreign body goes inside the
estraneo all'interno del motore idraulico. hydraulic motor.
1. Effettuare i seguenti collegamenti al freno (per 1. Pipe the brake as shown below (for hose sizes and
dimensione e tipo, fare riferimento al disegno di dimensions refer to the installation drawing).
installazione).
– Comando apertura freno; porte “5”. – Brake release ports: “5”.
– Comando azionamento dinamico freno; porte “6”. – Dynamic operated brake ports: “6”.
– Entrata olio lubrificazione forzata freno; porta “7”. – Forced oil brake lubrication inlet port: “7”.
– Uscita olio lubrificazione forzata freno; porta “8”. – Forced oil brake lubrication outlet port: “8”.

IDM-15220601200.tif

Caratteristiche olio lubrificazione forzata freno / Forced oil brake lubrication characteristics

Portata olio nominale / Nominal oil flow (l/1') 23

Portata olio max intermittente / Max intermittent oil flow (l/1') 33

Contropressione massima intermittente alla porta "9"

(bar) 6
Intermittent max back pressure at drain port "9"

Temperatura max olio in uscita porta "8"

(°C) 100
Max oil output temperature port "8"

INFORMAZIONI SULL’INSTALLAZIONE - 14 - INSTALLATION INFORMATIONS

522 BOMAG 008 911 17
Travel gear 13.3

3.6. Caratteristiche olio lubrificazione forzata freno 3.6. Characteristics of oil forced brake lubrication

L’olio deve rispondere alle caratteristiche ISO VG 46. Lubrication must reflect the ISO VG 46 characteristics.
L’olio deve essere filtrato con grado massimo di It must be filtered with a maximum grade of 50 μm.
50 μm.
It is advised not to mix together oils with different
È opportuno non mescolare fra loro olii con proprietà properties.
differenti.
It is advised to use a filter with a led indicator that can
È consigliato usare un filtro con indicatore visivo be seen externally, with a flow control valve that blocks
d’intasamento visibile dall’esterno, con una valvola the flow of oil when the filter is clogged.
limitatrice che blocchi il flusso dell’olio quando il filtro
If it is necessary to work in low temperatures (artic
sia intasato.
climates) it is essential to use specific guidelines
Qualora si dovesse lavorare a basse temperature (contact the manufacturer).
(climi artici) sono necessarie norme specifiche
Checking the temperature of the hydraulic oil is one of
(contattare il costruttore).
the most critical aspects of the hydraulic system.
Il controllo della temperatura dell’olio idraulico è una
High operational temperatures will cause a
delle costanti più critiche nel sistema idraulico.
degradation of the oxidation resistance level and will
Alte temperature di esercizio, causano un degrado accelerate the deterioration process of the hydraulic
della resistenza all’ossidazione ed accelerano il oil.
deterioramento dell’olio idraulico.

INFORMAZIONI SULL’INSTALLAZIONE - 15 - INSTALLATION INFORMATIONS

008 911 17 BOMAG 523
13.3 Travel gear

3.7. Riempimento olio lubrificante del riduttore 3.7. Filling-up the gearbox with lubricating oil
La lubrificazione è separata fra motore e riduttore. The motor and the gearbox have separate lubrication.
La lubrificazione del riduttore è a sbattimento in The gearbox is lubricated by oil splashing.
bagno d'olio. L'olio consigliato è del tipo per The recommended type of oil is SAE 80W/90 or
trasmissioni ad ingranaggi, con viscosità SAE 85W/140 with EP features complying with
SAE 80W/90 oppure SAE 85W/140 con MIL-L-2105 C & API GL5.
caratteristiche EP rispondente a: MIL-L-2105 C & In following table the most common brands of lubricant
API GL 5. and the types recommended are shown.
Nella tabella seguente sono riportate le marche più
diffuse di lubrificanti con i tipi di olio consigliati.

Informazioni Information
Durante l'esercizio e solo per brevi momenti l'olio During operation the oil temperature must not
può raggiungere, ma non superare, la temperatura exceed 85-90°C intermittent.
di 85-90°C intermittente.

Elenco olii consigliati a Norme SAE 80W/90 e SAE 85W/140 con caratteristiche API GL5
Lubricant oils suggested according SAE 80W/90 and SAE 85W/140 API GL5 grade

Temperatura ambiente
-20°C / +30°C +10°C / +45°C
Ambient temperature
SAE 80W/90 SAE 85W/140
Viscosità olio / Oil viscosity

Produttori / Manufacturers Tipo olio / Oil Brand

SHELL SPIRAX HD SPIRAX HD

AGIP ROTRA MP ROTRA MP

ARAL GETRIEBEOL HYP GETRIEBEOL HYP

BP-MACH HYPOGEAR EP HYPOGEAR EP

CASTROL HYPOY HYPOY

CHEVRON UNIVERSAL GEAR LUBRICANT UNIVERSAL GEAR LUBRICANT

ELF TRANSELF B TRANSELF B

ESSO GEAR OIL GX PONTONIC MP GEAR OIL GX PONTONIC MP

I.P. PONTIAX HD PONTIAX HD

MOBIL MOBILUBE HD MOBILUBE HD

TOTAL TRASMISSION TM TRASMISSION TM

Informazioni Information
In caso di lubrificazione con olii sintetici, è consigliato In case of lubrication with syntetic oils, is
utilizzare solo quelli a base Polialfaolefine (PAO). recommended to use only oils with PAO base.
Non mescolare olii di marca o caratteristiche diverse. Do not mix together oils of different brands or
characteristics.

INFORMAZIONI SULL’INSTALLAZIONE - 16 - INSTALLATION INFORMATIONS

524 BOMAG 008 911 17
Travel gear 13.3

Informazioni Information
Il riduttore viene fornito privo di olio ma The gearbox is supplied without oil; anyway it has
predisposto con tappi di carico, scarico e livello. filling, draining and oil level plugs. Before putting
Prima della messa in funzione occorre eseguire il the gearbox into operation, it is necessary to fill it
riempimento. with oil.
Eseguire questa operazione come di seguito indicato. This procedure is undertaken following the indications
given below.

1. Con l'asse del riduttore in orizzontale, ruotare il 1. Check that the gearbox axis is horizontal. Rotate
corpo fino a che il tappo di scarico (3) si trovi in the gearbox housing until the drain plug (3) is on
basso sull'asse verticale del coperchio di chiusura. the bottom of the vertical axis of the end cover.
2. Svitare i tappi di carico e livello olio (1-2). 2. Unscrew the fill and level oil plugs (1-2).
3. Riempire dal foro (1) fino a che l'olio lubrificante 3. Fill from the hole (1) until the lubricant oil flows out
non fuoriesca dal foro (2). from the hole (2).
4. Avvitare i tappi di carico e livello olio (1-2) e 4. Tighten the fill and level oil plugs (1-2) and let the
mettere in funzione il riduttore; attendere qualche gearbox run. After a few minutes, stop and check
istante, poi verificare nuovamente il livello dell'olio. the oil level.
5. Aggiungere olio lubrificante se necessario. 5. If necessary, refill with lubricant oil.

IDM-15220601600.tif

INFORMAZIONI SULL’INSTALLAZIONE - 17 - INSTALLATION INFORMATIONS

008 911 17 BOMAG 525
13.3 Travel gear

3.8. Prima messa in esercizio e rodaggio 3.8. First start up and running in

In questa prima fase, si raccomanda di adottare alcune In this first stage it is advised to follow the measures
precauzioni come di seguito indicato. given below.

1. Eliminare eventuale aria residua dal circuito 1. Bleed air from every part of the hydraulic circuit
idraulico e aggiungere olio nel serbatoio se and add oil in the tank if necessary.
necessario.

Informazioni Information
La presenza di aria residua nel circuito idraulico si The presence of residual air in the hydraulic circuit
manifesta con la presenza di schiuma nel will manifest itself with the presence of foam in the
serbatoio e causa un funzionamento a strappi del tank and will lead to a jerking of the motor as well
motore ed un eccessiva rumorosità del motore e as excessive noise coming from the motor and the
delle valvole. valves.
2. Avviare il motoriduttore a bassa velocità ed 2. Start the gearmotor at a low speed and gradually
incrementare gradualmente, dopo avere verificato increase it after having verified that it is functioning
che il funzionamento sia corretto, in assenza di correctly without any noises or vibrations.
rumore e vibrazioni.

Informazioni Information
Non arrivare alla massima pressione sino a Do not reach maximum pressure unless the entire
quando tutto l'impianto non sia stato filtrato per system has been filtered to eliminate any particles
l'eliminazione di eventuali particelle di impurità. of dirt that may be present.

Durante il rodaggio eseguire le operazioni di seguito During the running-in stage follow the steps given
indicate. below.

3. Controllare che il numero dei giri ed il senso di 3. Make sure that the speed and direction of rotation
rotazione siano corretti. are correct.
4. Controllare che il funzionamento sia regolare ed in 4. Make sure that the functioning is regular and
assenza di rumore eccessivo e vibrazioni. without any excessive noises and vibrations.
5. Controllare che la temperatura dell’olio non superi 5. Make sure that the oil temperature does not
i 90°C. exceed 90°C.
Al termine di questo primo rodaggio eseguire le After having terminated this first running-in follow the
operazioni di seguito indicate. steps given below.
6. Controllare che non vi siano perdite d’olio. In caso 6. Check that there are no oil leakages. If present,
contrario provvedere alla loro eliminazione proceed to remove them.
7. Controllare il livello dell’olio lubrificante del 7. Check the level of lubricating oil in the gearmotor.
motoriduttore. 8. It could happen that due to the presence of air,
8. Durante il primo avviamento, causa l’eventuale during the first start up, the opening action of the
presenza di aria, l’apertura del freno potrebbe brake could be slowed down. It is advised to repeat
risultare ritardata. Ripetere alcune volte il the opening and closing function of the brake.
comando di apertura e chiusura del freno. 9. Check that there are no other problems in general.
9. Controllare che non vi siano altri problemi.

INFORMAZIONI SULL’INSTALLAZIONE - 18 - INSTALLATION INFORMATIONS

526 BOMAG 008 911 17
Travel gear 13.3

4. INFORMAZIONI SULLA MANUTENZIONE 4. MAINTENANCE INFORMATIONS

4.1. Manutenzione periodica 4.1. Periodic maintenance

Il riduttore necessita solamente delle operazioni di The gearbox only requires the scheduled maintenance
manutenzione programmata prevista dal costruttore procedures set out by the manufacturer (see Table
(vedi tabella). below).

Una buona manutenzione consentirà la continuità di Good maintenance will ensure an on going functioning
funzionamento nel tempo con la massima affidabilità. in time as well as maximum reliability.

Nel caso in cui insorgano anomalie di funzionamento Should irregularities in function arise, it will be
sarà necessario consultare la check-list della ricerca necessary to consult the troubleshooting checklist to
guasti per trovare una soluzione adeguata. find the most adequate solution.

In caso contrario potrebbe essere necessario If unsuccessful, it may be necessary to disassemble a

effettuare lo smontaggio parziale o completo del partially or completely the motorgearbox (see
motoriduttore (vedi paragrafo 4.4.) section 4.4.)

Controllo / Inspection Frequenza / Frequency Azione / Action

Serraggio viti Dopo le prime 50 ore Verifica serraggio viti

Tightening screws After the first 50 hours Screws tighening torque check

Livello olio Ogni 100 ore Rabboccare l’olio

Oil level Every 100 hours Refill oil

Primo cambio olio A 150 ore Sostituire olio

1st oil change At 150 hours Oil replacement

Cambi olio successivi Ogni 1000 ore o 1 anno Sostituire olio

Following oil changes Every 1000 hours or 1 year Oil replacement

INFORMAZIONI SULLA MANUTENZIONE - 19 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 527
13.3 Travel gear

4.2. Sostituzione dell'olio lubrificante 4.2. Changing the lubricating oil

1. Con l'asse del riduttore in orizzontale, ruotare il 1. Check that the gearbox axis is horizontal. Rotate
corpo fino a che il tappo di scarico (3) si trovi in the gearbox housing until the drain plug (3) is on
basso sull'asse verticale del coperchio di chiusura. the bottom of the vertical axis of the end cover.
2. Svitare i tappi (1-3) e fare defluire l'olio in un 2. Unscrew the plugs (1-3) and let the oil flow in a
recipiente sufficientemente capiente; per large enough container; in order to facilitate the
agevolare l'operazione di scarico è bene operare draining must be oil still warm.
con olio caldo.
3. Wait a few minutes until all the oil is drained and
3. Attendere qualche minuto affinché tutto l'olio sia then proceed to screw on the plugs (1-3).
uscito, quindi avvitare i tappi (1-3).
4. Proceed with the oil fill-up following the procedures
4. Effettuare il riempimento dell'olio seguendo le given (see section 3.7.).
modalità predefinite (vedi paragrafo 3.7.).

Informazioni Information
Si raccomanda di non miscelare oli a base Never mix mineral oils with synthetic oils and vice
minerale con oli a base sintetica e viceversa. versa.

Cautela - Precauzione Caution

Non disperdere l'olio nell'ambiente ma smaltirlo Do not dispose of the oil in the natural
rispettando le leggi vigenti in materia. environment but be careful to eliminate it in
compliance with the relative rules and regulations
that govern locally.

IDM-15220601700.tif

INFORMAZIONI SULLA MANUTENZIONE - 20 - MAINTENANCE INFORMATIONS

528 BOMAG 008 911 17
Travel gear 13.3

4.3. Ricerca guasti 4.3. Troubleshooting

La seguente tabella è stata realizzata per una The following table is realized to localize troubles in the
individuazione dei guasti nei riduttori per traslazione. gearbox.

Anomalie / Anomalies Cause / Causes Rimedi / Remedies

Perdita olio esterna / External oil leakage:
Dalla tenuta frontale a)Tenuta frontale danneggiata a)Sostituzione tenuta frontale
From the lifetime seal Lifetime damaged Replace lifetime seal

Dal coperchio a)Guarnizione O-ring danneggiata a)Sostituzione guarnizioni O-ring

From the end cover O-ring seal damaged Replace O-ring seals

a)Guarnizione tappo danneggiata a)Sostituzione guarnizione tappo

Plug seal damaged Replace plug seal
Dai tappi
From the plugs
b)Tappi o viti allentate b)Serrare tappi/viti
Plugs or screws loose Tighten the plugs/screws
Eccessiva rumorosità / Too much noise:
Rumore idraulico (in fase a)Impianto idraulico a)Verificare l'impianto idraulico
di rallentamento malfunzionante
velocità motore) Hydraulic circuit malfunctioning Verify hydraulic circuit
Hydraulic noise (during the
slowing down of the motor
speed)

Interno al riduttore (zona a)Danneggiamento interno a)Verificare riduttore

ingranaggi) Internal damage Check the gearbox
Inside the gearmotor
(reductions)
Altro / Other:
a)Livello olio scarso a)Verificare livello olio e aggiungerne
se necessario
Insufficient oil level Check the oil level and refill if
necessary
Surriscaldamento
Overheating b)Olio idraulico troppo caldo b)Verificare circuito idraulico
Hydraulic oil too warm Check the hydraulic circuit

c)Incompleta apertura freno c)Verificare pressione apertura freno

Brake not fully released Check brake release pressure

Malfunzionamento freno di stazionamento

Parking brake malfunctioning
Coppia frenante
a)Dischi freno usurati a)Sostituzione dischi freno
insufficiente
Brake discs worm Replace brake disc pack
Insufficient braking torque
b)Parti danneggiate b)Verifica componenti freno
Damaged parts Check brake components

a)Freno bloccato a)Verifica completa apertura freno

Parking brake locked Check the complete brake release
Rotazione ruota bloccata
b)Componenti meccanici b)Sostituzione parti danneggiate
Wheel locked
danneggiati
Mechanical components Replace damaged parts
damaged

INFORMAZIONI SULLA MANUTENZIONE - 21 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 529
13.3 Travel gear

4.4. Smontaggio del motoriduttore 4.4. Motorgearbox disassembly

Nel caso in cui sia necessario effettuare una revisione In the case that it was necessary to undergo a (partial
(parziale o totale) è necessario smontare il riduttore or total) revision, it will be necessary to dismount the
dalla macchina. Considerando che questo è un gearbox from the machine. As this is known as an out
intervento di manutenzione straordinaria, è opportuno of the ordinary maintenance procedure, it is important
che venga realizzato da personale con competenze that only personnel with specific skills and experience
specifiche e capacità acquisite. undertake it.

E' altresì importante che tale intervento sia effettuato in It is also important that this procedure is undertaken in
una officina opportunamente attrezzata. Oltre ai a workshop that is adequately tooled. As well as normal
normali attrezzi, è necessario disporre delle workshop tools it will be necessary to use special tools
attrezzature speciali che possono essere costruite that can be made (see special tools attachment) or may
(vedi allegati attrezzature speciali) oppure richieste be requested from the manufacturer.
direttamente al costruttore.

