Instructions for repair

BW 213 DH / PDH - 4
BW 214 DH / PDH - 4
S/N 101 582 51 ..... S/N 101 582 52 .....
S/N 101 582 58 ..... S/N 101 582 59 .....

Single drum roller

Catalogue number
008 913 76 10/2005
Table of Contents

General 5
1.1 Foreword 6
1.2 Safety regulations 7
1.3 General repair instructions 10
1.4 Tightening torques 13
1.5 Connection overview 14
1.6 Technische Daten 16
1.7 Table of fuels and lubricants 32
Tests and adjustments 33
2.1 Special tools, tests and adjustments 34
2.2 Activate service mode 37
2.3 Driving against the closed brake 39
2.4 Check the engine speed 41
2.5 Pressure tests in the travel circuit 42
2.6 Checking / adjusting the neutral positions of the travel pump 44
2.7 Pressure measurements in the vibration circuit 46
2.8 Check the leakage rate of the vibration motor 47
2.9 Pressure test in steering circuit 48
Flushing and bleeding 51
3.1 Special tools for flushing 52
3.2 Flushing - general 56
3.3 Flushing schematic travel circuit (distribution travel pump) 58
3.4 Flushing the travel circuit (travel pump distribution) 60
3.5 Flushing schematic travel circuit (distribution axle motor) 68
3.6 Flushing the travel circuit (axle motor distribution) 73
3.7 Flushing schematic for vibration drive 78
3.8 Flushing the vibration circuit 81
3.9 Bleeding the travel circuit 85
3.10 Bleeding the vibration circuit 87
Technical Manual 91
4.1 Technical Manual / Basic Electrics 93
4.2 Technical Manual / Electrics 145
4.3 Technical Manual / DH/PDH 217
Air conditioning system 351
5.1 Notes on safety for the air conditioning system 352
5.2 Notes on repair of the air conditioning system 353
5.3 Physical basics 355
5.4 Refrigerant R134a 357
5.5 Compressor oil / refrigeration oil 358
5.6 Working principle of the air conditioning system 359
5.7 Refrigeration diagram 360
5.8 Description of components 361
5.9 Checking the compressor oil level 367
5.10 Checking the magnetic clutch 368
5.11 Inspection and maintenance work 369
5.12 Measuring the pressure in the refrigerant circuit 369

008 913 76 BOMAG 3

Table of Contents

5.13 Check condition and tension of refrigerant compressor V-belt, replace the V-belt
370
5.14 Servicing the air conditioning 371
5.15 Drying and evacuation 373
5.16 Emptying in case of repair 374
5.17 Leak test 374
5.18 Filling instructions 375
5.19 Heating control / air conditioning control 379
Replacing the cab window panes 385
6.1 Assembly of window panes 386
6.2 Special tools 387
6.3 Auxiliary materials 388
6.4 Removing and installing the window pane 390
Drum 395
7.1 Special tools 396
7.2 Repair overview for drum 398
7.3 Removing and installing the drum 407
7.4 Repairing the drum 414
7.5 Dismantling, assembling the change-over weights 446
7.6 Changing the rubber buffers and adjusting the pretension 449
Oscillating articulated joint 453
8.1 Special tools 454
8.2 Repair overview oscillating articulated joint 456
8.3 Removing and installing the oscillating articulated joint 459
8.4 Dismantling the oscillating articulated joint 461
8.5 Assembling the oscillating articulated joint 466
Suppliers documentation 477
9.1 Travel pump / vibration pump series 90R 479
9.2 Vibration motor A2FM 569
9.3 Travel drive series 51 599
9.4 Transmission CR 681
9.5 Axle DANA 193 707
Circuit diagrams 797
10.1 Wiring diagram 799
10.2 Hydraulic diagram 833

4 BOMAG 008 913 76

1 General

008 913 76 BOMAG 5

1.1 Foreword

Introduction
1.1 For eword

These repair instructions contain all necessary infor-

mation for training and repair work.
Notes on maintenance, care and trouble shooting can
be found in the operating and maintenance instruc-
tions.
This instruction manual contains only assembly
groups needed for this type of machine.
The repair instructions describe the removal or dis-
mantling and assembly of components and assembly
groups.
The repair of disassembled assembly groups is de-
scribed 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.

! Danger
Danger of injury
Please observe strictly the safety regulations in
these operating instructions and the applicable
accident prevention regulations.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.

You should only use genuine BOMAG spare parts.

These repair instructions are not subject of an updat-
ing service; for this reason we would like to draw
your attention to our additional "Technical Service
Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this repair manual must
not be reproduced and distributed, nor must they be
used for the purpose of competition. All rights accord-
ing to the copyright law remain expressly reserved.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG

6 BOMAG 008 913 76

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

auxiliary equipment must be fully functional and in

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

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

008 913 76 BOMAG 7

1.2 Safety regulations

l
Do not smoke when refuelling or when checking the The lower the boiling point, the higher the pressure.
acid level in the battery. 2. The height of the temperature. The following ap-
plies: The higher the temperature, the higher the
l
Do not check the acid level of the battery with a na-
pressure.
ked flame, danger of explosion!
l
In a refrigerant container there must be a steam
l
Old batteries contain lead and must be properly dis-
space above the liquid space. The liquid expands
posed of.
with increasing temperature. The steam filled space
l
There is a danger of scalding when draining off en- becomes smaller. From a certain time on the con-
gine or hydraulic oil at operating temperature. tainer will be filled with just liquid. After this only a
l
on machines with rubber tires a tire may busr if in- minor temperature increase is enough to generate
correctly assembled. This can cause severe injury. very high pressures in the container, because the
liquid would like to expand, but there is no more
l
Do not exceed the specified highest permissible tire room. The related forces are high enough to cause
pressure. the container to burst. In order to avoid overfilling of
a container the pressure gas directive clearly spec-
Hydraulics ifies how many kilograms of refrigerant may be filled
into the container per litre volume.
l
Hydraulic oil escaping under pressure can pene-
trate the skin and cause severe injury. You should l
In case of occurring mechanical damage or corro-
therefore relieve the pressure in the system before sion on the refrigerant container, the container must
disconnecting any lines. be replaced, in order to prevent it from bursting and
causing further damage.
l
Before applying pressure to the system make sure
that all line connections and ports have been prop- l
Since the fluid container is pressurized, the manu-
erly tightened and are in perfect condition. facture and testing of these pressure vessels is gov-
l
Hydraulic oil leaking out of a small opening can erned by the pressure vessel directive. (New edition
hardly be noticed, therefore please use a piece of from April 1989). This directive classifies the pres-
cardboard or wood when checking for leaks. When sure vessels into the test groups in dependence on
being injured by hydraulic oil consult a physician im- their permissible operating pressure "p" in bar, its
mediately, as otherwise this may cause severe in- volume "l" in litres and the pressurized product p x
fections. l. On the basis of these prerequisites
the fluid containers must be classified as per testing
l
Do not step in front of or behind the drums/wheels group II. Paragraph 10 of the pressure vessel direc-
when performing adjustment work in the hydraulic tive demands that these pressure containers must
system while the engine is running. Block drums be periodically inspected and tested by a specialist,
and/or wheels with wedges. according to paragraph 32. . In this case
periodically recurring inspections consist of external
Reattach all guards and safety installations after
examinations, normally on containers in opera-
all work has been completed.
tion . The refrigerant container must be vis-
ually examined twice every year in connection with
Air conditioning system the inspection. Special attention must thereby
be paid to signs of corrosion and mechanical dam-
age. If the pressure vessel is in no good condi-
i Note
tion, it should be replaced for safety reasons, thus
In some countries the legislator demands minimum
to make sure that sufficient precautions have been
requirements concerning the qualification of the main-
applied to protect the operator and third par-
tenance personnel. In the Federal Republic of Germa-
ties. .
ny refrigeration and air conditioning equipment must
only be serviced by persons who are in the posses- l
Wear safety goggles! Put on your safety goggles.
sion of a so-called qualification certificate. This will protect your eyes against coming into con-
tact with refrigerant, which could cause severe
damage by freezing.
! Danger
l
Wear safety gloves and an apron! Refrigerant are
Do not open refrigerant containers which contain
excellent solvents for greases and oils. In contact
refrigerant!
with skin they will remove the protective grease film.
l
When opening refrigerant containers the contents However, degreased skin is very sensitive against
may escape in liquid or vaporous state. The higher cold temperatures and germs.
the pressure in the container, the fiercer this proc- l
Do not allow liquid refrigerants to come into contact
ess will take place. The height of the pressure de-
with skin! Refrigerant takes the heat required for
pends on two conditions. 1. Which type of
evaporation from the environment. Very low tem-
refrigerant is in the container. The following applies:

8 BOMAG 008 913 76

Safety regulations 1.2
peratures may be reached. The results may be local
frost injuries (boiling point of R134a -26.5°C at am-
bient pressure).
l
Do not inhale higher concentrations of refrigerant
vapours! Escaping refrigerant vapours will mix with
the ambient air and displace the oxygen required for
breathing.
l
Smoking is strictly prohibited! Refrigerants may be
decomposed by a glowing cigarette. The resulting
substances are highly toxic and must not be in-
haled.
l
Welding and soldering on refrigeration equipment!
Before starting welding or soldering work on vehi-
cles, (in the vicinity
of air conditioning components) all refrigerant must
be drawn out and the rests removed by blowing out
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
strong corrosive effect, so that pipes and system
components may be attacked. The substance is
mainly fluorohydrogen.
l
Pungent smell! In case of a pungent smell the afore
mentioned decomposition products have already
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respi-
ratory system, the lungs and other organs may be
harmed.
l
When blowing out components with compressed air
and nitrogen the gas mixture escaping from the
components must be extracted via suitable exhaust
facilities (workshop exhaust systems).