Attrezzature speciali Special Tools

Anello montaggio Tool for lifetime seal
tenuta frontale .......................... Codice/: 6689960610 assembly ...................................... Code/: 6689960610
Moltiplicatore di coppia............ Codice/: ATZ.09.003.1 Torque multiplier......................... Code/: ATZ.09.003.1

Per la realizzazione di queste attrezzature vedi disegni To be able to produce these equipments refer to the
costruttivi in fondo al manuale. production drawings at the end of this manual.

INFORMAZIONI SULLA MANUTENZIONE - 22 - MAINTENANCE INFORMATIONS

530 BOMAG 008 911 17
Travel gear 13.3

Nelle pagine seguenti vengono riportate tutte le fasi di In the following pages all the procedures for
smontaggio e rimontaggio del riduttore: rispettarle disassembling and reassembling the gearbox are
scrupolosamente. given, it is important to strictly adhere to them.
Eseguire questi interventi adottando tutte le Proceed with these operations using all the necessary
necessarie precauzioni, come ad esempio: safety measures, like for example:
1. chiudere tutti gli attacchi all'impianto oleodinamico 1. Plug all the Hydraulic ports on the gearbox to avoid
sul riduttore per evitare l'introduzione accidentale the introduction of any foreign particles in the
di corpi estranei nel circuito e nel riduttore. circuit and the gearbox.
2. fare attenzione che le superfici di accoppiamento 2. Making sure that the coupling surfaces are not
non vengano danneggiate. damaged.
3. eseguire la movimentazione in modo che non crei 3. Following the handling so as to be sure that there
pericoli per la sicurezza delle persone e garantisca are no risks for human safety and to guarantee the
l'integrità del riduttore. reliability of the gearbox.
4. predisporre la zona di lavoro al fine di rispettare le 4. Making available a work area that is in line with
leggi in materia di sicurezza e salute nei posti di work and health safety in the workplace guidelines.
lavoro.

NOTA: di seguito sono indicate tutte le fasi per NOTE: Below are all the steps to follow during these
eseguire questi interventi. I numeri fra parentesi nel operations. Numbers in brackets in the text correspond
testo, corrispondono ai riferimenti riportati nel to the references in the exploded view.
seguente disegno esploso.

Gruppo riduttore
Gearbox kit A1
A2
A3
A4
A5

A4

A3
A11 A2
A1
A6

A7
A8
A9
A10

A12

A7
A13
A14
A15

IDM-15220600300.tif

INFORMAZIONI SULLA MANUTENZIONE - 23 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 531
13.3 Travel gear

Gruppo riduzioni
Reduction kit

B1
B2
B3
B4
B5
B6

B16
B13
B17
B14 B15
B18

B7
B8
B9
B10
B11
B12
IDM-15220600400.tif

Gruppo freno
Brake kit

C7
C8

C11 C1
C12 C2
C13 C3
C14 C4
C5
C6

C9
C15 C10
C16
C17
C18
C19
C20
C7
C8

C21
C22
C23

IDM-15220600500.tif

INFORMAZIONI SULLA MANUTENZIONE - 24 - MAINTENANCE INFORMATIONS

532 BOMAG 008 911 17
Travel gear 13.3

4.5. Fasi di smontaggio 4.5. Disassembling method

Informazioni Information
Per eseguire lo smontaggio del riduttore occorre For starting the gearbox disassembly it is now
smontarlo dalla macchina e recarsi in un'officina necessary to remove it from the machine and
opportunamente attrezzata. move it to a properly equipped workshop.
Per dare inizio alla fase di smontaggio, fare defluire Before wheel drive disassembling, make sure that the
completamente l'olio lubrificante dal riduttore secondo oil is discharged according to instructions specified in
quanto descritto al paragrafo 4.2. section 4.2.
Svitare e sfilare le n° 4 viti M16, classe di resistenza Unscrew and remove the nos. 4 screws M16, grade
8,8, e togliere il motore idraulico e la propria 8,8, and remove the hydraulic motor and its O-ring
guarnizione O-ring. seal.

4.6. Fasi di smontaggio riduttore 4.6. Gearbox disassembly method

1. Svitare le n° 16 viti M12x40 (A3), classe di

resistenza 12,9, dal 1° gruppo riduttore (A2).

Unscrew the nos. 16 screws M12X40 (A3), grade

12,9, from the 1st gearbox kit (A2).

2. Servendosi di un paranco sfilare il 1° gruppo

riduttore (A2).

Informazioni
Fare attenzione a non daneggiare il tubo (A6)
durante questa fase.

By using a tackle remove the 1st gearbox kit (A2).

Information
Taking care not to damage the tube (A6) during
this step.

3. Sfilare il tubo (A6).

Remove the tube (A6).

INFORMAZIONI SULLA MANUTENZIONE - 25 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 533
13.3 Travel gear

4.6. Fasi di smontaggio riduttore 4.6. Gearbox disassembly method

4. Svitare le n° 16 viti M12x40 (A3), classe di

resistenza 12,9, dal 2° gruppo riduttore (A2).

Unscrew the nos. 16 screws M12X40 (A3), grade

12,9, from the 2nd gearbox kit (A2).

5. Servendosi di un paranco sfilare il 2° gruppo

riduttore (A2).

By using a tackle remove the 2nd gearbox kit (A2).

6. Svitare le n° 8 viti M10x30 (A12), classe di

resistenza 8,8, dal gruppo freno (A15).

Unscrew the nos. 8 screws M10X30 (A12), grade

8,8, from the brake kit (A15).

7. Sfilare il gruppo freno (A15).

Remove the brake kit (A15).

INFORMAZIONI SULLA MANUTENZIONE - 26 - MAINTENANCE INFORMATIONS

534 BOMAG 008 911 17
Travel gear 13.3

4.6. Fasi di smontaggio riduttore 4.6. Gearbox disassembly method

8. Sfilare l’albero scanalato (A13) dal gruppo

freno (A15).

Remove the splined shaft (A13) from the brake

kit (A15).

9. Togliere le guarnizioni O-ring (A14) dalle proprie

sedi nell’albero scanalato (A13).

Remove the O-ring seals (A14) from their seats in

the splined shaft (A13).

10. Svitare le n° 16 viti M10x30 (A12), classe di

resistenza 8,8, dalla riduzione angolare (A5).

Unscrew the nos. 16 screws M10X30 (A12), grade

8,8, from the right angle reduction (A5).

11. Sfilare la flangia di collegamento (A10).

Remove the connecting flange (A10).

INFORMAZIONI SULLA MANUTENZIONE - 27 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 535
13.3 Travel gear

4.6. Fasi di smontaggio riduttore 4.6. Gearbox disassembly method

12. Togliere le guarnizioni O-ring (A7) dalle proprie

sedi nella flangia di collegamento (A10).

Remove the O-ring seals (A7) from their seats in

the connecting flange (A10).

13. Sfilare il giunto di collegamento (A8).

Remove the coupling (A8).

14. Servendosi di pinze sfilare l'anello elastico (A9)

dalla propria sede nel giunto di collegamento (A8).

By using pliers remove the circlip (A9) from its seat

in the coupling (A8).

INFORMAZIONI SULLA MANUTENZIONE - 28 - MAINTENANCE INFORMATIONS

536 BOMAG 008 911 17
Travel gear 13.3

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

15. Sfilare il solare di 1° riduzione (B1).

Remove the 1st stage sun gear (B1).

16. Estrarre, contemporaneamente, la 1°

riduzione (B2) e il solare di 2° riduzione (B10).

Remove, at the same time, the 1st reduction

assembly (B2) and the 2nd stage sun gear (B10).

17. Sfilare il solare di 2° riduzione (B10).

Remove the 2nd stage sun gear (B10).

18. Togliere la guarnizione O-ring (A4) dalla propria

sede nel mozzo flangiato (B3).

Remove the O-ring seal (A4) from its seat in the

flanged hub (B3).

INFORMAZIONI SULLA MANUTENZIONE - 29 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 537
13.3 Travel gear

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

19. Capovolgere il riduttore e svitare il tappo di livello

olio (B17) con chiave esagonale maschio.

Turn the gearbox upside down and unscrew the

level oil plug (B17) by a male hex head wrench.

20. Svitare i tappi di carico-scarico olio (B16) con

chiave esagonale maschio.

Unscrew the draining-filling oil plugs (B16) by a

male hex head wrench.

21. Svitare le n° 10 viti M10x20 (A1-B12), classe di

resistenza 8,8, dal coperchio di chiusura (B15).

Unscrew the nos. 10 screws M10x20 (A1-B12),

grade 8,8, from the end cover (B15).

22. Sfilare il coperchio di chiusura (B15).

Remove the end cover (B15).

INFORMAZIONI SULLA MANUTENZIONE - 30 - MAINTENANCE INFORMATIONS

538 BOMAG 008 911 17
Travel gear 13.3

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

23. Togliere la guarnizione "X-ring" (B14) dalla propria

sede nel coperchio di chiusura (B15).

Remove the "X-ring" seal (B14) from its seat in the

end cover (B15).

24. Togliere la guarnizione O-ring (B11) dalla propria

sede nel corpo riduttore (B6).

Remove the O-ring seal (B11) from its seat in the

gearbox housing (B6).

25. Servendosi di pinze sfilare gli anelli elastici (B9)

dalle proprie sedi situate nei perni del mozzo
flangiato (B3).

By using pliers remove the circlips (B9) from their

seats in the flanged hub’s pins (B3).

26. Servendosi di un estrattore sfilare i gruppi planetari

di 2° riduzione (B8).

By using a puller remove the planet assemblies of

the 2nd reduction (B8).

INFORMAZIONI SULLA MANUTENZIONE - 31 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 539
13.3 Travel gear

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

27. Servendosi di un trapano eliminare le cianfrinature

presenti sulla ghiera (B7).

By using a drill remove the calkings on the ring

nut (B7).

28. Posizionare il moltiplicatore di coppia

(ATZ.09.003.1) sulla ghiera (B7). Servendosi del
moltiplicatore di coppia svitare la ghiera (B7).

ATZ.09.003.1
Place the torque multiplier (ATZ.09.003.1) on the
ring nut (B7). By using the torque multiplier loosen
the ring nut (B7).

29. Rimuovere la ghiera (B7).

Take out the ring nut (B7).

30. Servendosi di una pressa e di un tampone

metallico, sfilare il mozzo flangiato (B3) dal corpo
riduttore (B6).

By using a press and a metal stopper, remove the

flanged hub (B3) from the gearbox housing (B6).

INFORMAZIONI SULLA MANUTENZIONE - 32 - MAINTENANCE INFORMATIONS

540 BOMAG 008 911 17
Travel gear 13.3

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

31. Servendosi di un paranco sfilare il mozzo

flangiato (B3) dal corpo riduttore (B6).

By using a tackle remove the flanged hub (B3)

from the gearbox housing (B6).

Informazioni Information
Può essere necessario in caso di perdite olio, In case of oil leakages, it might be necessary to
dover provvedere al controllo ed alla eventuale check and eventually replace the lifetime
sostituzione della tenuta frontale (B4), cioè di seal (B4), which means both the metal rings parts
entrambe le parti metalliche e delle guarnizioni and the O-ring seals.
O-ring.

32. Sfilare la 1° semitenuta frontale (B4) dal mozzo

flangiato (B3).

Remove the 1st half-seal (B4) from the flanged

hub (B3).

33. Sfilare la 2° semitenuta frontale (B4) dal corpo

riduttore (B6).

Remove the 2nd half-seal (B4) from the gearbox

housing (B6).

INFORMAZIONI SULLA MANUTENZIONE - 33 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 541
13.3 Travel gear

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

34. Servendosi di un estrattore e di un tampone

metallico, smontare l’anello interno del cuscinetto
dal mozzo flangiato (B3).

By using a puller and a metal stopper, remove the

bearing inner raceway from the flanged hub (B3).

35. Sfilare l'anello interno del cuscinetto dal mozzo

flangiato (B3).

Remove the bearing inner raceway from the

flanged hub (B3).

36. Servendosi di pinze estrarre l’anello di

spallamento (B5) dal corpo riduttore (B6).

By using pliers remove the elastic ring (B5) from

the gearbox housing (B6).

37. Sfilare i supporti in plastica e le sfere dal corpo

riduttore (B6).

Remove the plastic supports and the balls from the

gearbox housing (B6).

INFORMAZIONI SULLA MANUTENZIONE - 34 - MAINTENANCE INFORMATIONS

542 BOMAG 008 911 17
Travel gear 13.3

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

38. Sfilare l'anello interno del cuscinetto dal corpo

riduttore (B6).

Remove the bearing inner raceway from the

gearbox housing (B6).

Informazioni Information
Per lo smontaggio del secondo gruppo For the 2nd gearbox kit (A2) disassembly follow
riduttore (A2) seguire le stesse fasi descritte nel the same steps shown in section 4.7.
paragrafo 4.7.

INFORMAZIONI SULLA MANUTENZIONE - 35 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 543
13.3 Travel gear

4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method

39. Posizionare il gruppo freno (A15) su di un

distanziale.

Place the brake kit (A15) on a spacer.

40. Svitare le n° 8 viti M10x60 (C23), classe di

resistenza 8,8, dalla flangia predisposizione
motore (C22).

Unscrew the nos. 8 screws M10x60 (C23), grade

8,8, from the motor adaptor flange (C22).

Pericolo - Attenzione Danger - Warning

Svitare gradualmente le n° 8 viti (C23) in egual Loose the nos. 8 screws (C23) gradually by equal
misura in modo da bilanciare il carico delle molle amount each to balance the springs load on the
sulla flangia predisposizione motore (C22). motor adaptor flange (C22).

41. Sfilare la flangia predisposizione motore (C22).

Remove the motor adaptor flange (C22).

INFORMAZIONI SULLA MANUTENZIONE - 36 - MAINTENANCE INFORMATIONS

544 BOMAG 008 911 17
Travel gear 13.3

4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method

42. Togliere la guarnizione O-ring (C21) dalla propria

sede nella flangia predisposizione motore (C22).

Remove the O-ring (C21) from its seat in the motor

adaptor flange (C22).

43. Contrassegnare la posizione delle molle (C20) allo

scopo di avere un riferimento per il rimontaggio.

Mark the position of the springs (C20) as a

reference for the reassembling step.

44. Sfilare le molle (C20) dalle proprie sedi nel pistone

freno (C19).

Remove the springs (C20) from their seats in the

brake piston (C19).

45. Avvitare nei fori filettati di estrazione del pistone

freno (C19) n° 2 viti M5 e sollevarlo.

Tighten nos. 2 screws M5 in the extraction thread

holes of the brake piston (C19) and lift it.

INFORMAZIONI SULLA MANUTENZIONE - 37 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 545
13.3 Travel gear

4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method

46. Sfilare il pistone freno (C19).

Remove the brake piston (C19).

47. Togliere la guarnizione O-ring (C14) dalla propria

sede nel corpo freno (C6).

Remove the O-ring seal (C14) from its seat in the

brake housing (C6).

48. Sfilare il distanziale (C17).

Remove the spacer (C17).

49. Togliere la guarnizione O-ring (C18) dalla propria

sede nel distanziale (C17).

Remove the O-ring seal (C18) from its seat in the

spacer (C17).

INFORMAZIONI SULLA MANUTENZIONE - 38 - MAINTENANCE INFORMATIONS

546 BOMAG 008 911 17
Travel gear 13.3

4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method

50. Togliere le guarnizioni O-ring (C13) dalle proprie

sedi nel corpo freno (C6).

Remove the O-ring seals (C13) from their seats in

the brake housing (C6).

51. Sfilare, contemporaneamente, l’albero

freno (C16), il pacco dei dischi freno (C11-C12) e
il cuscinetto (C4).

Remove, at the same time, the brake shaft (C16),

the brake discs pack (C11-C12) and the
bearing (C4).

52. Sfilare il pacco dei dischi freno (C11-C12).

Remove brake discs pack (C11-C12).

53. Servendosi di un estrattore e di un tampone

metallico, sfilare il cuscinetto (C4) dall’albero
freno (C16).

By using a puller and a metal stopper, remove the

bearing (C4) from the brake shaft (C16).

INFORMAZIONI SULLA MANUTENZIONE - 39 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 547
13.3 Travel gear

4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method

54. Servendosi di pinze sfilare l'anello elastico (C15)

dalla propria sede nell’albero freno (C16).

By using pliers remove the circlip (C15) from its

seat in the brake shaft (C16).

55. Servendosi di pinze sfilare l'anello elastico (C1)

dalla propria sede nel corpo freno (C6).

By using pliers remove the circlip (C1) from its seat

in the brake housing (C6).

56. Sfilare il disco spingimolle (C2).

Remove the spring retainer disc (C2).

57. Togliere la guarnizione O-ring (C5) dalla propria

sede nel corpo freno (C6).

Remove the O-ring seal (C5) from its seat in the

brake housing (C6).