008 913 76 BOMAG 9

1.3 General repair instructions

General Fill new hydraulic units with hydraulic oil before

1.3 General rep air instructions
l

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

10 BOMAG 008 913 76

General repair instructions 1.3
Air conditioning system l
All O-rings as well as pipe and hose fittings must be
oiled withcompressor oil / refrigeration oilibefore as-
sembly.
i Note
l
When replacing a heat exchanger, e.g. evaporator
In some countries the legislator demands minimum
or condenser, any compressor oil / refrigeration oil
requirements concerning the qualification of the main-
lost by exchanging the components, must be re-
tenance personnel. In the Federal Republic of Germa-
placed with fresh oil.
ny refrigeration and air conditioning equipment must
only be serviced by persons who are in the posses- l
A too high compressor oil / refrigeration oil level ad-
sion of a so-called qualification certificate. versely affects the cooling performance and a too
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
at least 45 minutes to remove any moisture from the l
If a air conditioning unit needs to be opened, the
system, before you start to refill. Moisture bonded in dryer must be replaced in any case.
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 dam-
nents, these must be kept closed as far as possible, aged.
in order to prevent the invasion of air, moisture and
dirt, because the operational reliability of the system
l
Tighten screw fittings with the specified torque.
can only be assured if all components in the refrig- l
Check the connections of pipes, fittings or compo-
erant circuit are clean and dry from inside. nents thoroughly; do not use if damaged.
l
Make sure that no dirt or foreign parts can enter into l
Do not leave the refrigerant circuit unnecessarily
the compressor or the air conditioning system. The open to the atmosphere. Do not attempt to repair
area around the refrigerant hoses should be bent or burst pipes.
cleaned with a gasoline free solvent. l
Compressor valves must only be opened after the
l
All parts to be reused should be cleaned with a system has been properly sealed.
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-
l
Before opening all components should have known and its effect on compressor oil and rubber
warmed up to ambient temperature, to avoid that elements is not predictable. The use of leak detec-
damp air is drawn into the component by the differ- tion colouring matter makes any warranty claims
ence in temperatures. null and void.
l
Damaged or leaking parts of the air conditioning l
Tools used on refrigeration circuits must be of ex-
must not be repaired by welding or soldering, but cellent condition, thus to avoid the damage of any
must generally be replaced. connections.
l
Do not fill up refrigerant, but extract existing refrig- l
The dryer is to be installed last, after all connections
erant and refill the system. in the refrigerant circuit have been tightened.
l
Different types of refrigerant must not be mixed. l
After completion of repair work screw locking caps
Only the refrigerant specified for the corresponding (with seals) on all connections with valves and on
air conditioning system must be used. the service connections. Start up of the air condi-
l
Refrigerant circuits with refrigerant type R134a tioning system. Observe the filling capacity.
must only be operated with the compressor oil / re- l
Before start up of the air conditioning system after a
frigeration oil approved for the compressor. new filling: - Turn the compressor approx. 10 revo-
l
Used compressor oil / refrigeration oil must be dis- lutions by hand using the clutch or V-belt pulley of
posed of as hazardous waste. the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
l
Due to its chemical properties compressor oil / re- speed of the engine has stabilized switch on the
frigeration oil must never be disposed of together compressor and run it for at least 10 minutes at idle
with engine or transmission oil. speed and maximum cooling power.
l
Compressor oil / refrigeration oil is highly hydro- l
Never operate the compressor over longer periods
scopic. Oil cans must strictly be kept closed until of time with high engine speeds without a sufficient
use. Oil rests should not be used, if the can had amount of refrigerant in the system. This could
been opened over a longer period of time. probably cause overheating and internal damage.

008 913 76 BOMAG 11

1.3 General repair instructions

Electrics
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Electric signals must be checked at
the locations to which they are applied, i.e. on con-
trol unit or sensor technology. So, if the system had
been diagnosed without unplugging the control unit
and checking the wiring, one should be alerted.
l
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l
Perform trouble shooting in a systematic way. Do
not become confused by the high number and vari-
ety of electric cables, current can only flow in a
closed circuit. You should first become acquainted
with the function of the corresponding electric circuit
by following the correct wiring diagram. Detected
faults should be rectified immediately. If the system
still does not work correctly after this measure, trou-
ble shooting must be continued. Several faults very
rarely occur at the same time, but it is not impossi-
ble.
l
Surge voltages in the electric system must be strict-
ly avoided: For electric and inert gas welding all
electric components, battery and generator must be
electrically isolated. When performing welding work
always fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location. Strict-
ly disconnect the cables from the generator before
starting work.
l
Do not disconnect or connect battery or generator
while the engine is running. Do not operate the main
battery switch under load. Do not use jump leads af-
ter the battery has been removed.

12 BOMAG 008 913 76

Tightening torques 1.4
Tightening torques
1.4 Tightening tor ques

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

Caution
!

Self-locking nuts must be generally renewed.

Tightening torques for screws with metric unified thread

Tightening torque Nm* (ft-lb)

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

Tightening torques Nm * (ft-lb)

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

008 913 76 BOMAG 13

1.5 Connection overview

Fig. 1

14 BOMAG 008 913 76

Connection overview 1.5
1 Proportional valve, vibration low frequency 16 Charge pressure test port
2 Proportional valve, vibration high frequency 17 Multi-function valve 400 bar (boost check and
3 Proportional valve, travel drive forward pressure relief valve), vibration high frequency
4 Proportional valve, travel drive reverse 18 Multi-function valve 400 bar (boost check and
pressure relief valve), vibration low frequency
5 Multi-function valve 400 bar (boost check and
pressure relief valve), travel system 19 Pressure test port, vibration low frequency
6 Multi-function valve 400 bar (boost check and 20 Pressure test port, vibration high frequency
pressure relief valve), travel system 21 High pressure port, high frequency
7 High pressure port B, reverse 22 High pressure port, low frequency
8 High pressure port A, forward 23 Charge pressure relief valve vibration pump
9 Charge pressure relief valve, travel pump 24 Port L2 (connection to travel pump 12)
10 Charge pressure (connection to travel pump 15) 25 Leak oil port (connection to thermostat housing
11 Charge oil to filter port A)
12 Port L2 (connection to vibration pump 24) 26 Port S, suction line between hydraulic oil tank and
charge pump (charge pump in vibration pump)
13 Pressure test port MA, high pressure forward
27 Charge pump (only in vibration pump)
14 Pressure test port MB, high pressure reverse
28 Pressure test port X1/X2, travel pump, control
15 Charge pressure to solenoid valve for brake and
chamber
speed range selection (charge oil vibration 10)
29 Adjustment screw, mechanical neutral position

008 913 76 BOMAG 15

1.6 Technische Daten

16 BOMAG 008 913 76

Technische Daten 1.6

008 913 76 BOMAG 17

1.6 Technische Daten

18 BOMAG 008 913 76

Technische Daten 1.6

008 913 76 BOMAG 19

1.6 Technische Daten

20 BOMAG 008 913 76

Technische Daten 1.6

008 913 76 BOMAG 21

1.6 Technische Daten

22 BOMAG 008 913 76

Technische Daten 1.6

008 913 76 BOMAG 23

1.6 Technische Daten

24 BOMAG 008 913 76

Technische Daten 1.6

008 913 76 BOMAG 25

1.6 Technische Daten

26 BOMAG 008 913 76

Maschinentyp BOMAG 27
Fig. 2

Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 213 DH-4 2960 2250 1500 2268 2972 490 5808 60 60 35 2130
BW 213 PDH-4 2960 2250 1480 2268 2972 490 5808 60 60 25 2130

*
BW 213 DH-4 BW 213 PDH-4

Weights
Operating weight (CECE) kg 12700 13100
with ROPS and cabin
Axle load, drum (CECE) kg 7200 7600
Axle load, wheels (CECE) kg 5500 5500
Static linear load kg/cm 33,8 -

Travel characteristics
Travel speed km/h 0 ... 13 0 ... 13
Max. gradability (depend- % 55 58
ing on soil)

28 BOMAG Maschinentyp
* BW 213 DH-4 BW 213 PDH-4
Engine
Engine manufacturer Deutz Deutz
Type BF4M 1013 EC BF4M 1013 EC
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 3046 kW 114 114
Rated speed rpm 2200 2200
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Permissible ambient tem- °C -20 ... +50 -20 ... +50
perature

Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.

Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic

Vibration
Vibrating drum 1
Drive system hydrostatic hydrostatic
Frequency Hz 30 ... 36 30 ... 36
Amplitude mm 2,0 / 0,9 1,84/0,9

Tires
Tire size 23.1/18-26/TL-8PR-AWT 23.1-26/12TL R1
Air pressure bar 1,4 1,4

Filling capacities
Engine Litres 10 10
Fuel Litres 300 300
Hydraulic oil Litres 60 60
* The right for technical modifications remains reserved

Maschinentyp BOMAG 29
Fig. 3

Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 214 DH-4 2960 2250 1500 2268 2972 490 5808 60 60 35 2130
BW 214 PDH-4 2960 2250 1480 2268 2972 490 5808 60 60 35 2130

*
BW 214 DH-4 BW 214 PDH-4

Weights
Operating weight (CECE) kg 14390 14790
with ROPS and cabin
Axle load, drum (CECE) kg 8890 92900
Axle load, wheels (CECE) kg 5500 5500
Static linear load kg/cm 41,7 -

Travel characteristics
Travel speed km/h 0 ... 13 0 ... 13
Max. gradability (depend- % 50 53
ing on soil)

30 BOMAG Maschinentyp
* BW 214 DH-4 BW 214 PDH-4
Engine
Engine manufacturer Deutz Deutz
Type BF4M 1013 EC BF4M 1013 EC
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 3046 kW 114 114
Rated speed rpm 2200 2200
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Permissible ambient tem- °C -20 ... +50 -20 ... +50
peratures

Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.

Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic

Vibration
Vibrating drum 1
Drive system hydrostatic hydrostatic
Frequency Hz 31 ... 36 31 ... 36
Amplitude mm 2,0 / 0,9 1,84/0,9

Tires
Tire size 23.1/18-26/TL-8PR-AWT 23.1-26/12TL R1
Air pressure bar 1,4 1,4

Filling capacities
Engine Litres 10 10
Fuel Litres 300 300
Hydraulic oil Litres 60 60
* The right for technical modifications remains reserved

Maschinentyp BOMAG 31
1.7 Table of fuels and lubri-
cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil ACEA: E3-96/E5-02 or approx. 13 litres without

oil filter

API: CG-4/CH-4

SAE 10W/40

(-20 °C to +40 °C)

SAE 15W/40

(-15 °C to +40 °C)

Fuel

Diesel Winter diesel fuel approx. 300 litres

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

46 mm2/s at 40 °C

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

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

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

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

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

Air conditioning system Refrigerant R134A approx. 1400 g

Engine cooling system Cooling system protection agent approx. 16 litres

Tires Water approx. 295 litres

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

(MgCl2)

32 BOMAG Maschinentyp
2 Tests and adjustments

008 913 76 BOMAG 33

2.1 Special tools, tests and adjustments

2.1 Special tools, tests and adjustments

1. Vibration reed frequency meter

BOMAG part-no.: 300 120 80

Fig. 1
2. RPM-meter for diesel engine

BOMAG part-no.: 059 711 12

Fig. 2
3. Hydraulic test case, large

BOMAG part-no.: 007 610 03

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

Fig. 3
4. Hydraulic test case, small

BOMAG part-no.: 079 930 01

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

Fig. 4

34 BOMAG 008 913 76

Special tools, tests and adjustments 2.1
5. Pressure test hoses

1000 mm BOMAG part-no.: 079 930 02

2500 mm BOMAG part-no.: 079 930 03

Fig. 5
6. Pressure gauge

60 bar BOMAG part-no.: 059 721 07

600 bar BOMAG part-no.: 059 721 04

Fig. 6
7. Adapter for pressure test hose

BOMAG part-no.: 055 439 02

Fig. 7
8. Gear pump testing device

BOMAG part-no.: 007 610 05

Fig. 8

008 913 76 BOMAG 35

2.1 Special tools, tests and adjustments

9. Vacuum pump for hydraulic oil tank

BOMAG part-no.: 007 610 04 (12 Volt)

BOMAG part-no.: 007 610 24 (24 Volt)

Fig. 9
10. Electric test case

BOMAG part-no.: 057 505 70

Fig. 10

36 BOMAG 008 913 76

Activate service mode 2.2
2.2 Activate service mode
Activate the input mode
1. Set the travel lever to braking position

i Note
The function can only be activated when the trav-
el lever is engaged in braking position.
2. Switch on the ignition.
3. Press both Info-buttons (Fig. 1) longer than three
seconds to access the input mode.

Fig. 1
Activate service mode
T

i Note
The input mode starts with flashing of the left
hand digit (Fig. 2). Here you have the possibility
to change to the service mode using access code
"9999".
The green buttons F2, F4 (Fig. 3) can be used to
increase or reduce the corresponding digit.
With the blue button F5, F3 (Fig. 4) you can jump
to the corresponding next digit.
Once the last digit has been entered the code will
Fig. 2
be transmitted to the control by pressing the right
hand blue button (F3) again.
4. Enter access code "9999".
T

Fig. 3

008 913 76 BOMAG 37

2.2 Activate service mode

i Note
If the access code has been entered correctly,
the "spanner" symbol appears in the display and
the first digit flashes again.

Individual operating states can now be inter-

rogated, activated or deactivated by transmit-
ting further input codes to the control.

Deactivating the service mode

5. Quit the service mode by switching the ignition
off.

Fig. 4

38 BOMAG 008 913 76

Driving against the closed brake 2.3
2.3 Driving against the closed brake

i Note
On this machine the electric plug connection to
the brake valve must not be pulled off, because
the ESX-control would in this case detect a line
interruption in the current path to the brake.
Activate the input mode
1. Set the travel lever to braking position

i Note
The function can only be activated when the trav-
el lever is engaged in braking position.
2. Switch on the ignition.
3. Press both Info-buttons (Fig. 1) longer than three
seconds to access the input mode.

Fig. 1
Activate service mode
T

i Note
The input mode srats with flashing of the left hand
digit (Fig. 2). Here you have the possibility to
change to the service mode using access code
"9999".
The green buttons F2, F4 (Fig. 3) can be used to
increase or reduce the corresponding digit.
With the blue button F5, F3 (Fig. 4) you can jump
to the corresponding next digit.
Once the last digit has been entered the code will
Fig. 2 be transmitted to the control by pressing the right
hand blue button (F3) again.
4. Enter code number "9999".
T

Fig. 3

008 913 76 BOMAG 39

2.3 Driving against the closed brake

i Note
If the access code has been entered correctly,
the "spanner" symbol appears in the display and
the first digit flashes again.

Fig. 4
Activating the brake function
5. Enter code number "0500" via the LC display
(Fig. 5).
The brake will not be released when actuating the
travel lever.
The warning buzzer sounds to inform the opera-
tor about this status. The brake control light in the
LC display remains activated.

Deactivating the brake function

6. Enter code number "501" or switch the ignition off
to stop this function.
Fig. 5

40 BOMAG 008 913 76

Check the engine speed 2.4
2.4 Check the engine speed
Special tools
Vibration reed frequency meter, RPM-meter for
diesel engines.

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

Fig. 1

Check the engine speed

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

Nominal value high idle speed

see technical data, engine.
5. Switch the vibration on .

Nominal value nominal speed

see technical data
Fig. 2
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting for the engine.

008 913 76 BOMAG 41

2.5 Pressure tests in the travel circuit

2.5 Pressure tests in the travel circuit

Special tools
Hydraulic test case

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

Fig. 1

! Danger
The closed brake mode must be activated!

i Note
Drive against the closed brake, see correspond-
ing chapter.
2. Enter code number "0500" to close the brake
(Fig. 2).

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

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

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

42 BOMAG 008 913 76

Pressure tests in the travel circuit 2.5
6. Move the travel lever (Fig. 4) quickly forward and
backward, read the pressure gauge.

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

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

Deactivate the closed brake mode

7. Quit this mode by switching the ignition off.

008 913 76 BOMAG 43

2.6 Checking / adjusting the neutral positions of the travel pump

2.6 Checking / adjusting the neutral posi-

tions of the travel pump
Special tools
Hydraulic test case

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

Fig. 1

! Danger

The closed brake mode must be activated!

i Note
Drive against the closed brake, see correspond-
ing chapter.
2. Enter code number "0500" to close the brake
(Fig. 2).

Fig. 2
3. Connect a 600 bar pressure gauge each to the
high pressure test ports for "forward travel" and
"reverse travel" (Fig. 3).

Fig. 3

44 BOMAG 008 913 76

Checking / adjusting the neutral positions of the travel pump 2.6
! Danger

The closed brake mode must be activated!

i Note
Drive against the closed brake, see correspond-
ing chapter.
4. As a measure to avoid signal residues from the
hydraulic neutral position connect both control
chambers X1 and X2 with a hose (Fig. 4).
5. Start the engine and run it with maximum speed.

Fig. 4
6. Read the high pressure gauges (Fig. 5).

Nominal value
Both pressure gauges (Fig. 5) must show equal
pressure (charge pressure).

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

Fig. 5
Evaluation of test

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

chanical neutral position (Fig. 6), until the pres-
sures on both pressure gauges are identical.

Fig. 6

008 913 76 BOMAG 45

2.7 Pressure measurements in the vibration circuit

2.7 Pressure measurements in the vibra-

tion circuit
Special tools
Hydraulic test case

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

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

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

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

46 BOMAG 008 913 76

Check the leakage rate of the vibration motor 2.8
2.8 Check the leakage rate of the vibration
motor

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

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

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

Nominal value
max. 1.5 litre/min

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

008 913 76 BOMAG 47

2.9 Pressure test in steering circuit

2.9 Pressure test in steering circuit

Special tools
Hydraulic test case, gear pump testing equipment

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

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

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

Nominal value

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

Evaluation of test 1
If the nominal value is reached, check the steer-
ing cylinder.
Measurement 2
5. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) on the steering cylinders and close
them with plugs.
6. Start the engine and run it at idle speed.
7. Turn the steering wheel.
8. Read the pressure gauge.

Nominal value
see technical data for steering/charge pump.

Evaluation of test 2
Fig. 2 If the nominal value is reached, replace the steer-
ing cylinder.
If the nominal value is not reached, check the
steering/charge pump.
9. Reconnect the hydraulic hoses to the steering
cylinders.

48 BOMAG 008 913 76

Pressure test in steering circuit 2.9
Measurement 3
10. Close the pump outlet port (Fig. 4) with the gear
pump test equipment.
11. Crank the engine with the starter

Nominal value
see technical data for steering/charge pump.

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

008 913 76 BOMAG 49

2.9 Pressure test in steering circuit

50 BOMAG 008 913 76

3 Flushing and bleeding

008 913 76 BOMAG 51

3.1 Special tools for flushing

3.1 Special tools for flushing

1. Filling and filtering unit with oil bag

BOMAG part-no.: 007 610 01

2. Filter element

BOMAG part-no.: 079 930 35

Fig. 1
3. Flushing filter (S connection)

BOMAG part-no.: 007 000 01

4. Filter element 1µ

BOMAG part-no.: 079 930 52

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

BOMAG part-no.: 055 509 19

6. Screw socket R1“ - 25S (2 pieces)

BOMAG part-no.: 055 400 52

Fig. 2
7. Flushing filter (L connection)

BOMAG part-no.: 079 390 29

8. Filter element

BOMAG part-no.: 079 390 14

9. Flushing hose 15L (2 pieces)

BOMAG part-no.: 055 510 09

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

BOMAG part-no.: 055 400 89

Fig. 3
11. SAE-flange 1“ - 20S

BOMAG part-no.: 058 142 60

12. O-ring

BOMAG part-no. 062 203 30

Fig. 4

52 BOMAG 008 913 76

Special tools for flushing 3.1
13. Flanged plate 1“ - 25S

BOMAG part-no.: 007 160 18

14. O-ring

BOMAG part-no. 062 202 22

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

BOMAG part-no.: 055 422 92

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

BOMAG part-no.: 055 422 98

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

BOMAG part-no.: 055 423 26

Fig. 8

008 913 76 BOMAG 53

3.1 Special tools for flushing

18. Connecting socket 18L

BOMAG part-no.: 055 426 06

Fig. 9
19. Connecting socket 16S

BOMAG part-no.: 055 459 43

Fig. 10
20. Connecting fitting 20S

BOMAG part-no.: 055 459 44

Fig. 11
21. Connecting fitting 25S

BOMAG part-no.: 055 459 45

Fig. 12

54 BOMAG 008 913 76

Special tools for flushing 3.1
22. Angular fitting 18L

BOMAG part-no.: 055 421 26

Fig. 13
23. Elbow 20S

BOMAG part-no.: 055 421 37

Fig. 14
24. Elbow 25S

BOMAG part-no.: 055 421 38

Fig. 15

008 913 76 BOMAG 55

3.2 Flushing - general

3.2 Flushing - general

! Caution
Solid particles in the circuit will very quickly
cause damage to machine components.