INFORMAZIONI SULLA MANUTENZIONE - 40 - MAINTENANCE INFORMATIONS

548 BOMAG 008 911 17
Travel gear 13.3

4.8. Valutazione
4.9. Fasi di smontaggio
dei pezzigruppo freno
da sostituire 4.8. Evaluating
4.9. Brake kit disassembly method
that pieces to replace

58. Togliere l’anello di tennuta (C3) dalla propria sede

nel disco spingimolle (C2).

Informazioni
Eseguire questa fase solo in caso di sostituzione.

Remove the seal ring (C3) from its seat in the

spring retainer disc (C2).

Information
Carry out this step only in case of replacement.

Informazioni Information
Lo smontaggio del riduttore termina con The gearbox disassembly ends with the above
quest'ultima operazione: tutti i particolari sono ora operation. All items are now available for the
a disposizione per le verifiche necessarie. necessary inspections.

4.9. Valutazione dei pezzi da sostituire 4.9. Evaluating that pieces to replace
I componenti soggetti ad usura sono i seguenti. The pieces that are subject to general wear and tear
– Ingranaggi. are the following:
– Cuscinetti. – Gears.
– Tutte le guarnizioni. – Bearings.
– All the seals
Sostituire i componenti usurati o guasti rispettando le Replace the used or irregular parts respecting the
seguenti indicazioni: following steps:
1. Rimuovere accuratamente lo sporco, in particolare 1. Accurately remove dirt, and in particular properly
pulire le sedi delle guarnizioni, dei cuscinetti e degli clean the seals, bearings and locking rings
anelli di bloccaggio. seating.
2. Lubrificare i componenti prima di montarli. 2. Lubricate the parts before connecting them.
3. In caso di ingranaggi danneggiati, esempio un 3. In the case of damaged gears, for example a
planetario, non sostituire il singolo ingranaggio ma planetary, do not proceed to replace the individual
tutta la riduzione. gear but the entire reduction assembly.
4. Sostituire sempre tutte le guarnizioni interessate 4. When reconnecting a part always replace all the
alla parte da rimontare. Aggiungere uno strato di seals involved. Add some grease on the seats and
grasso sulle sedi di montaggio e sulle guarnizioni on the new seals to make easier the reassembly.
nuove per facilitarne il montaggio.
5. Replace all the damaged parts with original spare
5. Sostituire le parti danneggiate con ricambi originali parts and doing so follow all the steps given by the
e rispettando le indicazioni fornite dal costruttore manufacturer in Section 4.10.
nel paragrafo 4.10.

INFORMAZIONI SULLA MANUTENZIONE - 41 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 549
13.3 Travel gear

4.10.Fasi di rimontaggio gruppo freno 4.10.Brake kit reassembling method

1. Montare l’anello di tenuta (C3) nella propria sede

nel disco spingimolle (C2).

Assemble the seal ring (C3) into its seat in the

spring retainer disc (C2).

2. Servendosi di un martello in gomma e di un

tampone metallico, spingere l’anello di tenuta (C3)
in battuta nella propria sede.

By using a rubber hammer and a metallic stopper,

push the seal ring (C3) against the seat shoulder.

3. Montare la guarnizione O-ring (C5) nella propria

sede nel corpo freno (C6).

Assemble the O-ring seal (C5) into its seat in the

brake housing (C6).

4. Inserire il disco spingimolle (C2).

Insert the spring retainer disc (C2).

INFORMAZIONI SULLA MANUTENZIONE - 42 - MAINTENANCE INFORMATIONS

550 BOMAG 008 911 17
Travel gear 13.3

4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method

5. Servendosi di un martello in gomma spingere il

disco spingimolle (C2) in battuta nella propria
sede.

By using a rubber hammer push the spring retainer

disc (C2) against the seat shoulder.

6. Servendosi di pinze, montare l’anello elastico (C1)

nella propria sede nel corpo freno (C6).

By using pliers, assemble the circlip (C1) into its

seat in the brake housing (C6).

7. Servendosi di pinze, montare l’anello

elastico (C15) nella propria sede nell’albero
freno (C16).

By using pliers, assemble the circlip (C15) into its

seat in the brake shaft (C16).

8. Inserire il cuscinetto (C4) sull’albero freno (C16).

Insert the bearing (C4) on the brake shaft (C16).

INFORMAZIONI SULLA MANUTENZIONE - 43 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 551
13.3 Travel gear

4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method

9. Servendosi di un martello in gomma e di un

tampone metallico, spingere il cuscinetto (C4) in
battuta nella propria sede.

By using a rubber hammer and a metal stopper,

push the bearing (C4) against the seat shoulder.

10. Montare l'albero freno (C16) all'interno del corpo

freno (C6).

Assemble the brake shaft (C16) inside the brake

housing (C6).

11. Montare il pacco dei dischi freno secondo il

seguente ordine: inserire per primo un disco in
bronzo sinterizzato (C11) a dentatura esterna.

Assemble the brake discs package according to

the following order: firstly, insert one sintered
bronze disc (C11) with external teeth.

12. Inserire successivamente un disco in acciaio (C12)

a dentatura interna. Ripetere l'operazione sino ad
ottenere una successione di n° 9 dischi in bronzo
sinterizzato e n° 8 in acciaio.

Then insert, an internally toothed steel disc (C12).

Repeat the operation until all nos. 9 sintered
bronze discs and nos. 8 steel discs have been
assembled.

INFORMAZIONI SULLA MANUTENZIONE - 44 - MAINTENANCE INFORMATIONS

552 BOMAG 008 911 17
Travel gear 13.3

4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method

13. Lubrificare la sede della guarnizione all'interno del

distanziale (C17) e montare la guarnizione
O-ring (C18).

Lube the seal seat into the spacer (C17) and

assemble the O-ring seal (C18).

14. Lubrificare le sedi delle guarnizioni all'interno del

corpo freno (C6) e montare le guarnizioni
O-ring (C13).

Lube the seal seats into the brake housing (C6)

and assemble the O-ring seals (C13).

15. Montare il distanziale (C17) all'interno del corpo

freno (C6), facendo attenzione a non danneggiare
le guarnizioni precedentemente montate.

Assemble the spacer (C17) inside the brake

housing (C6), paying attention not to damage the
seals already fitted.

16. Lubrificare la sede della guarnizione all'interno del

corpo freno (C6) e montare la guarnizione
O-ring (C14).

Lube the seal seat into the brake housing (C6) and
assemble the O-ring seal (C14).

INFORMAZIONI SULLA MANUTENZIONE - 45 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 553
13.3 Travel gear

4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method

17. Inserire il pistone freno (C19) all'interno del corpo

freno (C6), facendo attenzione a non danneggiare
le guarnizioni precedentemente montate.

Insert the brake piston (C19) inside the brake

housing (C6), paying attention not to damage the
seals already fitted.

18. Inserire le molle (C20) nelle sedi del pistone

freno (C19) rispettando le posizioni segnate in
precedenza.

Insert the springs (C20) into the holes in the brake

piston (C19) marked previously.

19. Montare la guarnizione O-ring (C21) nella propria

sede nella flangia predisposizione motore (C22).

Assemble the O-ring seal (C21) into its seat in the

motor adaptor flange (C22).

20. Posizionare la flangia predisposizione

motore (C22) sul corpo freno (C6).

Place the motor adaptor flange (C22) on the brake

housing (C6).

INFORMAZIONI SULLA MANUTENZIONE - 46 - MAINTENANCE INFORMATIONS

554 BOMAG 008 911 17
Travel gear 13.3

4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method

21. Serrare le n° 8 viti M10x60 (C23), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.

Tighten the nos. 8 socket head screws

M10x60 (C23),grade 8,8, by a torque wrench at
50 Nm torque.

50 Nm

Pericolo - Attenzione Danger - Warning

Avvitare gradualmente le n° 8 viti (C23) in egual Tighten the nos. 8 screws (C23) gradually by equal
misura in modo da bilanciare il carico delle molle amount each to balance the springs load on the
sulla flangia predisposizione motore (C22). motor adaptor flange (C22).

INFORMAZIONI SULLA MANUTENZIONE - 47 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 555
13.3 Travel gear

4.11.Fasi di rimontaggio gruppo riduttore 4.11.Gearbox kit reassembling method

22. Montare l’anello interno del cuscinetto nel corpo

riduttore (B6).

Assemble the bearing inner raceway in the

gearbox housing (B6).

23. Assemblare il primo giro di sfere al corpo

riduttore (B6).

Assemble the 1st ball row to the gearbox

housing (B6).

24. Assemblare il supporto in plastica al primo giro di

sfere.

Assemble the plastic support to the 1st ball row.

25. Servendosi di un paranco posizionare il corpo

riduttore (B6) su di un distanziale.

By using a tackle place the gearbox housing (B6)

on a spacer.

INFORMAZIONI SULLA MANUTENZIONE - 48 - MAINTENANCE INFORMATIONS

556 BOMAG 008 911 17
Travel gear 13.3

4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

26. Montare il 2° supporto in plastica nel corpo

riduttore (B6).

Assemble the 2nd plastic support in the gearbox

housing (B6).

27. Assemblare il secondo giro di sfere al supporto in

plastica.

Assemble the 2nd ball row to the plastic support.

28. Montare l’anello interno del cuscinetto nel corpo

riduttore (B6).

Assemble the bearing inner raceway in the

gearbox housing (B6).

29. Servendosi di pinze, montare l’anello di

spallamento (B5) nella propria sede nel corpo
riduttore (B6).

By using pliers, assemble the elastic ring (B5) into

its seat in the gearbox housing (B6).

INFORMAZIONI SULLA MANUTENZIONE - 49 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 557
13.3 Travel gear

4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

Preparazione della tenuta frontale: Make ready of the lifetime seal:

1. Effettuare una accurata pulizia degli 1. Carefully clean the seats (A and B) using, if
alloggiamenti (A e B) facendo uso, se necessary, metallic brushes or solvent (surfaces in
necessario, di spazzole metalliche o solventi (le contact with or (C) must be perfectly clean and
superfici a contatto con gli anelli di gomma (C) dry).
devono essere perfettamente pulite ed asciutte). 2. Make sure that sealing surfaces (D) of metal
2. Assicurarsi che le superfici di tenuta (D) degli rings (E) are free from scratches, dinges or foreign
anelli (E) siano esenti da qualsiasi rigatura, substances; metallic ring surfaces must be
ammaccatura o corpi estranei e che le perfectly clean and dry. We suggest to dip the
superfici (F) degli stessi anelli siano metallic rings in volatile solvent or industrial
perfettamente pulite ed asciutte. Si raccomanda degreasing alcohol.
l'immersione degli anelli metallici in solvente 3. Carefully clean the lapped surface (D) of metal
volatile o alcool bianco. rings (E) and remove dust or fingerprints. Then
3. Togliere dalle superfici lappate (D) degli lubrificate them with a thin oil film, taking care not
anelli (E) ogni traccia di polvere o impronte digitali to oil the other components.
e umettarle poi con un leggero strato di olio,
avendo cura di non ungere le rimanenti parti.

D D

A B

F F

C C

E E

IDM-1521530040

30. Montare la 1° semitenuta frontale (B4) sull'attrezzo

(6689960610).

6689960610 Assemble the 1st half seal (B4) on the tool

(6689960610).

INFORMAZIONI SULLA MANUTENZIONE - 50 - MAINTENANCE INFORMATIONS

558 BOMAG 008 911 17
Travel gear 13.3

4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

31. Eseguire il montaggio della 1° semitenuta

frontale (B4) sul corpo riduttore (B6).

Assemble the 1st half seal (B4) on the gearbox

housing (B6).

32. Montare la 2° semitenuta frontale (B4) sull'attrezzo

(6689960610).
6689960610
Eseguire il montaggio della 2° semitenuta
frontale (B4) sul mozzo flangiato (B3).

Assemble the 2nd half seal (B4) on the tool

(6689960610).
Assemble the 2nd half seal (B4) on the flanged
hub (B3).

B4
Informazioni
Controllo corretto assemblaggio tenuta
frontale (B4).

B3
Information
Correct lifetime seal assembly check (B4).

B4

B6

IDM-15220601500.tif

INFORMAZIONI SULLA MANUTENZIONE - 51 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 559
13.3 Travel gear

4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

33. Pulire accuratamente le superfici metalliche della tenuta

frontale (B4).

Cautela - Precauzione
Applicare un leggero strato di olio su una o entrambe le
superfici metalliche facendo attenzione a non ungere le
altre parti della tenuta frontale.

Clean carefully the seal faces (B4).

Caution
Apply a thin oil film on the entire metallic face of one or
both seals. Oil must not contact surfaces other than the
sealing faces.

34. Posizionare il mozzo flangiato (B3) all'interno del

corpo riduttore (B6).

Place the flanged hub (B3) inside the gearbox

housing (B6).

35. Servendosi di una pressa e di un tampone

metallico, spingere il mozzo flangiato (B3) in
battuta nel corpo riduttore (B6) fino ad ottenere il
completo assemblaggio del gruppo.

By using a press and a metallic stopper, push the

flanged hub (B3) against the shoulder in the
gearbox housing (B6) until assembling of the unit
is complete.

Cautela - Precauzione
Avvitare parzialmente la ghiera (B7) per evitare la
fuoriuscita del mozzo flangiato (B3) dal corpo
riduttore (B6) durante le fasi successive.

Caution
Screw the nut (B7) partially in order to avoid the
out coming of the flanged hub (B3) from the
gearbox housing (B6) during the following steps.

INFORMAZIONI SULLA MANUTENZIONE - 52 - MAINTENANCE INFORMATIONS

560 BOMAG 008 911 17
Travel gear 13.3

4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

36. Posizionare il moltiplicatore di coppia (ATZ.09.003.1)

sulla ghiera (B7). Servendosi del moltiplicatore di
coppia, serrare la ghiera (B7) con una chiave
dinamometrica con coppia in ingresso al moltiplicatore
ATZ.09.003.1 di 113,5±3,5 Nm, corrispondente ad una coppia in
uscita dal moltiplicatore di 3500±100 Nm.

Place the multiplier (ATZ.09.003.1) on the ring

nut (B7). By using the multiplier, tighten the ring
nut (B7), by a torque wrench with an input
multiplier torque of 113,5±3,5 Nm corresponding to
an output multiplier torque of 3500±100 Nm.
3500±100 Nm

37. Cianfrinare la ghiera (B7) in corrispondenza dei 2

incavi del mozzo flangiato (B3).

Stake the ring nut (B7) near 2 seats of the flanged

hub (B3).

Informazioni
Cianfrinare Ø 4÷5 mm (profondità 1÷1,5 mm).

Information
Stake Ø 4÷5 mm (depth 1÷1,5 mm).

IDM-15217301600.tif

38. Posizionare i 4 gruppi planetari di 2° riduzione (B8)

nei perni del mozzo flangiato (B3).

Place the 4 planet assemblies of the 2nd

reduction (B8) in the flanged hub’s pins (B3).

INFORMAZIONI SULLA MANUTENZIONE - 53 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 561
13.3 Travel gear

4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

39. Servendosi di un martello in gomma e di un

tampone metallico, spingere i gruppi planetari di 2°
riduzione (B8) in battuta fino ad ottenere il
completo assemblaggio.

By using a rubber hammer and a metal stopper

push the planet assemblies of the 2nd
reduction (B8) against the shoulder until assembly
is complete.

40. Servendosi di pinze montare gli anelli elastici nelle

sedi dei perni del mozzo flangiato (B3).

By using pliers assemble the circlips in the flanged

hub pin seats (B3).

41. Montare la guarnizione O-ring (B11) nella propria

sede nel coperchio di chiusura (B15).

Assemble the O-ring seal (B11) into its seat in the

end cover (B15).

42. Applicare uno strato di grasso RETINAX HD-2 o

prodotto similare sulla guarnizione "X-ring" (B14).
Inserire la guarnizione "X-ring" (B14) nella propria
sede nel coperchio di chiusura (B15).

Apply a coat of grease RETINAX HD-2 or similar

product on the "X-ring" seal (B14).
Insert the "X-ring" seal (B14) in its seat in the end
cover (B15).

INFORMAZIONI SULLA MANUTENZIONE - 54 - MAINTENANCE INFORMATIONS

562 BOMAG 008 911 17
Travel gear 13.3

4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

43. Posizionare il coperchio di chiusura (B15) sul

corpo riduttore (B6).

Place the end cover (B15) on the gearbox

housing (B6).

44. Serrare le n° 10 viti M10x20 (A1-B12), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.

Tighten the nos. 10 socket head screws

M10x20 (A1-B12), grade 8,8, by a torque wrench
at 50 Nm torque.

50 Nm

45. Capovolgere il riduttore e montare la guarnizione

O-ring (A4) nella propria sede nel mozzo
flangiato (B3).

Turn the gearbox upside down and assemble the

O-ring seal (A4) into its seat in the flanged
hub (B3).

46. Inserire il solare di 2° riduzione (B10) nel mozzo

flangiato (B3).

Insert the 2nd stage sun gear (B10) in the flanged

hub (B3).

INFORMAZIONI SULLA MANUTENZIONE - 55 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 563
13.3 Travel gear

4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

47. Montare la 1° riduzione (B2).

Assemble the 1st reduction assembly (B2).

Informazioni Information
Per per il rimontaggio del secondo gruppo For the 2nd gearbox kit (A2) reassembly follow the
riduttore (A2) seguire le stesse fasi descritte nel same steps shown in section 4.11.
paragrafo 4.11.

INFORMAZIONI SULLA MANUTENZIONE - 56 - MAINTENANCE INFORMATIONS

564 BOMAG 008 911 17
Travel gear 13.3

4.12.Fasi di rimontaggio riduttore 4.12.Gearbox reassembling method

48. Inserire il solare di 1° riduzione (B1) nella riduzione

angolare (A5).

Insert the 1st stage sun gear (B1) in the right angle
reduction (A5).

49. Servendosi di un paranco montare il 1° gruppo

riduttore (A2).

By using a tackle assemble the 1st gearbox

kit (A2).

50. Applicare LOCTITE tipo 243 sulla filettatura delle

n° 16 viti M12x40 (A3), classe di resistenza 8.8.

Apply LOCTITE type 243 on the thread of the

nos. 16 screws M12x40 (A3), grade 8.8.

51. Serrare le n° 16 viti M12x40 (A3), classe di

resistenza 12,9, con una chiave dinamometrica
alla coppia di 145 Nm.

Tighten the nos. 16 socket head screws

M12x40 (A3), grade 12,9, by a torque wrench at
145 Nm torque.

145 Nm

INFORMAZIONI SULLA MANUTENZIONE - 57 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 565
13.3 Travel gear

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

52. Smontare il coperchio di chiusura (B15) del 2°

gruppo riduttore (A2) e, servendosi di un paranco,
montare il 2° gruppo riduttore (A2).

Remove the end cover (B15) of the 2nd gearbox

kit (A2) and, by using a tackle, assemble the 2nd
gearbox kit (A2).

53. Applicare LOCTITE tipo 243 sulla filettatura delle

n° 16 viti M12x40 (A3), classe di resistenza 8.8.

Apply LOCTITE type 243 on the thread of the

nos. 16 screws M12x40 (A3), grade 8.8.

54. Serrare le n° 16 viti M12x40 (A3), classe di

resistenza 12,9, con una chiave dinamometrica
alla coppia di 145 Nm.

Tighten the nos. 16 socket head screws

M12x40 (A3), grade 12,9, by a torque wrench at
145 Nm torque.

145 Nm

55. Inserire il tubo (A6) nel 2° gruppo riduttore (A2).

Insert the tube (A6) in the the 2nd gearbox kit (A2).

INFORMAZIONI SULLA MANUTENZIONE - 58 - MAINTENANCE INFORMATIONS

566 BOMAG 008 911 17
Travel gear 13.3

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

56. Montare la guarnizione O-ring (B11) nella propria

sede nel coperchio di chiusura (B15).

Assemble the O-ring seal (B11) into its seat in the

end cover (B15).

57. Applicare uno strato di grasso RETINAX HD-2 o

prodotto similare sulla guarnizione "X-ring" (B14).
Inserire la guarnizione "X-ring" (B14) nella propria
sede nel coperchio di chiusura (B15).

Apply a coat of grease RETINAX HD-2 or similar

product on the "X-ring" seal (B14).
Insert the "X-ring" seal (B14) in its seat in the end
cover (B15).

58. Posizionare il coperchio di chiusura (B15) sul 2°

gruppo riduttore (A2).

Place the end cover (B15) on the 2nd gearbox

kit (A2).

59. Serrare le n° 10 viti M10x20 (A1-B12), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.

Tighten the nos. 10 socket head screws

M10x20 (A1-B12), grade 8,8, by a torque wrench
at 50 Nm torque.

50 Nm

INFORMAZIONI SULLA MANUTENZIONE - 59 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 567
13.3 Travel gear

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

60. Inserire i tappi (B16) nei fori di carico e scarico olio

del coperchio di chiusura (B15). Serrare i tappi con
una chiave dinamometrica alla coppia di 25±5 Nm.

Insert the plugs (B16) into the oil draing-filling

holes of the end cover (B15).Tighten the plugs by
a torque wrench at 25±5 Nm torque.

25±5 Nm

61. Inserire il tappo (B17) nel foro di livello olio del

coperchio di chiusura (B15). Serrare il tappo con
una chiave dinamometrica alla coppia di 10±2 Nm.

Insert the plug (B17) into the oil level hole of the
end cover (B15).Tighten the plug by a torque
wrench at 10±2 Nm torque.

10±2 Nm

62. Servendosi di pinze montare l’anello elastico (A9)

nella propria sede nel giunto di collegamento (A8).

By using pliers assemble the circlip (A9) into its

seat in the coupling (A8).

63. Montare il giunto di collegamento (A8) sulla

riduzione angolare (A5).

Assemble the coupling (A8) on the right angle

reduction (A5).

INFORMAZIONI SULLA MANUTENZIONE - 60 - MAINTENANCE INFORMATIONS

568 BOMAG 008 911 17
Travel gear 13.3

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

64. Montare la guarnizione O-ring (A7) nella propria

sede nella flangia di collegamento (A10).

Assemble the O-ring seal (A7) into its seat in the

connecting flange (A10).

65. Montare la flangia di collegamento (A10) sulla

riduzione angolare (A5).

Assemble the connecting flange (A10) on the right

angle reduction (A5).

66. Applicare LOCTITE tipo 243 sulla filettatura delle

n° 16 viti M10x30 (A12), classe di resistenza 8.8.

Apply LOCTITE type 243 on the thread of the

nos. 16 screws M10x30 (A12), grade 8.8.

67. Serrare le n° 16 viti M10x30 (A12), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.

Tighten the nos. 16 socket head screws

M10x30 (A12), grade 8,8, by a torque wrench at
50 Nm torque.

50 Nm

INFORMAZIONI SULLA MANUTENZIONE - 61 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 569
13.3 Travel gear

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

68. Montare le guarnizioni O-ring (A14) nelle proprie

sedi nell’albero scanalato (A13).

Assemble the O-ring seals (A14) into their seats in

the splined shaft (A13).

69. Inserire l’albero scanalato (A13) nel giunto di

collegamento (A8).

Insert the splined shaft (A13) in the coupling (A8).

70. Montare la guarnizione O-ring (A7) nella propria

sede nella flangia di collegamento (A10).

Assemble the O-ring seal (A7) into its seat in the

connecting flange (A10).

71. Montare il gruppo freno (A15) sulla flangia di

collegamento (A10).

Assemble the brake kit (A15) on the connecting

flange (A10).

INFORMAZIONI SULLA MANUTENZIONE - 62 - MAINTENANCE INFORMATIONS

570 BOMAG 008 911 17
Travel gear 13.3

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

72. Applicare LOCTITE tipo 243 sulla filettatura delle

n° 8 viti M10x30 (A12), classe di resistenza 8.8.

Apply LOCTITE type 243 on the thread of the

nos. 8 screws M10x30 (A12), grade 8.8.

73. Serrare le n° 8 viti M10x30 (A12), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.

Tighten the nos. 8 socket head screws

M10x30 (A12), grade 8,8, by a torque wrench at
50 Nm torque.

50 Nm

Informazioni
Prima di montare il motore idraulico, verificare,
con un calibro per interni, il corretto assemblaggio
del riduttore controllando la quota assiale indicata
nel disegno a fianco.

Information
Before assembling the hydraulic motor, verify by a
depth slide gauge the correct assembly of the unit
checking the axial distance as shown in the
IDM-15220601300.tif
scheme.

INFORMAZIONI SULLA MANUTENZIONE - 63 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 571
13.3 Travel gear

4.13.Controllo finale e reinstallazione 4.13.Final test and reinstallation

Verificare il prodotto reinstallandolo sulla macchina. Check the product by remounting it to the machine.
Verificare la funzionalità della trasmissione eseguendo Check the function of the transmission following all the
tutti i controlli indicati nel paragrafo 3.8. checks shown in section 3.8.
Qualora si sia eseguito un intervento sul freno, è If work on the brake was undertaken, it is important to
necessario controllare che non ci siano perdite d’olio. check that there are no oil leakages. Follow the
Procedere come segue: procedure below:
1. Collegare al foro comando freno (porta 5) un 1. Connect the pressure pilot line with the manometer
manometro (con fondo scala a 100 bar) e la (with a base scale of 100 bars) to the brake release
relativa valvola di comando afflusso olio. port (port 5).
2. Aprire la valvola di comando afflusso olio e 2. Open the flow valve and release the brake with the
sbloccare il freno, raggiungendo la pressione di pilot pressure of 50 bar.
50 bar.
3. Close the flow valve and keep the brake released
3. Chiudere la valvola di comando afflusso olio e 3 minutes or longer.
mantenere la pressione nel freno per un periodo di
4. Using the manometer, check that the pressure
almeno 3 minuti.
remains constant.
4. Verificare con il manometro che la pressione
5. Follow the same steps (1-2-3-4) for the dinamic
rimanga costante.
operated brake port (port 6).
5. Ripetere le stesse operazioni (1-2-3-4) per il
comando di azionamento dinamico del freno
(porta 6).

Informazioni Information
Se la pressione diminuisce significa che le If the pressure drops it may mean that the brake
guarnizioni del freno non fanno tenuta, in tal caso si seals are not tight and consequently they must be
dovrà procedere alla loro sostituzione, oppure che il replaced or it may mean that the reassembling was
rimontaggio non è stato eseguito in modo corretto. not completed properly.

IDM-15220601400.tif

INFORMAZIONI SULLA MANUTENZIONE - 64 - MAINTENANCE INFORMATIONS

572 BOMAG 008 911 17
Travel gear 13.3

6. Al termine delle operazioni rimontare il motore 6. After having reassembled the gearbox, fit the
idraulico come indicato nel paragrafo 3.2. hydraulic motor, as shown in section 3.2.
7. Effettuare il riempimento dell'olio lubrificante come 7. Fill the gearmotor with the lubricant oil as shown in
illustrato al paragrafo 3.7. section 3.7.

4.14.Dismissione e rottamazione del prodotto 4.14.Dismantling and destroying the product

La dismissione del riduttore va effettuata rispettando le When dismantling the gearbox follow the indications
seguenti indicazioni: given below:
1. Smontare il riduttore dalla sua sede e svuotare 1. Dismount the gearbox from its seating and empty
l'olio lubrificante. the lubricating oil.
2. Smontare completamente il riduttore e rimuovere 2. Completely dismount the gearbox and remove all
l'olio e il grasso dai componenti. oil and grease from its parts.
3. Avviare i materiali pericolosi e/o inquinanti ai 3. Send all dangerous and/or polluted parts to the
rispettivi centri di smaltimento, come richiesto dalle authorised demolishing centres whilst keeping in
leggi vigenti in materia. line with respective local rules and regulations.

INFORMAZIONI SULLA MANUTENZIONE - 65 - MAINTENANCE INFORMATIONS

008 911 17 BOMAG 573
13.3 Travel gear

INFORMAZIONI SULLA MANUTENZIONE - 66 - MAINTENANCE INFORMATIONS

574 BOMAG 008 911 17
Travel gear 13.3

008 911 17 BOMAG 575

13.3 Travel gear

576 BOMAG 008 911 17

Travel gear 13.3

Data / Date

Revisioni manuale
Manual revisions

Rev. 01 02 03 04 05 06 07 08 09 10
- Paragrafo / Paragraph
- Fase / Step

- Disegno / Drawing
sostituito dal
replaced by

Questa pubblicazione annulla e sostituisce ogni precedente edizione This publication replaces and supersseds any previous issue and
o revisione. la BONFIGLIOLI TRASMITAL si riserva il diritto di revision. BONFIGLIOLI TRASMITAL reserves the right to implement
apportare modifiche senza preavviso. E' vietata la riproduzione modifications without notice. This manual cannot be reproduced,
anche parziale senza specifica autorizzazione. even partially, without prior written consent.

008 911 17 BOMAG 577

13.3 Travel gear

HEADQUARTERS HUNGARY
BONFIGLIOLI RIDUTTORI S.p.A. AGISYS AGITATORS & TRANSMISSIONS Ltd
Via Giovanni XXIII, 7/A 40012 Lippo di Calderara di Reno 2045 Törökbálint, Tö u.2. Hungary
Bologna (ITALY) Tel. +36 23 50 11 50 - Fax +36 23 50 11 59
Tel. (+39) 051 6473111 www.agisys.hu - [email protected]
Fax (+39) 051 6473126
www.bonfiglioli.com - [email protected]
BONFIGLIOLI TRASMITAL INDIA
Via Enrico Mattei,12 - Z.I. Villa Selva BONFIGLIOLI TRANSMISSIONS PVT Ltd.
47100 Forli' (ITALY) PLOT AC7-AC11 Sidco Industrial Estate
Tel. (++039) 0543789111 Thirumudivakkam - Chennai 600 044
Fax (++039) 0543789242 - 0543789245 Tel. +91(0)44 24781035 / 24781036 / 24781037
E-mail: [email protected] Fax +91(0)44 24780091 / 24781904
www.bonfiglioli.co.in - [email protected]
AUSTRALIA NEW ZEALAND
BONFIGLIOLI TRANSMISSION (Aust) Pty Ltd. SAECO BEARINGS TRANSMISSION
48-50 Adderley St. (East) - Auburn (Sydney) N.S.W. 2144 36 Hastie Avenue, Mangere
Tel. (+61) 2 8748 4400 - Fax (+61) 2 9748 8740 Po Box 22256, Otahuhu - Auckland
P.o. Box 6705 Silverwater NSW 1811 Tel. +64 9 634 7540 - Fax +64 9 634 7552
www.bonfiglioli.com.au - [email protected] [email protected]
BELGIUM POLAND
N.V. ESCO TRANSMISSION S.A. POLPACK Sp. z o.o. - Ul. Chrobrego 135/137 - 87100 Torun
Culliganlaan 3 - 1831 Machelem Diegem Tel. 0048.56.6559235 - 6559236 - Fax 0048.56.6559238
Tel. 0032 2 7204880 - Fax 0032 2 7212827 - Tlx 21930 Escopo B www.polpack.com.pl - [email protected]
www.escotrans.be - [email protected]
CANADA RUSSIA
BONFIGLIOLI CANADA INC. HYDRAPAC POWER SYSTEM
2-7941 Jane Street - Concord, ONTARIO L4K 4L6 17, build. 1, Shosse Entuziastov, Moscow 111024
Tel. (+1) 905 7384466 - Fax (+1) 905 7389833 Tel.007.095.785.47.58/785.47.59
www.bonfigliolicanada.com - [email protected] Fax 007.095.785.47.56
E-mail:[email protected] - web site: www.h-pac.ru
CHINA SPAIN
BONFIGLIOLI DRIVES CO. LTD. TECNOTRANS SABRE S.A.
No. 8 Building, Area C1 - 318, SuHong Road Pol. Ind. Zona Franca sector C, calle F, n 6 08040 Barcelona
Qingpu - Shanghai 201700 Tel. (+34) 93 4478400 - Fax (+34) 93 3360402
Tel. +86 21 59228800 - Fax +86 21 59228811 www.tecnotrans.com - [email protected]
www.bonfiglioli.cn - [email protected]
FRANCE SOUTH AFRICA
BONFIGLIOLI TRANSMISSIONS S.A. BONFIGLIOLI POWER TRANSMISSION Pty Ltd.
14 Rue Eugène Pottier BP 19 55 Galaxy Avenue, Linbro Business Park - Sandton
Zone Industrielle de Moimont II - 95670 Marly la Ville Tel. (+27) 11 608 2030 OR - Fax (+27) 11 608 2631
Tel. (+33) 1 34474510 - Fax (+33) 1 34688800 www.bonfiglioli.co.za - [email protected]
www.bonfiglioli.fr - [email protected]
GERMANY SWEDEN
BONFIGLIOLI GETRIEBE GmbH BONFIGLIOLI SKANDINAVIEN AB
Hamburger Straße 18 - 41540 Dormagen Kontorsgatan - 234 34 Lomma
Tel. (+49) 2133 50260 - Fax (+49) 2133 502610 Tel. (+46) 40 412545 - Fax (+46) 40 414508
www.bonfiglioli.de - [email protected] www.bonfiglioli.se - [email protected]
VECTRON Elektronik GmbH
Europark Fichtenhain A 6 47807 Krefeld
Tel. (+49) 2151 83960 - Fax (+49) 2151 839699
www.vectron.net - [email protected]
GREAT BRITAIN THAILAND
BONFIGLIOLI (UK) LIMITED K.P.T MACHINERY (1993) CO.LTD.
5 Grosvenor Grange - Woolston - Warrington 259/83 Soi Phiboonves, Sukhumvit 71 Rd. Phrakanong-nur,
Cheshire WA1 4SF Wattana, Bangkok 10110
Tel. (+44) 1925 852667 - Fax (+44) 1925 852668 Tel. 0066.2.3913030/7111998
www.bonfiglioliuk.co.uk - [email protected] Fax 0066.2.7112852/3811308/3814905
www.kpt-group.com - [email protected]
GREECE USA
BONFIGLIOLI HELLAS S.A. BONFIGLIOLI USA INC
O.T. 48A T.O. 230 - C.P. 570 22, Industrial Area - Thessaloniki 1000 Worldwide Boulevard - Hebron, KY 41048
Tel. (+30) 2310 796456 - Fax (+30) 2310 795903 Tel.: (+1) 859 334 3333 - Fax: (+1) 859 334 8888
www.bonfiglioli.gr - [email protected] www.bonfiglioliusa.com
[email protected]
[email protected]
HOLLAND VENEZUELA
ELSTO AANDRIJFTECHNIEK MAQUINARIA Y ACCESSORIOS IND.-C.A.
Loosterweg, 7 - 2215 TL Voorhout Calle 3B - Edif. Comindu - Planta Baja - Local B
Tel. (+31) 252 219 123 - Fax (+31) 252 231 660 La Urbina - Caracas 1070
www.elsto.nl - [email protected] Tel. 0058.212.2413570 / 2425268 / 2418263
Fax 0058.212.2424552 - Tlx 24780 Maica V
www.maica-ve.com - [email protected]

578 BOMAG 008 911 17

14 Circuit diagrams

008 911 17 BOMAG 579

Circuit diagrams
l
The circuit diagrams valid at the date of printing are
part of these repair instructions.
l The circuit diagrams valid for the machine serial
number can be found in the spare parts catalogue
for the machine.