Changing a component

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

Chips (abrasion) in the oil

1. Open and clean all components in the oil circuit,
replace if necessary.
2. Clean all high pressure hoses in the oil circuit, re-
place if necessary.
3. If abrasion is found in the travel circuit you should
also flush the vibration circuit.
4. If abrasion is found in the vibration circuit you
should also flush the travel circuit.

Before flushing
Change the filter element
1. Change the hydraulic oil filter element (1).

Fig. 1 Clean the hydraulic tank

! Caution
Change the oil in case of excessive contami-
nation, oil discolouration or if the oil change
interval is almost due.
2. Filter the tank content with the filling and filtering
unit and pump it into the oil bag.

Fig. 2

56 BOMAG 008 913 76

Flushing - general 3.2
3. Mark all hoses and disconnect them from the
tank cover.
4. Unscrew the fastening screws for the cover and
remove the cover.
5. Clean the hydraulic oil tank thoroughly from in-
side, reassemble cover and hoses.
6. Fill the hydraulic oil tank again with the filling and
filtering unit.

Fig. 3

Bleeding
1. Always bleed the closed hydraulic circuit if lines
had been removed or connected.

Fig. 4

Servicing the flushing filter kit

1. Replace the filter element of the flushing filter
when the red control pin of the contamination in-
dicator is pressed out during the filtering process.
2. Clean hoses and connections and store the flush-
ing kit in a clean and protected environment.

Fig. 5

008 913 76 BOMAG 57

3.3 Flushing schematic travel circuit (distribution travel pump)

3.3 Flushing schematic travel circuit (dis-

tribution travel pump)

58 BOMAG 008 913 76

Flushing schematic travel circuit (distribution travel pump) 3.3
1 Elbow union (tool) 13 High pressure hose (A, drum drive motor for-
ward)
2 Connecting union (tool)
3 Drum drive motor 14 High pressure hose (B, axle motor reverse)
15 High pressure hose (A, axle motor forward)
4 Axle motor
16 High pressure hose (B, axle motor reverse)
5 Screw socket R1 - 25S (tool)
17 High pressure port (B, drum drive motor reverse)
6 Flushing hose 25S - 20S (tool)
18 Flushing hose 25S - 20S (tool)
7 Flushing hose 25S - 20S (tool)
19 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1µ (tool)
9 Elbow union (tool)
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (B, drum drive motor reverse)

008 913 76 BOMAG 59

3.4 Flushing the travel circuit (travel pump distribution)

3.4 Flushing the travel circuit (travel

pump distribution)

Flushing the drum drive

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

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

! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
1. Disconnect the high pressure hose 12 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 17) and connect
it with the flushing hose (7) (flushing filter inlet
"IN").
Fig. 1 2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port 17) on the travel
pump.

Disconnect the drum drive motor

3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.

Fig. 2

60 BOMAG 008 913 76

Flushing the travel circuit (travel pump distribution) 3.4
Bleeding the travel circuit
4. Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".

Fig. 3 Flushing the hoses

5. Block drums and wheels with suitable chocks.

Fig. 4
6. Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 5

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

008 913 76 BOMAG 61

3.4 Flushing the travel circuit (travel pump distribution)

Flushing the drum drive motor

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

Fig. 7
14. Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 8

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

Fig. 9 18. Remove the flushing filter and reconnect the high
pressure lines.

62 BOMAG 008 913 76

Flushing the travel circuit (travel pump distribution) 3.4
Flushing the axle drive
Installing the flushing filter
19. Disconnect the high pressure hose 14 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 16) and connect
it with the flushing hose (18) (flushing filter inlet
"IN").
20. Connect the flushing hose (19) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.

Fig. 10

Disconnecting the axle motor

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

Fig. 11
Bleeding the travel circuit
22. Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".

Fig. 12

008 913 76 BOMAG 63

3.4 Flushing the travel circuit (travel pump distribution)

Flushing the hoses

23. Block drums and wheels with suitable chocks.

Fig. 13
24. Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 14

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

64 BOMAG 008 913 76

Flushing the travel circuit (travel pump distribution) 3.4
Flushing the axle motor

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

Fig. 16
32. Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 17

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

Fig. 18 36. Remove the flushing filter and reconnect the high
pressure lines.

Bleeding the travel circuit

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

Keep circulating the tank content.

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

008 913 76 BOMAG 65

3.4 Flushing the travel circuit (travel pump distribution)

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

Fig. 19

66 BOMAG 008 913 76

Flushing the travel circuit (travel pump distribution) 3.4

008 913 76 BOMAG 67

3.5 Flushing schematic travel circuit (distribution axle motor)

3.5 Flushing schematic travel circuit

(distribution axle motor)

68 BOMAG 008 913 76

Flushing schematic travel circuit (distribution axle motor) 3.5

008 913 76 BOMAG 69

3.5 Flushing schematic travel circuit (distribution axle motor)

70 BOMAG 008 913 76

Flushing schematic travel circuit (distribution axle motor) 3.5

008 913 76 BOMAG 71

3.5 Flushing schematic travel circuit (distribution axle motor)

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

72 BOMAG 008 913 76

Flushing the travel circuit (axle motor distribution) 3.6
3.6 Flushing the travel circuit (axle motor
distribution)

Flushing the drum drive

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

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

! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
1. Disconnect the high pressure hose 14 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 16) and connect
it with the flushing hose (19) (flushing filter inlet
"IN").
Fig. 1 2. Connect the flushing hose (18) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.

Disconnect the drum drive motor

3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.

Fig. 2

008 913 76 BOMAG 73

3.6 Flushing the travel circuit (axle motor distribution)

Bleeding the travel circuit

4. Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".

Fig. 3 Flushing the hoses

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

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

Fig. 5

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

74 BOMAG 008 913 76

Flushing the travel circuit (axle motor distribution) 3.6
Flushing the drum drive motor

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

Fig. 7
14. Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 8

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

Fig. 9

008 913 76 BOMAG 75

3.6 Flushing the travel circuit (axle motor distribution)

Flushing the axle motor

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

Fig. 10
21. Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 11

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

Fig. 12 25. Remove the flushing filter and reconnect the high
pressure lines.

Bleeding the travel circuit

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

Keep circulating the tank content.

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

76 BOMAG 008 913 76

Flushing the travel circuit (axle motor distribution) 3.6
Function test
28. Check the hydraulic oil level in the tank, fill up if
necessary.
29. Check all connections for leaks with the engine
running (visual inspection).
30. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
31. Check all ports and connections for leak tightness
(visual inspection).

Fig. 13

008 913 76 BOMAG 77

3.7 Flushing schematic for vibration drive

3.7 Flushing schematic for vibration drive

78 BOMAG 008 913 76

Flushing schematic for vibration drive 3.7

008 913 76 BOMAG 79

3.7 Flushing schematic for vibration drive

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

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

80 BOMAG 008 913 76

Flushing the vibration circuit 3.8
3.8 Flushing the vibration circuit
Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

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

! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the vibration
pump in high frequency.
1. Disconnect the high pressure hose 10 (see chap-
ter "Flushing schematic - vibration circuit") from
the vibration pump (4) and connect it with the
flushing hose (7) (flushing filter inlet "IN").
2. Connect the flushing hose (6) (flushing filter outlet
Fig. 1 "OUT") to the (high pressure port A) on the vibra-
tion pump.

Disconnect the vibration motor

3. Take the vibration motor out of the hydraulic cir-
cuit by joining the high pressure hoses (10 and
11) on the vibration motor together.

Bleeding the vibration circuit

Fig. 2
4. Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".

Fig. 3

008 913 76 BOMAG 81

3.8 Flushing the vibration circuit

Flushing the hoses

5. Block drums and wheels with suitable chocks.

Fig. 4
6. Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 5

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

82 BOMAG 008 913 76

Flushing the vibration circuit 3.8
Flushing the vibration motor
12. Unscrew the fastening screws for the vibration
motor and pull the motor out of the coupling.

Fig. 7
13. Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 8

! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
14. Start the engine and run it with maximum speed.
15. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
16. Shut down the engine.
17. Remove the flushing filter and reinstall the vibra-
Fig. 9 tion motor.

Bleeding the travel circuit

18. Bleed the vibration circuit (see corresponding
chapter).

Keep circulating the tank content.

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

008 913 76 BOMAG 83

3.8 Flushing the vibration circuit

Function test
20. Check the hydraulic oil level in the tank, fill up if
necessary.
21. Test drive.
22. Check all ports and connections for leak tightness
(visual inspection).

Fig. 10

84 BOMAG 008 913 76

Bleeding the travel circuit 3.9
3.9 Bleeding the travel circuit

Environment
Catch hydraulic oil and dispose of environ-
mentally.
23. Block drums and wheels with suitable chocks.
24. Apply the brake.
25. Install a pressure test hose to the charge pres-
sure test port.
26. Install a pressure test hose each to the high pres-
sure test ports.

Fig. 11
27. Actuate the emergency stop switch.

! Danger
The engine should not start.

Fig. 12
28. Hold the open ends of the pressure test hoses
(Fig. 1) into a container.
29. Operate the starter motor for approx. 30 seconds.
Wait one minute and repeat this procedure, until
oil starts to run out from the pressure test hoses.
30. Remove the pressure test hoses.