580 BOMAG 008 911 17

14.1 Wiring diagram

008 911 17 BOMAG 581

14.1 Wiring diagram

582 BOMAG 008 911 17

Inhaltsverzeichnis: BW 24 RH, 27 RH / C550 H, C560 H

008 911 17
table of contents: BW 24 RH, 27 RH / C550 H, C560 H
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing ï no.
Wiring diagram

001 538 100 01 Stromlaufplan Circuit Diagram

002 538 100 01 Versorgung, Starten, Steckdose supply, starting unit, socket
003 538 100 01 Bremse, NotïAus, Warnsummer brake, emergency off, warning buzzer
004 538 100 01 Überwachung monitoring unit
005 538 100 01 Berieselung, Signalhorn sprinkler system, warning horn
007 538 100 01 Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) illumination, working light (StVZO)
009 538 100 01 Fahrtricht., Fahrstufenumschalt., Rückfahrwarnsum. traveling directon, speed selection, warning buzzer,
012 538 100 01 Tachograph, Geschwindigkeitsanzeige tachograph, speedometer
013 538 100 01 Heizung, Klimaanlage heating, air conditioning
014 538 100 01 Kabine cab
015 538 100 01 Arbeitsscheinwerfer ROPS worklamp RORS
016 538 100 01 Diebstahlschutz System anti ï theft system
101 538 100 01 Bauteilliste component listing

BOMAG
09.01.2007
001 001
Nallin Stromlaufplan 538 100 01
09.01.2007
14.1

583
circuit diagram 001
Werner
584
X2:3ï1
X2:1ï2 X2:1ï1

X2:2ï1
14.1

F01
X2:4ï1 F37
5:2 30A
Sicherung F05
X2:6ï1 fuse
X2:2ï2 Sicherung
fuse
X2:4ï1
15A
X2:7ï1 30
7:5 30 X2:3ï2
30 X13:A K11
P0123
P01 2:18
S00

X89:B

X89:A
87 87a

Zündstartschalter
K32 14:1 ignition switch 15 54 58 19 17
50a
X1:13
F124 X13:B X13:C
7:2 15 3:1 K11 3:6
X2:6ï1
2 ZA/option Sicherung F119
F00
X2:6ï1 fuse 7,5A
125A Sicherung Battrie
fuse, battery Sicherung F124 X2:6ï2 F119
1 F119 2:15 2:12 F119 14:6
25A
X2:6ï2 1 ZA/option X1:129
(6) V46

1 2 Meldeleuchte Ladekontrolle X1:100 13 X1:17

Sicherung indicator light, charge control
X1:163 30
G01+ 2:8 fuse F15 X6:+ 2:16 K05 X6:+ X6:+
86 1
125A 9:13
B+ 2 K62 R09 H08 S165 2:12
2:8 87 87a 14
X6:14 H52

BOMAG
30 85 2
2
+ G01 102AH X1:106
K14 2:15 X6:6

X1:23
+ G03 P00
W D+ X14:A X14:B X1:18
ï Batterie 87 G02 Betriebsstundenzähler
battery
ï 2.Batterie Generator operating hour meter X1:101
2.battery generator X6:ï X1:21
3:5
Bï B+ X1:166
2 X1:104
2:5 Mï ZA/option

50(5) 15(7) S(2)

S30 G01+ K11
Batterietrennschalter 2:1 86 + XS
A13
switch battery disconnect B+ L(1)
2:1 2 Y01 12V
2 85 ï
30 50
X51:C br X63:3 V01 T(4) X1:165 R(6) X1:171 31(3)
R79
1 X1:167 X1:169
R19 M01 1 2
X91:B K31 1
13:1 ï B53 K14
Kï 3:9
Mï 2:7 Mï (R)_t X1:28
2:7 Mï 3:3
2 1
X1:164 X1:168 X1:170 X1:172 X1:125 31 3:1
Heizflansch 4:1 Startmehrmenge 2:5 2:15 Steckdose
heatingïflange start boost fuel
socket
Temperatursensor
Kraftstoffvorheizung temperature switch
fuel, preïheating Starter Steuergerät Heizflansch Kontrollampe Glühüberwachung
starter
controll unit, heatingïflange indicator light, glow plug

09.01.2007
1 1

008 911 17
Wiring diagram

Nallin Versorgung, Starten, Steckdose 538 100 01

09.01.2007
Werner supply, starting unit, socket 002
2:12 15 15 4:1
2:19 K11 K11 5:1
X2:7ï1 F14
Sicherung 10A
fuse F25 X2:13ï1
Sicherung 10A
X2:7ï2 fuse

008 911 17
X1:56
X2:13ï2
F25
X1:8
S111 9:12
MD+
X1:1 5:1
Wiring diagram

B0T 12 21 31
S111
B0
K143 30 K144 30

Bremsschalter 4:8 4:6

switch brake A15
87 87a 87 87a
11 22 32
B148

X1:9

K22 30

3:17 X1:46
87 87a
X6:1
X6:9

A100:6 9:2 1

3:3
9:7
X1:144 V03
11 21 31
2

X1:145 S01 X1:44

12 22 32
K112 30 NotïAusïSchalter
21 switch, emergency off

BOMAG
S01 3:9 86
X1:14
NotïAusïSchalter 87 87a
switch, emergency off 3:12
22 X1:97
85 K22 X30:1

+
X1:15
X1:98 X1:48 H82
ï
X1:47 86
K112
X6:12 X6:11
2 Y13 1 + H20 + H01 Y04 1 2

ï ï 85
V41 1 2 X30:2
(1) 2 V42 1
Mï X6:ï Mï (2)
2:12 Mï 3:11 2:12 X6:ï 3:4 Mï 7:1
2:19 Kï Kï 3:17 3:10 Kï Kï 9:6
X1:49
31 X1:49 X1:49 X1:49
2:20 31 5:1
Hubmagnet 3:7 Bremsventil 3:3 Warnsummer
shut off solenoid, engine solenoid valve, brake warning buzzer

Meldeleuchte Bremskontrolle
indicator light, brake Meldeleuchte Bremse Überwachungsmodul

12.12.2006
1 1 538 100 01
Nallin Bremse, NotïAus, Warnsummer
12.12.06
14.1

585
Werner brake, emergency off, warning buzzer 003
586
3:20 15
X2:9ï1
F129 F149
X2:8ï1 X2:10ï1 F04 5A
14.1

15A
Sicherung 5A
Sicherung Sicherung
fuse fuse
fuse
X2:8ï2 X2:10ï2 F04 X2:9ï2
F04
7:13

F120
7:19
86
K149 X6:20
F25 Meldeleuchte Motoröl
3:17
indicator light, engine oil pressure
30 1
K149 85
H79 V47 9:1 Meldeleuchte Motorüberhitzung
4:4 idicator ligh, engine overheating
87a 87 2 Meldeleuchte Luftfilter
indicator light, air cleaner
Differenzdruck Hy.

Wasserrestmenge
X1:141
B148 idicator ligh, hydr.oil filter
3:16 1 2:17 X6:+
86
2 K144 H43 H73 H09 H49 H15 H23

Meldeleuchte
V43 2

Bremsöltemp.
R20

Wasserrestmenge
1
85 X6:5 X6:16 X6:17 X6:15 X6:13

Bremsöltemp.
X1:155 X1:45 X1:25 X1:26 X1:24 X1:22
X1:108 X1:109 X1:107
R21
R22

H70
1 Tankanzeige
H86 level gauge

Bremsdruck <5,7bar
X6:3
X6:4

2 X1:142 X1:105 Q P01

Bremsdruck

BOMAG
X1:153

30 86 86 X1:19 X1:20 X6:2

30 K36 K143 B22 3
K62 K104 X1:102 X1:103 X1:42
5:5
2:8 X6:ï X6:ï
X1:157 3:8
87 87a 85 85 p 4 X1:126

X1:91
87 87a

X1:92
X1:151 X10:2 X10:1
X1:128 X1:91
X27:1
3 B21
3 B148 B102 3 B12 1 1 B06 3 B152 B03 3 1
1 B33 B55

gn/gr
R03

br/br
_t P P P _t p
4 p
4 5 BAR 4 2 B124 X6:10
2 2 4 4 2

MD+ X27:2 Mï
3:17 MD+ 5:1 3:12 Mï 7:1

ws/wh
X1:156 X1:158 X10:3
X1:125 X1:154 X1:49 X1:159
31

5.7+/ï0.6BAR
3:20 31 5:1
option Meldeleuchte Wasser im Diesel
4:3 3:16 7:19 3:15 indicator light, water in fuel
Kühlmittelvorrat Motor
indicator light, eng. coolant res. Wasserabscheider
sensor, water seperator fuel
Geber Kraftstofftank
sender, level gauge
Fußbremse
foot brake

12.12.2006
1 1

008 911 17
Wiring diagram

Nallin Überwachung 538 100 01

12.12.2006
Werner monitoring unit 004
3:20 K11 K11 7:1

3:17 MD+

F37 X2:22ï1
2:5 Sicherung
fuse F06

008 911 17
10A
X2:12ï1
X2:22ï2

Sicherung F37
fuse 20A
Sicherung
F23 fuse
Wiring diagram

10A

X2:4ï2
86
K104
X2:12ï2

85
Berieselung
sprinkler system

23 13
1 0 2
S05 10

24 14 X1:52

13

X1:12 S03
13
Taster Signalhorn
15/54 14

BOMAG
A04 switch warning horn
30 Modul Berieselung
modul, sprinkler system
87
X1:43
X1:132

X17:1
+ X1:127

M02 2
+
11A V02
ï B11
1
X17:2 ï
Signalhorn
X1:133 X1:111 X1:49 warning horn
X1:125 31
3:20 31 7:1
4:5
Berieselungspumpe
sprinkler pump

20.07.2006
1 1 538 100 01
Nallin Berieselung, Signalhorn
04.08.2006
14.1

587
Werner sprinkler system, warning horn 005
588
5:20 K11 K11 9:1
30 X2:15ï1 F04 F04 12:1 X2:23ï1 X2:17ï1
X2:11ï1 2:5 F70 F120
2:7 F124 F07 F156
Sicherung 20A Sicherung
14.1

Sicherung 15A 15A 15A

F22 Sicherung fuse fuse 1 fuse
15A S185
fuse X2:7ï2 X2:15ï2 X2:23ï2 X2:17ï2
X2:11ï2 X1:41 Überwachungsmodul X1:4
X1:146 monitoring module Schalter Beleuchtung F120
13 23 2
L0R A15 switch head lights 11 23
S37 X6:8 012
13
S26 Schalter Nachtbeleuchtung
Schalter Blinker 14 24 switch, night lamp
switch indicator S15 12 24
14 X1:6 X1:7 X1:2 X1:3

X1:147
E61 49L 49R
+ 30 X2:18ï1 X2:19ï1
Blinkgeber X2:20ï1 X2:21ï1
flasher F09 Sicherung Sicherung F10
A02 10A fuse fuse 10A

X1:93
ï 31 Sicherung F12 Sicherung
fuse fuse
E04 X2:18ï2 X2:19ï2 10A
F11 10A
+ 82
X2:20ï2 X2:21ï2

switch, working head lights

X1:54 A42
L R 14:6

Schalter Arbeitsbeleuchtung
ï X6:19
30
X6:18 X1:31 X1:121 X1:122 X1:32 X1:130 X1:131 K36
13 4:7
01 23 X1:55 X1:123 X95:2ï2
X1:33 X1:124 X95:1ï2 87 87a
X1:34 V12
S14
X95:1ï2
X95:2ï3

X1:50
+ + + +
E12 E14 E16 E17

X96:1ï2
X96:2ï7

14 24 V13
ï ï ï X1:94
+ ï +

X95:1ï1
X96:1ï1
X95:2ï1
X96:2ï1
X96:1ï3
E13 E15

BOMAG
H05 ZA
X96:2ï3 2 1 ï option
X97:1 X97:1 ï
1 1
1 1 H(ï)
H06 7:7 E41 E43
X95:1ï6
X95:2ï6

56b 56b
X96:1ï7
X96:7ï7

E08 E10
E18 E19 1 1 2 2 1 1

switch, hazard light

2 2

Schalter Warnblinker
31 31 E09 E11 E33 E34
X97:2 X97:2
X95:1ï4 2 2 2 2
X96:1ï5
X96:2ï5

X95:2ï4 X95:1ï5 X95:2ï5

links/left
X96:1ï6 X96:1ï4 X96:2ï4

rechts/right
X96:2ï6 X6:7
H06 MV 7:13 7:8 MV MV 7:17 7:16 MV

3:12 Mï Mï 7:8 H(ï) 7:11 7:3 Mï Mï 9:8

31

X1:49

X1:111
5:20 X1:125 31 9:1

X1:49
Arbeitsscheinwerfer Meldeleuchte Blinker Scheinwerfer links
indicator light, indicators Parkleuchte links
working head light Meldeleuchte Warnblinker Blinkleuchte VL Blinkleuchte VR head light LH
Bel. Reifendruckanz. indicator light, hazard light indicator front,lh. indicator front,rh. parking light lh.
illum. wheel pressure Schlußleuchte links Parkleuchte rechts Scheinwerfer rechts
Bel. Geschwindigkeitsanz.. Blinkleuchte HL tail light,lh parking light rh. head light RH
indicator rear,lh
illum. speedometer Blinkleuchte HR Schlußleuchte rechts Bremsleuchte links
indicator rear,rh. tail light,rh brake light lh
Bremsleuchte rechts
brake light rh

04.08.2006
1 1

008 911 17
Wiring diagram

Nallin Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) 538 100 01

04.08.2006
Werner illumination, working light (StVZO) 007

Meldeleuchte Warnblinker
7:20 K11

F77 X2:16ï1 X2:14ï1

Sicherung 10A F26 10A
fuse Sicherung
X2:16ï2 fuse X2:14ï2

008 911 17
X1:143
X1:53
Wiring diagram

31
S01 Schalter, NOT AUS
3:12 switch, emergency off
32
X1:5
K42
9:9

+ br/brn X1:81 + br/brn

X11:1 X12:1
r0v r0v 13 21
S31 S184
123 S02
123
Fahrtrichtungsschalter R V Fahrtrichtungsschalter

bl/blu
sw/blk
rt/red
switch, travel direction R V switch, travel direction Fahrstufenschalter

rt/red
sw/blk
bl/blu
X11:2 X11:3 X11:4 X12:4 X12:3 X12:2 14 22 speed range selector

X1:82 X1:83 2 3 X1:148 X1:149 1

11 12 15/54 14 15 15/54 X1:16 X1:27
A100 (ï) X1:99 X1:110
6 7 5 4 Modul Lenkstocker Fahrtrichtung 9 13 10 8
A100:6 modul, lever switch, travel direction
3:16

BOMAG
Kabelaufdruck
A100:5
Kabelaufdruck
A100:7
V48 K42
2 1
86 9:6 Beide Fahrhebel in 0ïStellung:
V47 K42 S111
Out K05 high = Startfreigabe
4:9 V47 2 1 3:14
30
K42
X1:95 X1:96 85 9:7
87 87a
Y16
X3:1 1 Y03 1 Y130 1
X1:92
+ 85
Y17 2 2
H14 1 2 2
ï Y163 1 Y164 1 V45
X3:2 1 K05
2 2 2 86
3:18 Kï Mï
X1:133 7:20 Mï 13:6
X1:49 X1:111 X1:111
7:20 31 31 12:1

Warnsummer Rückfahrwarneinrichtung 9:10 Mag.ïventile Fahrtri 2:13 Mag.ventil Fahrstufe, links

warning buzzer back up alarm solenoid valves travel dir. switch over sol.valve speed range, l.h.

Mag.vent. Fahren, vorw. Mag.ventil Fahrstufe, rechts

sol.valve speed range, r.h.
solenoid valve traveling, forw.
Relais Startstrom
Mag.vent. Fahren, rückw. relay starting current
solenoid valve traveling, backw.

12.12.2006
1 1 538 100 01
Nallin Fahrtricht., Fahrstufenumschalt., Rückfahrwarnsum.
12.12.2006
14.1

589
Werner traveling directon, speed selection, warning buzzer, 009
590
7:15 F04 F04 16:1
14.1

Lernmodus
to learn
Anzeigetest
diagnose
Tachographenmodul

B15.1
module, tachograph Lern Test

15/54
15/54
12:12
X1:61
5 A16 4 A05
IN
2 1 6 3 7.8.9
12:12
OUT+ 1

OUTï
X1:10 + X1:11

B15.1
P04
P09.A2
14:6
P09.A1 ï
14:6
X1:73 X1:71 ZA
option

B4 B3 A2 A3 A1

BOMAG
X24:4
P09 C3

SW/BK X24:3
BR/BR X24:1
Anzeige
indicator

A5 A6
B15

X24:2

BL/BU
Rexroth

G02 X1:72
14:8
31 X1:111
9:20 31 13:12
Aufnehmer Geschwindigkeit Geschwindigkeitsanzeige
transducer speed
speedometer

ZA
option

09.01.2007
1 1

008 911 17
Wiring diagram

Nallin Tachograph, Geschwindigkeitsanzeige 538 100 01

09.01.2007
Werner tachograph, speedometer 012
F31
14:2
D
F31 F68:G
Box 1 G 14:2

4 F68 H F F15 14:2

008 911 17
B Box 1
F40 F15
0123 Schalter Kabinenlüfter 7 F68:7 14:6
BOX 1 BOX 1
switch, cabin ventilator Schalter Kabinenheizung
8 switch, cab heating 6
3
S44
L M H C 4 5
Wiring diagram

A72 2 A72:2
14:6
Steuergerät

low
mid
high
control unit
S28
1

6 11 12 6 2 1 3

ZA

X65:3

X65:2
30 option

X65:4
K85 X63:7 X63:4 X63:6 X53:6
14:19
X52:1 15 1 4 7 6
87 87a 1
Diagnose
B103 X49:1 diagnostics
Thermofühler Klimaanlage _t
temperature sensor 2
X52:2

X40:1
X50:1 1 P18

X40:3

X40:2
E30
X43:1 _t B131 Heizung
4 2 heater timer
Thermofühler Heizung
temperature sensor, heating
B104 P
Überwachung Kühlmitteldruck LP HP X49:2
3
monitoring coolant pressure

BOMAG
X43:3 X43:4 5 8 10
X53:3
X53:5

X43:2

X45:3

X42:3
X45:2

X42:2
X45:4

X42:4
ge rt or ge rt or X55:1 X54:1

X21:1 Y15 1 E30 13:18 13:14 E30

M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
9:10 Mï Magnetventil Heizung 12:20 31 31 16:1
solenoid valve, heating unit
X40:4 X55:2
2:4 K31 K31 14:1

Kabinenlüfter
cab ventilator indicator light, air conditioning Kraftstoffpumpe
fuel pump heating unit
Klimakompressor
air conditioning compr.

ZA ZA

option option

12.01.2007
1 1 538 100 01
Nallin Heizung, Klimaanlage
12.01.2007
14.1

591
Werner heating, air conditioning 013
592
K32 X91:A
2:6 K32 15:1
X51:B
14.1

F68:G 7:14 A42 A42

13:19 15:7
30
K32 2:19 F119 X51:A

14:16 X63:8 14:1 E72+ F143 14:17 14:15 F143

A72:2
87 13:11

Wischer vorne Wischer hinten 15A

F143
windscreen wiper, rear InlineïFuse
windscreen wiper, front
13:19 F15
E A B C
13:19 F31 13:11 F68:7 F27 F28 X63:5
F110 F41
25A Box 1 15A Box 1
Box 1 Box 1 P09.A1 X67:A X67:A 15A S163 5
15A 12:5
5 1 2 3
option Tachograph K141 30
E72+ X67:B
14:11 P09.A2
12:5 14:18 1
X67:B 87 87a
S20 7 S21 7
1 1 1
0 2 2 0 2 2
1 1 1 1 X66:1 X67:B X67:A 01 S53
01
E72
S20
2 2 2 2 1 +
S45 5 4 5 4
30 S38 A12 Radio R80 1 5
K118 E71 1
S53 S20 S21 S38 radio
switch, worklamp

14:20
Schalter Arbeitsscheinwerfer

5 15 30
87 87a X64:4 + 2
indicator

S158 2 X64:2
Kontrolleuchte

X63:1
X62:1
X63:2

X62:2

E72ï

X64:5
X64:3
X64:6
X64:8
14:7 B51 31 B51
Auffindbeleuchtung option X61:C X61:A

BOMAG
X64:7
E70
+
X67:C
X46:31b

ï
X46:53

X44:31b

X44:53
X46:53a

X44:53a
E32 ï G02
12:5
+ + X67:C X46 +

53
53a
31b
53
53a
31b
Abfallverzögert
3 min

E29 +
E23 E25 XS option X44
+ X67:C 86 K32 86 K118
53a

+ + 12V ï Tachograph I 15 86 K85

ï ï M04 M06 M05 M07

53a
E28 E27 K141
31b 53
31

ï 2,5A
31 ï 31 ï 31 85
ï ï 85 85

31b 53
31
E72ï X61:B X61:B
14:1 14:15 14:13
X64:1 X44:31 X46:31 X61:B

13:19 K31 K31 15:1

Arbeitsscheinwerfer vorne Steckdose Heizung Heckscheibe
working lights, front socket Wascher vorn heating rear screen
washer motor,front
Arbeitsscheinwerfer hinten Kennleuchte Nachtbeleuchtung Wischermotor vorn Wischermotor hinten 14:4 14:17 13:2 14:4
working lights, rear
rotary beacon night lamp wiper motor front wiper motor rear
Wascher hinten
Kabinenleuchte washer motor,rear
cabin inside light

20.07.2006
1 1

008 911 17
Wiring diagram

Nallin Kabine 538 100 01

04.08.2006
Werner cab 014
14:20 K32

008 911 17
14:20 A42
Wiring diagram

13 A
S53
F108

1
14
30
K135
15:14
87 87a

BOMAG
+ +
E23 E25
ï ï
86
K135
+ +
E28 E27
85 ï ï

14:20 K31

Arbeitsscheinwerfer vorne
working head lights, front

15:16 Arbeitsscheinwerfer hinten Arbeitsscheinwerfer hinten

working head lights, rear working head lights, rear

ZA
option

20.07.2006
1 1 538 100 01
Nallin Arbeitsscheinwerfer ROPS
04.08.2006
14.1

593
Werner worklamp RORS 015
594
14.1

A67 1 2 3
Keyboard
keyboard
4 5 6

7 8 9

* 0

X22:1

X22:2
A66
Steuereinheit
control unit

BOMAG
ZA
option

20.07.2006
1 1

008 911 17
Wiring diagram

Nallin Diebstahlschutz System 538 100 01

04.08.2006
Werner anti ï theft system 016
Name Bl. Pf. Benennung title TYP
A02
Wiring diagram
A04
A05
007
005
012
9
7
15
Blinkgeber
Modul Berieselung
Elektronik Geschwindigkeitsanzeige
flasher
modul sprinkler system
Electronic system, speedometer
4X21WATT
14.1
A12 014 9 Radio Radio
A13 002 14 Steuergeraet Heizung Control unit, heating
A15 003 18 Ueberwachungsmodul monitoring module
A15 007 10 Ueberwachungsmodul monitoring module
A16 012 6 Elektronik Tachograph Electronic system, tachograph
A66 016 9 Elektronik Steuereinheit Electronic control unit
A67 016 15 Eingabeeinheit Keyboard
A72 013 7 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A100 009 8 Modul, Lenkstockschalter Fahrrichtung modul, lever switch, travel direction

B03 004 14 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

Werner
9.1.07
Nallin
9. 1. 7

B06 004 12 Druckschalter Motoroel Pressure switch, engine oil

B11 005 16 Signalhorn Warning horn
B12 004 8 Druckschalter Bremse Pressure switch, brake 5.7+/ï0.6BAR
B15 012 10 Aufnehmer Geschwindigkeit Transducer, speed
B21 004 14 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B22 004 15 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B33 004 5 Sensor Wassertankrestmenge Sensor, water tank residual quantity
B51 014 9 Lautsprecher Radio Speaker radio
B51 014 10 Lautsprecher Radio Speaker radio
B53 002 13 Temperaturgeber Kuehlmittel Temperature switch, collant (R)_t
B55 004 10 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B102 004 7 Druckschalter Bremsleuchten Pressure switch, brake lights 5 BAR
B103 013 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning 4_GC
B104 013 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B124 004 16 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 013 9 Temperaturschalter Heizung Temperature switch, heating 110_GC
B148 004 4 Temperaturschalter Bremsöl Temperature switch, brake oil 120_GC
B152 004 13 Temperaturgeber Kühlmittel temperature switch, collant 110_GC

E04 007 4 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer 2W

E08 007 8 Blinkleuchte vorne links Indicator, front, lh. 21W
E09 007 9 Blinkleuchte hinten links Indicator, rear, lh. 21W
E10 007 9 Blinkleuchte vorne rechts Indicator, front, rh. 21W
E11 007 10 Blinkleuchte hinten rechts Indicator, rear, rh. 21W
E12 007 14 Parkleuchte links Parking light, lh. 5W
E13 007 13 Schlussleuchte links Tail light, lh. 5W
E14 007 15 Parkleuchte rechts Parking light, rh. 5W
E15 007 17 Schlussleuchte rechts Tail light, rh. 5W
E16 007 17 Scheinwerfer links Head light, lh. 55 W
component listing

E17 007 18 Scheinwerfer rechts Head light, rh. 55 W

E18 007 1 Arbeitsscheinwerfer links Working head light, lh. 55W
Bauteilliste

E19 007 2 Arbeitsscheinwerfer rechts Working head light, rh. 55 WATT

E23 014 2 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E23 015 17 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55 WATT
E25 014 3 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E25 015 18 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55 WATT
E27 014 3 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E27 015 19 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55 WATT
E28 014 1 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
E28 015 16 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55 WATT
E29 014 7 Innenleuchte Kabine Inside light, cabin 21W
E30 013 13 Heizgeraet Heating unit
E32 014 5 Kennleuchte Warning light 55W
E33 007 19 Bremsleuchte links Brake light, lh. 21W
E34 007 20 Bremsleuche rechts Brake light, rh. 21W
E41 007 13 Umrissleuchte vorne links Contour illumination front, lh.
E43 007 16 Umrissleuchte vorne rechts Contour illumination front, rh.
E61 007 3 Beleuchtung Reifendruckanzeige Illumination 2W
E70 014 7 Nachtleuchte Night lamp 5W
E71 014 17 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 014 1 Beleuchtung Bedienschalter illum. Switches 2W, 24V
E72 014 2 Beleuchtung Bedienschalter illum. Switches 2W, 24V
E72 014 2 Beleuchtung Bedienschalter illum. Switches 2W, 24V
E72 014 2 Beleuchtung Bedienschalter illum. Switches 2W, 24V

F00 002 1 Hauptsicherung Batterie Fuse, main, battery 125A

F01 002 12 Hauptsicherung Fuse, main 30A
F04 004 18 Sicherung Instrumente Fuse, gauges 5A
F05 002 20 Sicherung Steckdose Fuse, socket 15A
F06 005 5 Sicherung Berieselung Fuse, sprinkler system 10A
F07 007 6 Sicherung Warnblinker Fuse, hazard light 15A
F09 007 13 Sicherung Parkï u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 007 16 Sicherung Parkï u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 007 17 Sicherung Scheinwerfer links Fuse, head light, lh. 10A
F12 007 18 Sicherung Scheinwerfer rechts Fuse, head light, rh. 10A
F14 003 3 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 10A
F15 002 5 Sicherung Heizgeraet Fuse, heating unit 125A
F15 013 17 Sicherung Heizgeraet Fuse, heating unit 5A
1

F22 007 2 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 15A
F23 005 16 Sicherung Signalhorn Fuse, warning horn 10A
F25 003 9 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F26 009 17 Sicherung Magnetv. Fahrstufenumsch. Fuse, sol. valve, speed range sel. 10A
F27 014 12 Sicherung Wischer u. Wascher vorne Fuse, windscr. wiper and washer, fr. 15A
6

F28 014 14 Sicherung Wischer u. Wascher hinten Fuse, windscr. wiper and washer, re. 15A
F31 013 1 Sicherung Kabinenluefter Fuse, cabin ventilator 25A
F37 005 2 Sicherung Berieselungspumpe Fuse, sprinkler pump 20A
F40 013 14 Sicherung Kabinenheizung Fuse, heating unit cab 20A
538 100 01

F41 014 5 Sicherung Rundumkennleuchte Fuse, rotary beacon 15A

F68 013 9 Sicherung Potential 30 Fuse, potential 30 10A
F70 007 9 Sicherung Blinker Fuse, indicators 15A
F77 009 7 Sicherung Fahren Fuse, traveling 10A
F108 015 16 Sicherung Scheinwerfer mitte Fuse, head lights middle 25A
101

F110 014 4 Sicherung Scheinwerfer aussen Fuse, head lights outside 25A
F119 002 12 Sicherung Motor Fuse, motor 7,5A
008 911
F120 17 007 19 Sicherung Bremsleuchte BOMAG
Fuse, brake light 15A 595
Name Bl. Pf. Benennung title TYP

14.1 F124
F129
F143
002
004
014
6
1
17
Sicherung Kraftstoffvorwärmung
Sicherung, MD+
Sicherung Heckscheibenheizung
Fuse, fuel preïheating
Fuse, MD+
fuse rear screen heating unit
25A
Wiring diagram
15A
15A
F149 004 4 Sicherung Magnetventil Bremse Fuse, sol. valve brake 5A
F156 007 17 Sicherung StvzO Fuse, StvzO 20A

G01 002 1 Batterie Battery 102AH

G02 002 7 Generator Generator 90A
G03 002 3 Batterie Battery 102AH

H01 003 7 Meldeleuchte Bremse Indicator light, brake

H05 007 11 Meldeleuchte Blinker Indicator light, indicators
H06 007 6 Meldeleuchte Warnblinker Indicator light, hazard light
H06 007 6 Meldeleuchte Warnblinker Indicator light, hazard light
Werner
9.1.07
Nallin
9. 1. 7

H08 002 11 Meldeleuchte Ladekontrolle Indicator light, charge control

H09 004 12 Meldeleuchte Oeldruck Motor Indicator light, engine oil pressure
H14 009 2 Warnsummer Rueckwaertsfahrt Backïup alarm buzzer
H15 004 14 Meldeleuchte Motorluftfilter Indicator light, engine air filter
H20 003 6 Meldeleuchte Sitzkontaktschalter Indicator light, drivers seat contact
H23 004 15 Meldeleuchte Hydraulikoelfilter Indicator light, hydr.oil filter
H43 004 7 Meldeleuchte Bremsdruck Indicator light, brake pressure
H49 004 13 Meldeleuchte Motorueberhitzung Indicator light, engine overheating
H52 002 17 Anzeige Gluehueberwachung Glow plug indicator
H70 004 17 Anzeige Wasser im Diesel Indicator water in fuel
H73 004 10 Meldeleuchte Kuelmittelvorrat Indicator light, eng. coolant res.
H79 004 5 Meldeleuchte Wasserrestmenge Indicator light, Water res.
H82 003 18 Warnsummer Sitzkontakt Warning buzzer, seat contact
H86 004 3 Meldeleuchte Bremsöltemperatur Indicator light, brake oil temperature

K05 009 13 Relais Startstrom Relay, starting current BOSCHW

K11 002 18 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW
K14 002 15 Relais Vorgluehen Relay, glow plug system BOSCHL
K22 003 17 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K32 014 16 Relais Kabine Relay, cabin BOSCHL
K36 004 7 Relais Bremskontrolle Relay, brake control BOSCHW
K42 009 7 Umschaltrelais Relay, switch over BOSCHW
K62 002 8 Relais D+ Relay, D+ BOSCHW
K85 014 19 Umschaltrelais Relay, switch over BOSCHW
K104 005 5 Relais, Stoermeldungen Relay, failure indication BOSCHW
K112 003 9 Relais, Meldeleuchte Bremse Relay, indicator light brake BOSCHW
K118 014 20 Relais Arbeisscheinwerfer Relay, working lights BOSCHW
K135 015 14 Relais Arbeisscheinwerfer Relay, working lights BOSCHW
K141 014 18 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
component listing