Fig. 13

008 913 76 BOMAG 85

3.9 Bleeding the travel circuit

31. Unlock the emergency stop switch.

Fig. 1
1. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 2) and run the engine
max. 15 seconds at idle speed.
2. Pause for approx. 30 seconds and keep repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.

Fig. 2

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

! Danger

Run the engine with idle speed.

1. Start the engine.
2. Shift the travel lever (Fig. 3) approx. 1/3 to for-
ward direction.
Fig. 3 3. After approx. 1 to 2 minutes shut down the engine
for a minute.

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

86 BOMAG 008 913 76

Bleeding the vibration circuit 3.10
3.10 Bleeding the vibration circuit

Environment
Catch hydraulic oil and dispose of environ-
mentally.
5. Block drums and wheels with suitable chocks.
6. Apply the brake.
7. Install a pressure test hose to the charge pres-
sure test port.
8. Install a pressure test hose each to the high press
test ports.

Fig. 4
9. Actuate the emergency stop switch.

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

Fig. 6

008 913 76 BOMAG 87

3.10 Bleeding the vibration circuit

13. Unlock the emergency stop switch.

Fig. 7
14. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 8) and run the engine
max. 15 seconds at idle speed.
15. Wait for approx. 30 seconds and repeat the pro-
cedure, until the pressure gauge shows a con-
stant charge pressure.

Fig. 8

! Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
16. For bleeding switch on vibration with high fre-
quency (Fig. 9).
1. Start the engine.
2. After running the engine 1 to 2 minutes pause for
approx. one minute.

Fig. 9 i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
3. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.

88 BOMAG 008 913 76

Bleeding the vibration circuit 3.10

008 913 76 BOMAG 89

3.10 Bleeding the vibration circuit

90 BOMAG 008 913 76

4 Technical Manual
End of Import

Maschinentyp BOMAG 91
Maschinentyp BOMAG 92
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4.2 Technical Manual / Electrics

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Technical Manual / Electrics 4.2

Service Training
Electrics

Single Drum Rollers – 4

Version 2.07
Version/Status: V2.07 / 24.06.05 Page 1 of 67
Author: Seis / TE
Dateiname: p:\schulung\wz-4\elektrik\esx\englisch\schulung elektrik wz4 v2_07_gb.doc

008 913 76 BOMAG 147

4.2 Technical Manual / Electrics

Service Training WZ-4 DH Version and higher

Table of contents

1 CONFIRMATION OF CHANGES .................................................................................. 5

1.1 Document ..................................................................................................................................................................... 5
1.2 Software ....................................................................................................................................................................... 5

2 SELECTED FAULT REACTIONS OF THE ESX CONTROL ..................................6

3 DESCRIPTION OF ERRORS IN THE LC DISPLAY ................................................. 9

3.1 Calling up service mode............................................................................................................................................ 9
3.2 Entering input codes.................................................................................................................................................. 9
3.3 Adjusting the machine type....................................................................................................................................11
3.4 Changing the steering unit on BVC-4 machines (from version 1.09)...........................................................12
3.5 Teaching the travel direction sensor...................................................................................................................13
3.6 Automatic detection of surge currents in travel system................................................................................13
3.7 Teaching the electronic end stops of the steering angle sensor (BVC) .....................................................15
3.8 Automatic detection of surge currents on steering valves (BVC)................................................................17
3.9 Driving against the closed brake..........................................................................................................................18
3.10 Showing stored faults .............................................................................................................................................18
3.11 Delete all stored faults ............................................................................................................................................18

4 HOW TO PROCEED WHEN REPLACING COMPONENTS?...............................19

4.1 Replacement of an ESX-control............................................................................................................................19
4.2 Replacement of a travel pump / axle drive motor / drum drive motor .........................................................19
4.3 Replacement of a steering valve (BVC)...............................................................................................................19
4.4 Replacement of a steering angle sensor ...........................................................................................................19
4.5 How to proceed when replacing a front / rear axle sensors?.......................................................................19
4.6 Which components can be replaced without a subsequent adjustment procedure?............................20

5 DESCRIPTION OF THE SIGNALS ON THE ESX-CONTROL ..............................21

6 DESCRIPTION OF SIGNALS ON THE DATA COLLECTOR................................27

7 DESCRIPTION OF SIGNALS ON THE TRAVEL LEVER......................................29

8 DESCRIPTIONS OF SIGNALS ON THE LC - DISPLAY ........................................31

9 DESCRIPTION OF SIGNALS ON DIOS-MODULE..................................................32

10 FAULT CODES OF THE ESX CONTROL .............................................................34

10.1 Overview.....................................................................................................................................................................34
10.2 Description of fault reactions ................................................................................................................................35
10.3 Detailed description of fault codes and their possible causes....................................................................36

Version/Status: V2.07 / 24.06.05 Page 2 of 67

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Technical Manual / Electrics 4.2

Service Training WZ-4 DH Version and higher

10.3.1 General _________________________________________________________________ 36

10.3.2 Brake___________________________________________________________________ 37
10.3.3 Travel lever ______________________________________________________________ 37
10.3.4 Travel speed range selector switch ____________________________________________ 38
10.3.5 Travel system ____________________________________________________________ 39
10.3.6 Steering_________________________________________________________________ 42
10.3.7 Driver's seat arm rest sensor_________________________________________________ 43
10.3.8 Vibration ________________________________________________________________ 44
10.3.9 Attachment plates _________________________________________________________ 46
10.3.10 Diesel engine ____________________________________________________________ 47
10.3.11 Diesel engine EMR ________________________________________________________ 47
10.3.12 Miscellaneous ____________________________________________________________ 50
10.3.13 Machine type _____________________________________________________________ 50

11 INPUT CODES FOR ESX CONTROL ....................................................................51

11.1 Fault log.......................................................................................................................................................................51
11.2 Value displays ...........................................................................................................................................................51
11.2.1 General _________________________________________________________________ 51
11.2.2 Brake___________________________________________________________________ 51
11.2.3 Travel lever / driving ________________________________________________________ 52
11.2.4 Travel speed range selector switch ____________________________________________ 52
11.2.5 Travel pump: Travel direction forward___________________________________________ 53
11.2.6 Travel pump: Travel direction reverse___________________________________________ 53
11.2.7 Travel motor front (drum) ____________________________________________________ 54
11.2.8 Travel motor rear (wheel axle) ________________________________________________ 54
11.2.9 Adaption values for speed regulation___________________________________________ 54
11.2.10 Travel pressure sensor _____________________________________________________ 55
11.2.11 55
11.2.12 Inclination sensor _________________________________________________________ 55
11.2.13 Travel condition values _____________________________________________________ 55
11.2.14 Speed limitation___________________________________________________________ 55
11.2.15 Arm rest contact___________________________________________________________ 55
11.2.16 Adaption values traction control _______________________________________________ 56
11.2.17 Steering: Steering valve _____________________________________________________ 56
11.2.18 Steering: Angle sensor in articulated joint _______________________________________ 56
11.2.19 Steering: Steering wheel ____________________________________________________ 57
11.2.20 Vibration ________________________________________________________________ 57
11.2.21 Attachment plates, option (only BW213 BVC) _____________________________________ 58
11.2.22 Engine __________________________________________________________________ 59
11.2.23 Hydraulics _______________________________________________________________ 59
11.3 Test settings ..............................................................................................................................................................60
11.3.1 Brake___________________________________________________________________ 60
11.3.2 Disable electric supply to wheel and drum drive motors (switch off)____________________ 60
11.4 Settings / Teach / Emergency functions .............................................................................................................60
11.4.1 Changing the machine code _________________________________________________ 60
11.4.2 Automatic detection of surge currents in travel system ______________________________ 60
11.4.3 Speed detection, trimming of measuring values __________________________________ 61
11.4.4 Speed detection, teaching of distance pulses ____________________________________ 61
11.4.5 Detection of wheel rotation___________________________________________________ 61
11.4.6 Steering: Automatic detection of surge currents on steering valve _____________________ 62
11.4.7 Steering: Determining the steering stops________________________________________ 62
11.4.8 Steering: Emergency function ________________________________________________ 62
11.4.9 Steering: Other functions ____________________________________________________ 62
11.4.10 Vibration: Cancellation of the vibration permission in dependence on the travel speed _____ 62
11.4.11 Plates __________________________________________________________________ 63

12 TERMINOLOGY IN CONNECTION WITH ESX.....................................................64

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4.2 Technical Manual / Electrics

Service Training WZ-4 DH Version and higher

Version/Status: V2.07 / 24.06.05 Page 4 of 67

Author: Seis / TE
Dateiname: p:\schulung\wz-4\elektrik\esx\englisch\schulung elektrik wz4 v2_07_gb.doc

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Technical Manual / Electrics 4.2

Service Training WZ-4 DH Version and higher

1 Confirmation of changes

1.1 Document

No. Date Description of changes resp.

2.01 23.04.2004 Creation of version 1.00 Werner
2.02 06.05.2004 Revision, teach functions Fondel
2.03 11.05.2004 Revision, supplements version 1.01 Seis
2.04 24.06.2004 Revision, supplements to version 1.02
2.05 23.01.2005 Revision, supplement to software versions from 2.00 MASH
2.06 29.04.2005 Revision, supplement to software versions from 2.06 MASH
2.07 22.05.2005 Error code description 5121 changed Löw

1.2 Software

Ver. Date Description of changes resp.

1.03 02.09.2004 ⇒ Surge currents travel system teach function changed Schroeder,
⇒ Known faults Fondel
⇒ Revision of error codes
⇒ Deactivation of electric steering on BVC machines
⇒ How to proceed when replacing components?
2.00 16.12.2004 ⇒ List of error codes extended Schroeder
Fondel
MASH
2.02 08.03.2005 ⇒ Adaptive adaptation of gradability. Display codes for the factors MASH
"Front top" 1500 and "Tail top" 1501
⇒ Input code to shut down the speed dependent Vib-limitation
(3047..3049).
⇒ Error message (8440..8443) for invalid BabyBoard equipment of
the ESX-travel control.
⇒ Overspeed protection for wheel drives (axle and drum drives)

2.06 29.04.2005 ⇒ Input codes (1158/1159) for manual adaptation of axle speed MASH
recording.
⇒ Input codes to record the pulse frequency of the drives:
Recording of speeds (1160..1169)
⇒ Adapted tank characteristic.
⇒ Change of speed limitation for operation with plates.

2.07 22.05.2005 ⇒ Tank characteristic values changed. MASH

Version/Status: V2.07 / 24.06.05 Page 5 of 67

Author: Seis / TE
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4.2 Technical Manual / Electrics

Service Training WZ-4 DH Version and higher

2 Selected Fault Reactions of the ESX Control

Reaktion Symbol in fault Warning Warning Engine stop
message display
Signal Code output Code output Code output
without buzzer with buzzer with buzzer

Engine oil pressure

(from EMR) 5100 5101
5112 5112
1) 2)
after 10s
Coolant temperature
(from EMR)
5100 5101
5116 5116
1) 2)
after 15s
Coolant level
5024 5025
after 5s after 10s
Engine air filter
5026 5027
3)
after 5s after 2min.
Charge control

Preheating of engine

Brake

ASC
Various error causes and reaction times.
See error codes
Hydraulic oil filter
5502 5503
after 5s after 2min.
Water separator in fuel filter
5028 5029
after 5s after 2min.
Ant-theft warning display
(Option)

Seat contact
(Option)

Air conditioning fault

(Option)

1) 3)
After reaching the warning limit! Shut-down currently deactivated via parameter

Version/Status: V2.07 / 24.06.05 Page 6 of 67

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Technical Manual / Electrics 4.2

Service Training WZ-4 DH Version and higher

2)
After reaching the shut-down limit!

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

Effect: Cause:
Display remains dark, no voltage PIN in display plug X 28 bent
Error code 5100, 5140 and engine does not Switch the ignition off and on and restart the
respond to full speed switch or travel lever machine immediately.
After switching on the display shows "Error code Code 8224 is no error code, but a software fault in
8224“ the display software, which has been rectified in
display firmware version 1.36 and higher

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3 Description of errors in the LC display

Apart from its normal display function the LC display is also able to shpw error codes, which had
previously been visualized by means of the 3-digit error code display.

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

Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible. Negative
values are identified by a "Minus sign".

The following chapter describes the operation of the LC display via travel lever buttons.

3.1 Calling up service mode

For this purpose the display must be switched via input mode to service mode. This is accomplished via
the two yellow info buttons "INFO 1" and "INFO 2" on the back of the travel lever. Navigation in input and
service mode takes place via the green and blue buttons on the front of the travel lever.

Werte ändern Navigieren

INFO 1 Taste (grün) (blau)
(gelb)

INFO 2 Taste
(gelb) Werte ändern
(grün)
Navigieren
(blau)

The travel lever must be in locked braking position in order to activate input mode! Input mode
is switched on by simultaneously pressing both INFO – buttons over a period of approx. 3 seconds.

3.2 Entering input codes

Input mode starts with flashing of the left hand digit. Here service code 9 9 9 9 provides the possibility to
change to the service mode. The green buttons can be used to increase or reduce the values of the
corresponding digit. By operating one of the blue buttons one can jump to the next (left or right) digit.
Once the last right hand digit has been entered the code will be transferred to the control by pressing the
right hand blue button once again.
If the access code has been entered correctly, the "Spanner" symbol is displayed and the first input digit
flashes again. Individual operating states of the machine can now be interrogated by transferring the input
code to the control (as described above).
When operating both INFO buttons again for approx. 3 seconds, another input code can be entered. The
input of code "0 0 0 0 " or switching of the ignition quits the service mode.
If the travel lever is shifted out of the brake lock while in service mode, all machine functions will become
active, with the exception of the LC-display, which remains in service mode and continues to display the
operating values requested last.

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Normal mode (travel lever in brake gate!)

Call up optional displays via
Info button 1 and Info button 2

„Input“ - Modus:
Changeover display function
Display setting
Press INFO 1 +
INFO 2 approx. 3s
Plate adjustment deactivated!

Press INFO 1 +
INFO 2 approx. 3s Input
or shift travel Access code
lever out of 9999
brake gate

„Service“- Modus:
CODE – input „0000" or Input diagnostic codes
Ignition off
Calling up / deleting the error log
Change machine type
Plate adjustment deactivated!

Travel lever out of brake gate:

Diagnostics mode active in foreground

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3.3 Adjusting the machine type

Since the same control is used for all DH-4 single drum rollers with electronically controlled engine (EMR
II), it is necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This
adjustment of machine type is necessary, because the machines may be equipped with different drum
drive or axle drive motors or different tire sizes, thus resulting in different rolling circumferences, or they
may be equipped with attachment plates or other options.

For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module when switching the ignition on. It can also be checked by entering code 0720.

The following machine types can be adjusted:

0 1 2 3 4 5 6 7 8 9
72XX
0 Default BW 177 BW 177 BW 179 BW 179 BW 213/ BW 213 BW 213 BW 213 BW 216 DH
DH-4 PDH-4 DH-4 PDH-4 BW 214 BW 214 DH-4 PDH-4 DH-4
(dozer DH-4 PDH-4 USA USA
blade)
1 BW 216 BW 219 BW 219 BW 226 BW 226 BW 226 BW 226 DH
PDH-4 DH-4 PDH-4 DH-4 PDH-4 DH-4 PDH-4
147kW 147kW 174kW 174kW

2 DH

3 DH

4 DH

5 BW 177 BW 213 BW 213 BW 226 BW 226 BVC

DH-4 DH-4 DH-4 DH-4 DH-4
BVC BVC BVC w. BVC BVC
plates 147 kW 174 kW
6 BVC

7 BVC

8 BVC

9 BVC

EXAMPLE: Machine code for BW 219 PDH-4: 7212

Note: Parameter adjustments can only be performed when the engine is not running.
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Note: This function can only be activated / deactivated when the travel lever is locked in the
brake gate. ( Input mode)
The following procedure must be used for initial start-up of a control:

• The control has been installed into the machine.

• Switch the ignition on. Approx. 4 seconds after switching on the letters C O D E are displayed for
a period of approx. 3 seconds. After this the display changes and shows code 7200.
• Use the Arrow Up or Arrow Down keys to select the correct machine code from the list of codes.
• Confirm the selection with the Arrow Right key.

• After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for approx.
3 seconds. The new parameters are loaded according to the machine type setting. Do not switch
the ignition off during this time!
• After this switch the ignition off and on again to accept the configuration.
• After this the normal display will appear again.

The following applies for a correction of the machine type code after it has been set.

• Enter code number 9 9 9 9 (activation of service mode)

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

The display module now permanently shows the code 7 2 0 0 .

• Select the machine code from the table above and confirm it with the Arrow Right key. After operating
the Arrow Right key the control switches automatically off and on again.
• After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for approx.
3 seconds. The new parameters are loaded according to the machine type setting. Do not switch
the ignition off during this time!
• After this switch the ignition off and on again to accept the configuration.
• After this the normal display will appear again.

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

New controls are delivered with a default machine type setting 7 2 0 0 . This
does not enable to drive or steer the machine. It only serves the purpose of
commissioning.

3.4 Changing the steering unit on BVC-4 machines (from version 1.09)
By standard all BVC-4 machines (code 72xx) are equipped with electric steering. If the hydraulic steering
option is selected, the electric steering must be deactivated as follows.

• Enter code number 9999 (activation of service mode)

• Enter code number 2 0 6 0 . This code number activates the function "Adjusting the steering unit“.
• The following code numbers are available to activate the assembled steering unit.

Hydraulic steering 2062

Electric steering 2061

• The display shows O K

Attention: The steering unit can only be changed when the engine is not running!

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3.5 Teaching the travel direction sensor

Teaching of the travel direction sensor is required for initial commissioning and after the replacement of a
travel motor. Perform the following sequence
• Turn the speed range selector switch to "MAX"
• Shift the travel lever slowly out of neutral, until a travel speed of approx. 1 km/h is indicated.
• If one or both travel direction sensors detected a counteracting direction the error codes 1106 and/or
1116 will appear after approx. one machine length. Otherwise no error code will be displayed. The
travel direction detection is now automatically set.
However, should one of the two error codes appear, this must be caused by a sebsor fault.

3.6 Automatic detection of surge currents in travel system

This function is only valid from software version 1.09!

For a sensitive and exact function of the travel system the surge currents in the travel system must be
determined for both travel directions. The surge currents are automatically determined after entering a
code number, so that no electric meter is required.
The surge currents must only be determined during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and after
the replacement of the ESX-control.

The measurement is identical for both travel directions: After entering the respective code number the
current is increased by the control solenoid on the travel pump in steps of 5 mA, starting from 250 mA..
After each current increase the system waits for 3 seconds. If a considerable drum movement is
measured during the waiting time, the surge current is reached. In order to enhance the measuring result
this measurement is performed three times. The final surge current is the mean value of these three
measurements. This surge current is automatically stored and is valid from the next start of the machine.

Before the measurement you should strictly make sure that the machine is parked on level ground and
has a sufficient distance for movement to front and back, because the machine will move to the
respective direction when performing the measurement.

Attention! First set the machine to input mode (code 9 9 9 9 ). It must be strictly assured that the speed
sensor (in front right hand hydraulic motor) is working correctly. For a function test enter code number
1 1 0 6 at the display module. This code can be used to display the number path pulses from the speed
sensor. The displayed value must change when the machine is driven.
If this value does not change even though the machine is moving, the measurement must not
be performed!
The state of the speed sensor must first be corrected, as otherwise the movement of the drum will not be
detected. (See also: „Resetting the surge currents in the travel system”)
Attention!
During the measurement the machine will move when the surge current is reached!
Do not leave the machine while the measurement is progressing!
During the measurement keep an eye on your environment!
To stop the machine reset the travel lever to neutral position!