K143 004 8 Relais Druckschalter Bremse Relay, pressure switch, brake BOSCHW
K144 004 6 Relais Wassertankrestmenge Relay, water tank residual quantity BOSCHW
Bauteilliste

K149 004 4 Relais Bremsöltemperatur relay, brake oil temperature BOSCHW

M01 002 8 Starter Starter

M02 005 6 D*Berieselungspumpe E*Sprinkler pump 11A
M04 014 11 Scheibenwischermotor vorne Windscreen wiper motor, front 7,9A
M05 014 14 Scheibenwischermotor hinten Windscreen wiper motor, rear 7,9A
M06 014 13 Scheibenwaschermotor vorne Windscreen washer motor, front 2,5A
M07 014 15 Scheibenwaschermotor hinten Windscreen washer motor, rear 2,5A
M09 013 1 Kabinenluefter Cabin ventilator MAX.11A
M09 013 3 Kabinenluefter Cabin ventilator MAX.11A

P00 002 11 Betriebsstundenzaehler Operating hour meter

P01 004 18 Tankanzeige Level gauge
P04 012 15 Geschwindigkeitsanzeige Speedometer
P09 012 5 Frequenzï und Geschwindigkeitsanzeige Frequencyï and Speedometer
P18 013 18 Diagnose Diagnostics

R03 004 18 Geber Tankanzeige Sender, level gauge

R03 004 19 Geber Tankanzeige Sender, level gauge
R09 002 9 Vorwiderstand Dropping resistor 82 OHM
R19 002 5 Heizflansch heater flange 2000 WATT
R20 004 17 Widerstand Resistor
R21 004 16 Widerstand Resistor
R22 004 16 Widerstand Resistor
R79 002 6 Kraftstoffvorwärmung fuel preïheater 200W
R80 014 17 Heizung Heckscheibe heating rear screen MAX. 13A

S00 002 12 Startschalter Starter switch

S01 003 12 Schalter NOT AUS Switch, emergency off
S02 009 18 Fahrstufenschalter Switch, speed range selector
S03 005 16 Taster Signalhorn Push button, warning horn
S05 005 6 Berieselungsschalter Switch, sprinkler system
S14 007 6 Warnblinkschalter Switch, hazard light
S15 007 17 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 014 12 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 014 14 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S26 007 2 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
2

S28 013 17 Schalter Kabinenheizung Switch, cabin heating

S30 002 1 Batterietrennschalter Switch, battery disconnect
S31 009 4 Schalter Fahrtrichtung Switch, travel direction
S37 007 9 Schalter Blinker Switch, indicator
S38 014 5 Schalter Kennleuchte Switch, warning light
6

S44 013 1 Schalter Kabinenluefter Switch, cabin ventilator

S45 014 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 014 20 Schalter Arbeitsbeleuchtung Switch, working lights
S53 015 14 Schalter Arbeitsbeleuchtung Switch, working lights
538 100 01

S111 003 11 Schalter Feststellbremse Switch, parking brake

S158 014 7 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 014 18 Schalter Heckscheibenheizung switch rear screen heating unit
S165 002 15 Taster Vorgluehen Push button, glowing before start
S184 009 10 Schalter Fahrtrichtung switch, travel direction
102

S185 007 13 Schalter Nachtbeleuchtung Modul switch, night illumination module

596 V01 002 9 Diode BOMAG

Diode MR756,008 911
KABEL 17
Name Bl. Pf. Benennung title TYP
V02
Wiring diagram
V03
V09
005
003
013
18
18
6
Diode
Diode
Diode
Diode
Diode
Diode
14.1
FE5B, KABEL
FE5B, KABEL
FE5B
V10 013 10 Diode Diode STECKER Y138
V12 007 11 Diode Diode
V13 007 11 Diode Diode
V41 003 2 Diode (A1) Diode (A1) DIODENMODUL
V42 003 13 Diode (A2) Diode (A2) Diodenmodul
V43 004 3 Diode (A3) Diode (A3) DIODENMODUL
V45 009 11 Diode (A5) Diode (A5) DIODENMODUL
V46 002 8 Diode (A6) Diode (A6) DIODENMODUL
V47 009 3 Diode (A7) Diode (A7) DIODENMODUL
V48 009 4 Diode (A8) Diode (A8) DIODENMODUL
Werner
9.1.07
Nallin
9. 1. 7

X1:1 003 12 Wago Zentralelektrik Wago eïbox

X1:2 007 17 Wago Zentralelektrik Wago eïbox
X1:3 007 17 Wago Zentralelektrik Wago eïbox
X1:4 007 17 Wago Zentralelektrik Wago eïbox
X1:5 009 7 Wago Zentralelektrik Wago eïbox
X1:6 007 9 Wago Zentralelektrik Wago eïbox
X1:7 007 9 Wago Zentralelektrik Wago eïbox
X1:8 003 9 Wago Zentralelektrik Wago eïbox
X1:9 003 12 Wago Zentralelektrik Wago eïbox
X1:10 012 15 Wago Zentralelektrik Wago eïbox
X1:11 012 15 Wago Zentralelektrik Wago eïbox
X1:12 005 6 Wago Zentralelektrik Wago eïbox
X1:13 002 20 Wago Zentralelektrik Wago eïbox
X1:14 003 12 Wago Zentralelektrik Wago eïbox
X1:15 003 3 Wago Zentralelektrik Wago eïbox
X1:16 009 17 Wago Zentralelektrik Wago eïbox
X1:17 002 15 Wago Zentralelektrik Wago eïbox
X1:18 002 15 Wago Zentralelektrik Wago eïbox
X1:19 004 16 Wago Zentralelektrik Wago eïbox
X1:20 004 16 Wago Zentralelektrik Wago eïbox
X1:21 002 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:22 004 15 Wago Zentralelektrik Wago eïbox
X1:23 002 8 Wago Zentralelektrik Wago eïbox
X1:24 004 14 Wago Zentralelektrik Wago eïbox
X1:25 004 12 Wago Zentralelektrik Wago eïbox
X1:26 004 13 Wago Zentralelektrik Wago eïbox
X1:27 009 18 Wago Zentralelektrik Wago eïbox
X1:28 002 20 Wago Zentralelektrik Wago eïbox
X1:28 016 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
component listing

X1:31 007 13 Wago Zentralelektrik Wago eïbox

X1:32 007 17 Wago Zentralelektrik Wago eïbox
Bauteilliste

X1:33 007 9 Wago Zentralelektrik Wago eïbox

X1:34 007 10 Wago Zentralelektrik Wago eïbox
X1:41 007 9 Wago Zentralelektrik Wago eïbox
X1:42 004 18 Wago Zentralelektrik Wago eïbox
X1:43 005 16 Wago Zentralelektrik Wago eïbox
X1:44 003 17 Wago Zentralelektrik Wago eïbox
X1:45 004 10 Wago Zentralelektrik Wago eïbox
X1:46 003 16 Wago Zentralelektrik Wago eïbox
X1:47 003 7 Wago Zentralelektrik Wago eïbox
X1:48 003 6 Wago Zentralelektrik Wago eïbox
X1:49 003 2 Wago Zentralelektrik Wago eïbox
X1:49 003 13 Wago Zentralelektrik Wago eïbox
X1:49 003 14 Wago Zentralelektrik Wago eïbox
X1:49 003 18 Wago Zentralelektrik Wago eïbox
X1:49 004 17 Wago Zentralelektrik Wago eïbox
X1:49 005 10 Wago Zentralelektrik Wago eïbox
X1:49 007 4 Wago Zentralelektrik Wago eïbox
X1:49 007 5 Wago Zentralelektrik Wago eïbox
X1:49 009 11 Wago Zentralelektrik Wago eïbox
X1:50 007 10 Wago Zentralelektrik Wago eïbox
X1:52 005 16 Wago Zentralelektrik Wago eïbox
X1:53 009 17 Wago Zentralelektrik Wago eïbox
X1:54 007 7 Wago Zentralelektrik Wago eïbox
X1:55 007 7 Wago Zentralelektrik Wago eïbox
X1:56 003 16 Wago Zentralelektrik Wago eïbox
X1:61 012 8 Wago Zentralelektrik Wago eïbox
X1:71 012 12 Wago Zentralelektrik Wago eïbox
X1:72 012 10 Wago Zentralelektrik Wago eïbox
X1:73 012 10 Wago Zentralelektrik Wago eïbox
X1:81 009 7 Wago Zentralelektrik Wago eïbox
X1:82 009 4 Wago Zentralelektrik Wago eïbox
X1:83 009 4 Wago Zentralelektrik Wago eïbox
X1:91 004 8 Wago Zentralelektrik Wago eïbox
X1:91 004 10 Wago Zentralelektrik Wago eïbox
X1:92 004 10 Wago Zentralelektrik Wago eïbox
X1:92 009 10 Wago Zentralelektrik Wago eïbox
X1:93 007 2 Wago Zentralelektrik Wago eïbox
3

X1:94 007 19 Wago Zentralelektrik Wago eïbox

X1:95 009 4 Wago Zentralelektrik Wago eïbox
X1:96 009 5 Wago Zentralelektrik Wago eïbox
X1:97 003 12 Wago Zentralelektrik Wago eïbox
X1:98 003 3 Wago Zentralelektrik Wago eïbox
6

X1:99 009 17 Wago Zentralelektrik Wago eïbox

X1:100 002 15 Wago Zentralelektrik Wago eïbox
X1:101 002 15 Wago Zentralelektrik Wago eïbox
X1:102 004 16 Wago Zentralelektrik Wago eïbox
538 100 01

X1:103 004 16 Wago Zentralelektrik Wago eïbox

X1:104 002 17 Wago Zentralelektrik Wago eïbox
X1:105 004 14 Wago Zentralelektrik Wago eïbox
X1:106 002 8 Wago Zentralelektrik Wago eïbox
X1:107 004 14 Wago Zentralelektrik Wago eïbox
103

X1:108 004 12 Wago Zentralelektrik Wago eïbox

X1:109 004 13 Wago Zentralelektrik Wago eïbox
008 911
X1:11017 009 18 Wago Zentralelektrik BOMAG
Wago eïbox 597
Name Bl. Pf. Benennung title TYP

14.1 X1:111
X1:111
X1:111
005
007
009
7
4
12
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago eïbox
Wago eïbox
Wago eïbox
Wiring diagram
X1:111 009 17 Wago Zentralelektrik Wago eïbox
X1:111 012 16 Wago Zentralelektrik Wago eïbox
X1:121 007 14 Wago Zentralelektrik Wago eïbox
X1:122 007 15 Wago Zentralelektrik Wago eïbox
X1:123 007 8 Wago Zentralelektrik Wago eïbox
X1:124 007 9 Wago Zentralelektrik Wago eïbox
X1:125 002 18 Wago Zentralelektrik Wago eïbox
X1:125 004 5 Wago Zentralelektrik Wago eïbox
X1:125 005 16 Wago Zentralelektrik Wago eïbox
X1:125 007 8 Wago Zentralelektrik Wago eïbox
X1:126 004 18 Wago Zentralelektrik Wago eïbox
Werner
9.1.07
Nallin
9. 1. 7

X1:127 005 16 Wago Zentralelektrik Wago eïbox

X1:128 004 5 Wago Zentralelektrik Wago eïbox
X1:129 002 18 Wago Zentralelektrik Wago eïbox
X1:130 007 17 Wago Zentralelektrik Wago eïbox
X1:131 007 18 Wago Zentralelektrik Wago eïbox
X1:132 005 6 Wago Zentralelektrik Wago eïbox
X1:133 005 6 Wago Zentralelektrik Wago eïbox
X1:133 009 7 Wago Zentralelektrik Wago eïbox
X1:141 004 5 Wago Zentralelektrik Wago eïbox
X1:142 004 7 Wago Zentralelektrik Wago eïbox
X1:143 009 7 Wago Zentralelektrik Wago eïbox
X1:144 003 12 Wago Zentralelektrik Wago eïbox
X1:145 003 3 Wago Zentralelektrik Wago eïbox
X1:146 007 2 Wago Zentralelektrik Wago eïbox
X1:147 007 2 Wago Zentralelektrik Wago eïbox
X1:148 009 9 Wago Zentralelektrik Wago eïbox
X1:149 009 10 Wago Zentralelektrik Wago eïbox
X1:151 004 7 Wago Zentralelektrik Wago eïbox
X1:153 004 15 Wago Zentralelektrik Wago eïbox
X1:154 004 15 Wago Zentralelektrik Wago eïbox
X1:155 004 3 Wago Zentralelektrik Wago eïbox
X1:156 004 3 Wago Zentralelektrik Wago eïbox
X1:157 004 4 Wago Zentralelektrik Wago eïbox
X1:158 004 4 Wago Zentralelektrik Wago eïbox
X1:159 004 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:163 002 6 Wago Zentralelektrik Wago eïbox
X1:164 002 6 Wago Zentralelektrik Wago eïbox
X1:165 002 13 Wago Zentralelektrik Wago eïbox
X1:166 002 14 Wago Zentralelektrik Wago eïbox
component listing

X1:167 002 13 Wago Zentralelektrik Wago eïbox

X1:168 002 13 Wago Zentralelektrik Wago eïbox
Bauteilliste

X1:169 002 15 Wago Zentralelektrik Wago eïbox

X1:170 002 15 Wago Zentralelektrik Wago eïbox
X1:171 002 15 Wago Zentralelektrik Wago eïbox
X1:172 002 15 Wago Zentralelektrik Wago eïbox
X2:1ï1 002 4 Wago Zentralelektrik Wago eïbox
X2:1ï2 002 2 Wago Zentralelektrik Wago eïbox
X2:2ï1 002 2 Wago Zentralelektrik Wago eïbox
X2:2ï2 002 12 Wago Zentralelektrik Wago eïbox
X2:3ï1 002 2 Wago Zentralelektrik Wago eïbox
X2:3ï2 002 20 Wago Zentralelektrik Wago eïbox
X2:4ï1 002 2 Wago Zentralelektrik Wago eïbox
X2:4ï1 002 2 Wago Zentralelektrik Wago eïbox
X2:4ï2 005 2 Wago Zentralelektrik Wago eïbox
X2:6ï1 002 2 Wago Zentralelektrik Wago eïbox
X2:6ï1 002 6 Wago Zentralelektrik Wago eïbox
X2:6ï1 002 12 Wago Zentralelektrik Wago eïbox
X2:6ï2 002 6 Wago Zentralelektrik Wago eïbox
X2:6ï2 002 12 Wago Zentralelektrik Wago eïbox
X2:7ï1 002 2 Wago Zentralelektrik Wago eïbox
X2:7ï1 003 2 Wago Zentralelektrik Wago eïbox
X2:7ï2 003 3 Wago Zentralelektrik Wago eïbox
X2:7ï2 007 6 Wago Zentralelektrik Wago eïbox
X2:8ï1 004 1 Wago Zentralelektrik Wago eïbox
X2:8ï2 004 1 Wago Zentralelektrik Wago eïbox
X2:9ï1 004 18 Wago Zentralelektrik Wago eïbox
X2:9ï2 004 18 Wago Zentralelektrik Wago eïbox
X2:10ï1 004 3 Wago Zentralelektrik Wago eïbox
X2:10ï2 004 4 Wago Zentralelektrik Wago eïbox
X2:11ï1 007 2 Wago Zentralelektrik Wago eïbox
X2:11ï2 007 2 Wago Zentralelektrik Wago eïbox
X2:12ï1 005 16 Wago Zentralelektrik Wago eïbox
X2:12ï2 005 16 Wago Zentralelektrik Wago eïbox
X2:13ï1 003 10 Wago Zentralelektrik Wago eïbox
X2:13ï2 003 9 Wago Zentralelektrik Wago eïbox
X2:14ï1 009 17 Wago Zentralelektrik Wago eïbox
X2:14ï2 009 17 Wago Zentralelektrik Wago eïbox
X2:15ï1 007 8 Wago Zentralelektrik Wago eïbox
4

X2:15ï2 007 9 Wago Zentralelektrik Wago eïbox

X2:16ï1 009 7 Wago Zentralelektrik Wago eïbox
X2:16ï2 009 7 Wago Zentralelektrik Wago eïbox
X2:17ï1 007 19 Wago Zentralelektrik Wago eïbox
X2:17ï2 007 19 Wago Zentralelektrik Wago eïbox
6

X2:18ï1 007 13 Wago Zentralelektrik Wago eïbox

X2:18ï2 007 13 Wago Zentralelektrik Wago eïbox
X2:19ï1 007 16 Wago Zentralelektrik Wago eïbox
X2:19ï2 007 16 Wago Zentralelektrik Wago eïbox
538 100 01