The automatic measurement of the travel system surge currents is performed as follows:
• The speed selection switch must be in position ECO.
• If necessary enter code number 9 9 9 9 to access the service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents in
the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This code
number must be entered to be able to perform the following steps. From this point the machine
can no longer be operated with the travel lever! The travel lever will only be in function
again after the teach function has been completed or the machine has been restarted.

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• The measurements (forward/reverse) must be started by entering a code number. The code number
required to teach the travel direction is as follows:

Determination of control surge currents 1 0 9 1

• After the input of the above code number the display shows " F O R E ". Shifting the travel lever
forward starts the first surge current measurement for forward travel.
• During the measurement the actual current is displayed (display value = current in mA).
• Once the surge current measurement is finished the display will show the reading O K for a period of
5 seconds.
• After this wait time the display reading changes to " B A C K ". Now shift the travel lever backward
to start the surge current measurement in reverse.
• During the measurement the actual current is displayed (display value = current in mA).
• After completion of the measuring process in reverse the display will show O K again.
• The travel lever must now be returned to braking position.
• Once both surge currents have been learned correctly and the travel lever is in "braking position", the
display shows the reading "D O N E", the values are saved and the function is completed. Now the
machine can be operated again with the travel lever. The new surge current values for the travel
system are valid from the next start.
• The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.

The following procedure applies for software versions 1.07 and 1.08:

The automatic measurement of the travel system surge currents is performed as follows:
• The seat must be adjusted for travel direction forward!
• The speed selection switch must be in position ECO.
• If necessary enter code number 9 9 9 9 to access the service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents in
the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This code
number must be entered to be able to perform the following steps. From this point the machine
can no longer be operated with the travel lever! The travel lever will only be in function
again after the teach function has been completed or the machine has been restarted.
• Both measurements (forward/reverse) must be started by entering a code number. The code numbers
for both travel directions are:

Determine surge current for control forward 1 0 9 1

Determine surge current for control reverse 1 0 9 2

• After entering one of the above code numbers the measurement will only start after moving the travel
lever to the respective travel direction.
ATTENTION: The ASC fault indicator light will come on during the teach process. In this case this is
of no relevance. The warning will disappear when restarting the machine.
• During the measurement the actual current is displayed (display value = current in mA).
• Teaching is required for both travel directions.
• When returning the travel lever to neutral position after the two measurements, the display will show O
K for 3 seconds and the averaged values will be saved.
• Once both surge currents have been measured the machine can be operated again with the travel
lever. The new surge current values for the travel system are valid from the next start.
• The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.

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3.7 Teaching the electronic end stops of the steering angle sensor (BVC)

Attention: Does not apply for BVC machines with "hydraulic steering" option!

Note: During the measurement the machine should be parked on level ground.
The drum should be standing on old rubber tires or a metal plate.
Specify the engine speed -> travel lever out of braking position = neutral position
(Not while entering a code).

To prevent the steering from moving all the way to the mechanical stops of the steering cylinder it is
necessary to determine a defined safety distance to these end stops.

• Enter code number 9 9 9 9 to access the service mode.

• Enter code number 2 0 1 0 to activate the mode "Teach steering stops".
• Return the travel lever to neutral position (no braking function, but to relieve the machine of strain).
The display shows the standardized steering position (0..1000 → right ... left).
• Now turn the electric steering wheel clockwise, until the mechanical stop is reached The displayed
value should be in the range of 100..300. Then shift the travel lever to braking position and enter code
number 2 0 1 2 (press both Info-buttons first to access the input mode). In case of acceptance the
value 2 2 2 2 will appear for a moment. In case of a fault the value 9 9 9 9 upon acceptance (see
below).
• Return the travel lever to neutral position (no braking function, but to relieve the machine of strain).
The display shows the standardized steering position (0..1000 → right ... left).
• Now turn the electric steering wheel anti-clockwise, until the mechanical stop is reached The
displayed value should be in the range of 700..900. Then shift the travel lever to braking position and
enter code number 2 0 1 3 (press both Info-buttons first to access the input mode). In case of
acceptance the value 3 3 3 3 will appear for a moment. In case of a fault the value 9 9 9 9 upon
acceptance (see below).
• To leave the mode the machine must be switched off or code 2 0 1 1 must be entered.

Possible error causes (code 9 9 9 9 ) :

- Incorrect connection of hoses -> have checked by engineer -> correct.

- Connecting fault on potentiometer -> have checked by an electrician -> correct.
- Potentiometer faulty -> replace the potentiometer.

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START
Machine on level
ground

Tires or metal plate

under drum

Machine on level
ground

enter 9999

enter 2010

Travel lever in
neutral position

Turn steering wheel to the

RIGHT to the STOP
(PRV can be heard,
cylinder full extended or
retracted).

Travel lever in brake

position

Display shows Display shows

enter 2012 2222 9999
OK ERROR
Travel lever in
neutral position

Turn steering wheel to the

LEFT to the STOP
(PRV can be heard,
cylinder full extended or
retracted).

Travel lever in brake

position

Display shows Display shows

enter 2013
3333 9999
OK ERROR

Switch ignition off

and on again OR enter 2011

FINISHED

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3.8 Automatic detection of surge currents on steering valves (BVC)

Attention: Does not apply for BVC machines with "hydraulic steering" option!

Note: Execute this function only AFTER "Teaching electronic end stops of angle sensor".

During the measurement the machine should be parked on level ground.

Before the measurement both drums should be steered to straight ahead position.
The travel motor must be moved out of braking position -> raised idle speed!

To enable a sensitive and exact function of the steering the surge currents of the two control solenoids
and both steering valves must be measured. The surge currents are automatically adjusted after entering
a code number, so that no electric meter is required.
The surge currents must only be adjusted during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and after
the replacement of the ESX-control.
The measurement is identical for both solenoids:

Example BW 177 BVC:

After entering the respective code number the current is increased by the control solenoid in steps of 5
mA, starting from 650 mA.. After each increasing step the system waits for 2 seconds. If a change in
drum angle is measured after the waiting time, the surge current is reached. In order to enhance the
measuring result this measurement is performed three times. The final surge current is the mean value of
these three measurements. This surge current is automatically stored and is valid from the next start of
the machine.
For all other machine types the same procedure is used, however, currents and times will vary.
Before the measurement you must strictly make sure that the steering system is „bled“, because an air
cushion in the steering cylinders would have a negative effect on the measurement and therefore on the
steering performance of the machine. Sufficient bleeding is achieved by performing a few quick steering
movements at full engine speed.

The automatic measurement of the steering valve surge currents is performed as follows:
• The engine must be operated in ECO-mode!
• Enter code number 9 9 9 9 to access the service mode.
• Travel lever in neutral position (Brake must be relieved!)
• Enter code number 2 0 0 0 . This code number activates the function "Automatic detection of steering
valve surge currents"; the display now shows the reading 0 0 0 0 with the first digit flashing.
• Now code number 2 0 0 1 must be entered.
• After entering one of the above mentioned code numbers the measurement of the surge current will
start immediately.
• The drum is thereby first steered to the right and then to the left.
• During the measurement the actual valve current is displayed (display value in mA).
• Attention! During the measurement the drum cannot be steered ! The steering wheel has no
effect.
• During the measurement the machine should not be driven !
• Once the measurement is completed the display value OK will appear for 3 seconds, after this the
code number 0000 is displayed with the first digit flashing, the next measurement can be started.
• The new surge current values are valid from the next start.

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3.9 Driving against the closed brake

After entering the code number 0 5 0 0 the brake will not be released. If the travel lever is in this
condition shifted out of the brake gate and moved to any travel direction, the travel pumps will be
triggered according to the chosen travel direction. At the same time a warning (fault code 0 5 0 0 )
appears on the display and the warning buzzer is triggered, in order to keep the operator informed about
the condition. The brake control light in the LC-display remains activated.

In order to terminate this function and release the brake you must either enter code number 0 5 0 1 or
switch the ignition off. After entering code number 0 5 0 1 the function is aborted and OK is displayed as
confirmation for 5 seconds. After this the code needs to be entered again.

Note: This function can only be activated / deactivated when the travel lever is locked in the
brake gate. ( Input mode)

3.10 Showing stored faults

This function is only valid from software version 1.10!

Switch on function „Show stored faults“:

• Enter code number 0 7 0 0 . This code number enables the function „Show stored faults“.

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

Switch off function „Show stored faults“:

• Enter code number 0 7 0 1 . This code number disables the function „Show stored faults“.

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

Note: This function can only be activated / deactivated when the travel lever is locked in the
brake gate. ( Input mode)

3.11 Delete all stored faults

This function is only valid from software version 1.10!

Execute the function „Delete all stored faults“:

• The engine must not be running!
• Enter code number 0 7 1 0 .
• Switch the ignition off and on again.

All stored faults are now deleted.

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

Note: This function can only be activated / deactivated when the travel lever is locked in the
brake gate. ( Input mode)

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4 How to proceed when replacing components?

Each machine is adjusted individually during initial commissioning. This adjustment or teaching process
is necessary to make sure that the travel and steering functions are almost identical on all machines.
Background of these adjustment procedures are the tolerances of the components used, e.g. hydraulic
pump for travel system, proportional valves for steering, steering angle sensors and ESX control. These
tolerances apply for both mechanical as well as electrical functions and are unavoidable for
manufacturing reasons.
To enable simple and quick adjustment procedures we have decided to do without expensive tools. All
that is needed is this manual and a bit of time. By following the described procedure it is possible to take
a machine back into operation after the replacement of one of the components specified above and to re-
establish the usual functional quality, with almost any previous knowledge. Even an incorrectly or
incompletely conducted teaching procedure can be repeated without problems as often as necessary. At
the first glance it seems to be at bit awkward to perform this adjustment work on every machine, but this
procedure enables the operation of all machines with the same operating software. At the end of the day
this considerably increases the spare parts availability.

4.1 Replacement of an ESX-control

Since the control stores all teach values of the machine, each teaching procedure must be performed
with the new control after a replacement.