X2:20ï1 007 17 Wago Zentralelektrik Wago eïbox

X2:20ï2 007 17 Wago Zentralelektrik Wago eïbox
X2:21ï1 007 18 Wago Zentralelektrik Wago eïbox
X2:21ï2 007 18 Wago Zentralelektrik Wago eïbox
X2:22ï1 005 5 Wago Zentralelektrik Wago eïbox
104

X2:22ï2 005 5 Wago Zentralelektrik Wago eïbox

X2:23ï1 007 17 Wago Zentralelektrik Wago eïbox
598 X2:23ï2 007 17 Wago Zentralelektrik BOMAG
Wago eïbox 008 911 17
Name Bl. Pf. Benennung title TYP
X3:1
Wiring diagram
X3:2
X6:1
009
009
003
2
2
17
WARNSUMMER H14
WARNSUMMER H14
ARMATURENPULT
Warning buzer H14
Warning buzer H14
Instrument board
14.1
X6:2 004 18 ARMATURENPULT Instrument board
X6:3 004 16 ARMATURENPULT Instrument board
X6:4 004 16 ARMATURENPULT Instrument board
X6:5 004 10 ARMATURENPULT Instrument board
X6:6 002 17 ARMATURENPULT Instrument board
X6:7 007 6 ARMATURENPULT Instrument board
X6:8 007 11 ARMATURENPULT Instrument board
X6:9 003 18 ARMATURENPULT Instrument board
X6:10 004 17 ARMATURENPULT Instrument board
X6:11 003 7 ARMATURENPULT Instrument board
X6:12 003 6 ARMATURENPULT Instrument board
Werner
9.1.07
Nallin
9. 1. 7

X6:13 004 15 ARMATURENPULT Instrument board

X6:14 002 10 ARMATURENPULT Instrument board
X6:15 004 14 ARMATURENPULT Instrument board
X6:16 004 12 ARMATURENPULT Instrument board
X6:17 004 13 ARMATURENPULT Instrument board
X6:18 007 11 ARMATURENPULT Instrument board
X6:19 007 11 ARMATURENPULT Instrument board
X6:20 004 18 ARMATURENPULT Instrument board
XS 002 20 Steckdose Socket
XS 014 6 Steckdose Socket 15A
X10:1 004 19 KRAFTSTOFFTANK Fuel tank
X10:2 004 18 KRAFTSTOFFTANK Fuel tank
X10:3 004 18 KRAFTSTOFFTANK Fuel tank
X11:1 009 6 FAHRTRICHTUNGSSCHALTE switch, travel direction
X11:2 009 4 FAHRTRICHTUNGSSCHALTE switch, travel direction
X11:3 009 4 FAHRTRICHTUNGSSCHALTE switch, travel direction
X11:4 009 5 FAHRTRICHTUNGSSCHALTE switch, travel direction
X12:1 009 8 FAHRTRICHTUNGSSCHALTE switch, travel direction
X12:2 009 10 FAHRTRICHTUNGSCHALTER switch, travel direction
X12:3 009 9 FAHRTRICHTUNGSSCHALTE switch, travel direction
X12:4 009 8 FAHRTRICHTUNGSSCHALTE switch, travel direction
X13:A 002 12 FAHRERSTAND Operators platform
X13:B 002 12 FAHRERSTAND Operators platform
X13:C 002 13 FAHRERSTAND Operators platform
X14:A 002 13 FAHRERSTAND Operators platform
X14:B 002 13 FAHRERSTAND Operators platform
X17:1 005 6 BERIESELUNGSPUMPE Sprinkler pump
X17:2 005 6 BERIESELUNGSPUMPE Sprinkler pump
X19:1 016 5 KEYBOARD Keyboard
component listing

X19:2 016 5 KEYBOARD Keyboard

X19:3 016 5 KEYBOARD Keyboard
Bauteilliste

X19:4 016 5 KEYBOARD Keyboard

X19:5 016 5 KEYBOARD Keyboard
X19:7 016 5 KEYBOARD Keyboard
X19:8 016 12 KEYBOARD Keyboard
X19:9 016 5 KEYBOARD Keyboard
X19:10 016 5 KEYBOARD Keyboard
X19:11 016 5 KEYBOARD Keyboard
X19:12 016 5 KEYBOARD Keyboard
X21:1 013 7 KLIMAKOMPRESSOR Air conditioning compr.
X22:1 016 13 KEYBOARD Keyboard
X22:2 016 13 KEYBOARD Keyboard
X24:1 012 10 B15 B15
X24:2 012 10 B15 B15
X24:3 012 10 B15 B15
X24:4 012 9 B15 B15
X27:1 004 5 WASSERTANK Water tank
X27:2 004 5 WASSERTANK Water tank
X30:1 003 18 H82 H82
X30:2 003 18 H82 H82
X40:1 013 1 Kabine cabin
X40:2 013 2 Kabine cabin
X40:3 013 3 Kabine cabin
X40:4 013 3 Kabine cabin
X42:1 013 2 Kabine cabin
X42:2 013 2 Kabine cabin
X42:3 013 2 Kabine cabin
X42:4 013 1 Kabine cabin
X43:1 013 7 FAHRERSTAND Operators platform
X43:2 013 7 FAHRERSTAND Operators platform
X43:3 013 7 FAHRERSTAND Operators platform
X43:4 013 7 FAHRERSTAND Operators platform
X44:31 014 12 Kabine cabin
X44:53 014 11 Kabine cabin
X44:31b 014 12 Kabine cabin
X44:53a 014 12 Kabine cabin
X45:1 013 3 Kabine cabin
X45:2 013 4 Kabine cabin
5

X45:3 013 3 Kabine cabin

X45:4 013 3 Kabine cabin
X46:31 014 14 Kabine cabin
X46:53 014 14 Kabine cabin
X46:31b 014 14 Kabine cabin
6

X46:53a 014 14 Kabine cabin

X49:1 013 9 FAHRERSTAND Operators platform
X49:2 013 9 FAHRERSTAND Operators platform
X50:1 013 7 FAHRERSTAND Operators platform
538 100 01

X51:A 014 7 FAHRERSTAND Operators platform

X51:B 014 7 FAHRERSTAND Operators platform
X51:C 002 2 FAHRERSTAND Operators platform
X52:1 013 7 FAHRERSTAND Operators platform
X52:2 013 7 FAHRERSTAND Operators platform
105

X53:3 013 18 Kabine cabin

X53:5 013 19 Kabine cabin
008 911
X53:6 17 013 18 Kabine BOMAG
cabin 599
Name Bl. Pf. Benennung title TYP

14.1 X54:1
X54:2
X55:1
013
013
013
13
13
7
Kraftstoffpumpe
Kraftstoffpumpe
FAHRERSTAND
fuel pump heating unit
fuel pump heating unit
Operators platform
Wiring diagram
X55:2 013 6 FAHRERSTAND Operators platform
X61:A 014 15 Kabine cabin
X61:B 014 15 Kabine cabin
X61:C 014 13 Kabine cabin
X62:1 014 14 Kabine cabin
X62:2 014 14 Kabine cabin
X63:1 014 13 Kabine cabin
X63:2 014 15 Kabine cabin
X63:3 002 2 KABINE Cabin
X63:4 013 9 Kabine cabin
X63:5 014 20 Kabine cabin
Werner
9.1.07
Nallin
9. 1. 7

X63:6 013 11 Kabine cabin

X63:7 013 7 Kabine cabin
X63:8 014 7 Kabine cabin
X64:1 014 7 Kabine cabin
X64:2 014 20 Kabine cabin
X64:3 014 12 Kabine cabin
X64:4 014 5 Kabine cabin
X64:5 014 11 Kabine cabin
X64:6 014 12 Kabine cabin
X64:7 014 6 Kabine cabin
X64:8 014 14 Kabine cabin
X65:2 013 1 Kabine cabin
X65:3 013 2 Kabine cabin
X65:4 013 2 Kabine cabin
X66:1 014 4 Kabine cabin
X67:A 014 8 Kabine cabin
X67:A 014 9 Kabine cabin
X67:A 014 9 Kabine cabin
X67:B 014 8 Kabine cabin
X67:B 014 8 Kabine cabin
X67:B 014 9 Kabine cabin
X67:C 014 9 Kabine cabin
X67:C 014 9 Kabine cabin
X67:C 014 9 Kabine cabin
X89:A 002 1 FAHRERSTAND Operators platform
X89:B 002 2 FAHRERSTAND Operators platform
X91:A 014 2 MOTORRAUM Engine room
X91:B 002 3 MOTORRAUM Engine room
X95:1ï1 007 8 Blende vorn Srceen front
component listing

X95:1ï2 007 14 Blende vorn Srceen front

X95:1ï2 007 17 Blende vorn Srceen front
Bauteilliste

X95:1ï4 007 8 Blende vorn Srceen front

X95:1ï5 007 14 Blende vorn Srceen front
X95:1ï6 007 17 Blende vorn Srceen front
X95:2ï1 007 9 Blende vorn Srceen front
X95:2ï2 007 15 Blende vorn Srceen front
X95:2ï3 007 18 Blende vorn Srceen front
X95:2ï4 007 9 Blende vorn Srceen front
X95:2ï5 007 15 Blende vorn Srceen front
X95:2ï6 007 18 Blende vorn Srceen front
X96:1ï1 007 9 Blende vorn Srceen front
X96:1ï2 007 13 Blende hinten Screen rear
X96:1ï3 007 1 Blende hinten Screen rear
X96:1ï4 007 9 Blende hinten Screen rear
X96:1ï5 007 13 Blende hinten Screen rear
X96:1ï6 007 1 Blende hinten Screen rear
X96:1ï7 007 19 Blende hinten Screen rear
X96:2ï1 007 10 Blende hinten Screen rear
X96:2ï3 007 2 Blende hinten Screen rear
X96:2ï4 007 10 Blende hinten Screen rear
X96:2ï5 007 17 Blende hinten Screen rear
X96:2ï6 007 2 Blende hinten Screen rear
X96:2ï7 007 17 Blende hinten Screen rear
X96:7ï7 007 20 Blende hinten Screen rear
X97:1 007 13 ZA, Umrissleuchte Option, Contour illumination
X97:1 007 16 ZA, Umrissleuchte Option, Contour illumination
X97:2 007 13 ZA, Umrissleuchte Option, Contour illumination
X97:2 007 16 ZA, Umrissleuchte Option, Contour illumination

Y01 002 11 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y03 009 17 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector KABEL+STECKER
Y04 003 12 Magnetventil Bremse Solenoid valve, brake 2,41A HYTOS
Y13 003 3 Hubmagnet Motor Shut off solenoid, engine 4A
Y14 013 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit 2A
Y15 013 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y16 009 5 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 26,2W
Y17 009 4 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 26,2W
Y130 009 19 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector KABEL+STECKER
6

Y138 013 9 Magnetveentil Heizung Solenoid valve, heating unit 3,5A

Y163 009 9 Magnetventil Fahrtrichtung solenoid valve, travel direction
Y164 009 10 Magnetventil Fahrtrichtung solenoid valve, travel direction
6
538 100 01
106

600 BOMAG 008 911 17

14.2 Hydraulic diagram

008 911 17 BOMAG 601

14.2 Hydraulic diagram

602 BOMAG 008 911 17

Hydraulic diagram 14.2

008 911 17 BOMAG 603

14.2 Hydraulic diagram

604 BOMAG 008 911 17

14.3 Pneumatic diagram

008 911 17 BOMAG 605

14.3 Pneumatic diagram

606 BOMAG 008 911 17

Pneumatic diagram 14.3

008 911 17 BOMAG 607

14.3 Pneumatic diagram

608 BOMAG 008 911 17

15 Supplement to circuit diagram

008 911 17 BOMAG 609

15.1 Control elements

15.1 Control elements

Fig. 15

Pos. Designation in circuit diagram Designation

1 S31 / S184 Switch for travel direction
2 Steering wheel
3 not used
4 Tire pressure gauge
5 S01 Emergency stop switch
6 S14 Hazard light switch
7 A15 Monitoring board
8 P04 / E04 Speedometer / illumination of speedometer1
9 not used
10 S165 Push button for heating flange control*
11 S02 Speed range selector switch

610 BOMAG 008 911 17

Control elements 15.1
12 S185 Switch, night light
13 S05 Switch for sprinkling system
14 H86, monitoring module, old design Brake oil temperature control light
15 S111 Parking brake switch
16 H43, monitoring module, old design Brake pressure control light
17 S03 Button for warning horn
18 S37 Switch, direction indicator
19 S15 Light switch (StVZO)
20 S26 Switch for working lights
21 Throttle pedal
22 S00 Start switch
23 Brake pedal
24 Rotary switch for tire inflation
25 Rotary switch to relieve tire pressure
26 XS Socket
1 Optional equipment

008 911 17 BOMAG 611

15.1 Control elements

Fig. 16

Pos. Designation in circuit diagram Designation in circuit diagram

a S38 Switch, flashing beacon
b S20 Switch, front windscreen wiper
c S21 Switch rear windscreen wiper
d F41..... Fuse, cabin
e S44 Switch cabin fan
f A72 Control unit air conditioning, heater
g A72 Control unit air conditioning, heater
h S53 Switch for working lights
i E29 Cabin light
j E70 Night light
k S45 Switch, cabin light
l S158 Switch, night light
m S163 Rear windscreen heater switch

612 BOMAG 008 911 17

Monitoring board A15 15.2
15.2 Monitoring board A15
Old design

Fig. 17 Monitoring module A15, old design

Pos. Designation in circuit diagram Designation in circuit diagram

a H49 Control light, overheating of engine
b H09 Engine oil pressure control light
c H15 Control light for engine air filter
d H08 Charge control light
e H23 Hydraulic oil filter control light
f not used not used
g H01 Brake control light
h H05 Indicator control light
i H70 Control light, water in diesel filter
j H73, option Control light, coolant provision
k H52 Control light, preheating monitoring
l H06 Hazard light control light
m P00 Operating hour meter
n P01 Fuel gauge

008 911 17 BOMAG 613

15.2 Monitoring board A15

New version

Fig. 18 Monitoring module A15, new design

Pos. Designation in circuit diagram Designation in circuit diagram

a H43 Brake pressure control light
b H70 Control light, water in diesel filter
c H52 Control light, preheating monitoring
d H79 Remaining water quantity, sprinkling system
e H09 Engine oil pressure control light
f H73, option Control light, coolant provision
g H08 Charge control light
h H15 Control light for engine air filter
i H49 Control light, overheating of engine
j H23 Hydraulic oil filter control light
k H05 Indicator control light
l H86 Brake oil temperature control light
m H01 Brake control light
n P01 Fuel gauge
o not used
p P00 Operating hour meter

614 BOMAG 008 911 17

Terminal box 15.3
15.3 Terminal box

Pos. Designation in circuit diagram Designation in circuit diagram

X1 X1:1.... Terminal strip X1
X2 X2:1.... Terminal strip X2
a V41... V48 Diode module, diodes (A1 ....A8)
b A100 Module steering column switch, travel direction
c A04 Module sprinkling system
d R09 Dropping resistor, generator excitation
e K05 ... K149 Relays
f A05 Speedometer electronics

008 911 17 BOMAG 615

15.4 Engine compartment

15.4 Engine compartment

Fig. 4
1 B21, hydraulic oil filter (brake oil) differential pres-
Fig. 1 sure switch (Fig. 4)
1 B03, air filter differential pressure switch (Fig. 1) 2 B22, hydraulic oil filter (charge circuit) differential
pressure switch
3 B148, brake oil temperature switch

Fig. 2
1 B06, oil pressure switch (Fig. 2)
Fig. 5
1 B53, temperature sensor (Fig. 5) for heating
flange control1
2 B152, temperature switch for engine coolant tem-
perature

Fig. 3
1 B12, pressure switch for brake(Fig. 3)
2 B102, brake light pressure switch

1 Optional equipment

616 BOMAG 008 911 17

Engine compartment 15.4

Fig. 6
1 B104, pressure switch for refrigerant in air condi- Fig. 9

tioning1 (Fig. 6) 1 S30, battery disconnecting switch (Fig. 9)

2 A13, control unit for heating flange on engine 3
3 K14, pre-heating relay 4

Fig. 7
l
G02, generator (Fig. 7)
l
Terminal W, rotational speed signal Fig. 10
l Terminal D+, dynamo plus l
Y04, brake solenoid valve (Fig. 10)
l
Terminal B+, battery plus

Fig. 11
Fig. 8 1 Y01, boost fuel solenoid valve (Fig. 11)
1 B124, water separator sensor connection (Fig. 8)
2 R79, fuel pre-heating connection 2 2 Optional equipment
3 Optional equipment
1 Optional equipment 4 Optional equipment

008 911 17 BOMAG 617

15.4 Engine compartment

Fig. 12
1 Y13, engine solenoid (Fig. 12)

618 BOMAG 008 911 17