Attention: Before performing one of the following steps you must first set the corresponding
machine type (see chapt. 3.3)!
When changing the machine type all previously made adjustments will be lost!

Now the teach functions must be executed.

• From DH
• Automatic detection of travel system surge currents (see chapt. 3.6)

• On BVC
• Automatic detection of steering valve surge currents (see chapt. 3.7)
• Teaching the electronic end stops of the steering angle sensor (see chapt. 3.8)

4.2 Replacement of a travel pump / axle drive motor / drum drive motor
• Automatic detection of travel system surge currents (see chapt. 3.6)
•

4.3 Replacement of a steering valve (BVC)

• Automatic detection of steering valve surge currents (BVC) (see chapt. 3.7)
•

4.4 Replacement of a steering angle sensor

• Teaching the electric end stops of the steering angle sensor (see chapt. 3.8)

4.5 How to proceed when replacing a front / rear axle sensors?

• Teaching the travel direction sensor

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4.6 Which components can be replaced without a subsequent adjustment

procedure?
• Display
• Data collector
• Joystick
• Electric steering wheel
• Diesel engine
• All switches in the dashboard
• Vibration motor
• Vibration pump

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

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Service Training WZ – 4 Description of Signals on the ESX Control

008 913 76
5 Description of the Signals on the ESX-Control
Notes:
Wherever the value of 24 V is mentioned in the following text, it refers to the current battery voltage
under due consideration of voltage drops in the lines.

ESX terminal Signal description Nominal values (voltage / current)

Technical Manual / Electrics

X35:1 AGND = Analogue ground: Ground potential for sensors (steering angle approx. 0 V measured against ground (terminal 31)
sensor, steering unit etc.)
X35:2 Output amplitude changeover active, i.e. high amplitude approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. low amplitude 0V
X35:3 Output warning buzzer Warning buzzer active approx. 12 V
Digital output (max. 2.5 A) Warning buzzer inactive 0V
X35:4 RS 232 RxD interface, not used for normal operation. Measurement not possible!
X35:5 RS 232 TxD interface, not used for normal operation. Measurement not possible!
X35:6 Not used ---
X35:7 Not used ---

BOMAG
X35:8 Not used ---
X35:9 Not used ---
X35:10 Not used ---
X35:11 Not used ---
X35:12 Input axle speed Signal changes between approx. 0V and 12V, when machine is driving.
Frequency input (0....7,5kHz) Frequency with travel speed m/min
Machine type:
XX m/min approx.XX Hz
XX m/min approx.XX Hz
Machine type:
XX m/min approx.XX Hz
XX m/min approx.XX Hz
Machine type:
XX m/min approx.XX Hz
XX m/min approx.XX Hz
X35:13 Not used ---

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ESX terminal Signal description Nominal values (voltage / current)

X35:14 Not used ---
X35:15 Input seat contact switch Seat operated 0V
Digital input active high Seat not operated ?V
X35:16 Not used ---
X35:17 Input BTS brake (from travel lever) Brake released approx. 12 V
Digital input active high Brake applied 0V
X35:18 Input steering sensor (S1/A) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned.
Frequency depends on speed of turning
X35:19 Input steering sensor (S1/B) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned.
Frequency depends on speed of turning
X35:20 Output steering left Steering left active 0,4..1,6 A
PWM digital output (max. 4 A) Steering left inactive 0A
X35:21 Output steering right Steering right active 0,4..1,6 A
PWM digital output (max. 4 A) Steering right inactive 0A

BOMAG
X35:22 Output vibration pump attachment plate permissible current range: approx. 0..1,2 A
PWM digital output (max. 4 A) Vibration pump active 0,6..1,2 A
Vibration pump not active 0A
X35:23 Voltage supply for sensors Nominal voltage = 8,5 V
This output supplies steering angle sensor and steering unit. Permissible range: approx. 7,65..9,35 V
Without this voltage the control cannot work correctly and will switch toThis voltage must be measured against AGND.
override mode (emergency function).
X35:24 Output backup alarm Backup alarm inactive 0V
Digital output (max. 2.5 A) Backup alarm active approx. 12 V
X35:25 Not used ---
X35:26 Interface CAN-Bus 1 Wire -, is used for communication with MESX, data
collector, LCD-display and BOP. MEASUREMENT NOT POSSIBLE!
X35:27 Interface CAN-Bus 1 Wire +, is used for communication with MESX, data
collector, LCD-display and BOP. MEASUREMENT NOT POSSIBLE!
X35:28 Input potential terminal 15 Control switched on approx. 12 V
Digital input active high Control switched off approx.2 V
This signal must be present, so that the control can work.

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ESX terminal Signal description Nominal values (voltage / current)
X35:29 Input steering angle sensor Position steering angle sensor (measured against AGND)
Analogue input / voltage input 0..8.5 V right hand stop 0,50..1,00 V
straight ahead / neutral / middle ..V
left hand stop 6,80..8,70 V
X35:30 Input longitudinal inclination of machine Inclination of machine (measured against AGND)
Analogue input / voltage input 0..8.5 V -45° axle high 0,50..2,49 V
Neutral position 2,50 V
maximum down 2,51..4,50 V
Technical Manual / Electrics

X35:31 Input hydraulic pressure travel pump circuit 0 bar approx.4 mA

Analogue input (current input 4mA..20mA) from pressure sensor on travel 600 bar approx.20 mA
pump
X35:32 Not used ---
X35:33 Interface CAN-Bus 2 Wire -, is used for communication with travel lever
and engine EMR. MEASUREMENT NOT POSSIBLE!
X35:34 Input drum speed Signal changes between approx. 0V and 12V, when machine is driving.
Frequency input (0....7,5kHz) Frequency with travel speed m/min
Machine type:

BOMAG
XX m/min approx.XX Hz
XX m/min approx.XX Hz
Machine type:
XX m/min approx.XX Hz
XX m/min approx.XX Hz
Machine type:
XX m/min approx.XX Hz
XX m/min approx.XX Hz
X35:35 Input vibration motor Frequency with vibration frequency in Hz
Frequency input (0....2,0kHz) Machine type:
Vib. frequency XX Hz approx.XX Hz
Vib. frequency XX Hz approx.XX Hz
Machine type:
Vib. frequency XX Hz approx.XX Hz
Vib. frequency XX Hz approx.XX Hz
Machine type:
Vib. frequency XX Hz approx.XX Hz

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ESX terminal Signal description Nominal values (voltage / current)

Vib. frequency XX Hz approx.XX Hz
X35:36 Input sense of rotation of vibration motor Sense of rotation forward approx. 12 V
(currently not used) Sense of rotation backward approx.2 V
Digital input active high
X35:37 Input sense of rotation of drum Sense of rotation forward approx. 12 V
Digital input active high Sense of rotation backward approx.2 V
X35:38 Input sense of rotation of axle Sense of rotation forward approx. 12 V
Digitaleingang aktiv high Sense of rotation backward approx.2 V
X35:39 Not used ---
X35:40 Input steering sensor (S2/A) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned.
Frequency depends on speed of turning
X35:41 Input steering sensor (S2/B) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned.
Frequency depends on speed of turning
X35:42 Output emergency steering Emergency steering active approx. 12 V

BOMAG
Emergency steering inactive 0V
X35:43 Not used ---
X35:44 Not used ---
X35:45 Not used ---
X35:46 Output drum drive motor permissible current range: approx. 0..0,6 A
PWM power output (max. 4 A) Drum drive motor active 0,0..2,0 A
Drum drive motor not active 0A
X35:47 Output axle motor permissible current range: approx. 0..0,6 A
PWM power output (max. 4 A) Axle motor active 0,0..2,0 A
Axle motor not active 0A
X35:48 Output vibration pumpe permissible current range: approx. 0..0,6 A
PWM digital output (max. 4 A) Axle motor active 0,0..2,0 A
Axle motor not active 0A
X35:49 Output travel pump forward Travel forward active 0,0..2,0 A
PWM power output (max. 4 A) Travel forward inactive 0A

Sauer components with EDC

Travel forward active 18..80 mA

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ESX terminal Signal description Nominal values (voltage / current)
Travel forward inactive 0 mA
X35:50 Not used ---
X35:51 Not used ---
X35:52 Not used ---
X35:53 Interface CAN-Bus 2 Wire +, is used to communicate with the travel lever
and engine EMR. MEASUREMENT NOT POSSIBLE!
X35:54 Voltage supply for electronics (permanent voltage) Control running approx. 12 V
Control not running 0V
Technical Manual / Electrics

X35:55 Ground connection electronics 0 V (measured against ground)

X35:56 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:57 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:58 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:59 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:60 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:61 Output brake Open brake approx. 12 V
Digital output (max. 4 A) Close brake 0V
X35:62 Output blower coupling stage 2 (currently not used) Active approx. 12 V

BOMAG
Digital output (max. 4 A) Inactive 0V
X35:63 Output blower coupling stage 3 (currently not used) Active approx. 12 V
Digital output (max. 4 A) Inactive 0V
X35:64 Output travel pumps reverse Travel forward active 0,0..2,0 A
PWM power output (max. 4 A) Travel forward inactive 0A

Sauer components with EDC

Travel forward active 18..80 mA
Travel forward inactive 0 mA
X35:65 Test connection Baby Boards approx. 0 V

X35:66 Test connection Baby Boards approx. 0 V

X35:67 Test connection Baby Boards approx. 0 V

X35:68 Test connection Baby Boards approx. 0 V

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ESX terminal Signal description Nominal values (voltage / current)

BOMAG
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Service Training WZ – 4 Description of Signals on the Data Collector

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6 Description of signals on the data collector
Notes:
Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage
under due consideration of voltage drops in the lines.

PIN data Signal description Nominal values (voltage / current)

Technical Manual / Electrics

collector
X26:1 Input indicator right Indicator right active approx. 12 V
Digital input active high Indicator right inactive 0V
X26:2 Input indicator left Indicator left active approx. 12 V
Digital input active high Indicator left inactive 0V
X26:3 Input engine running (D+) Engine running approx. 12 V
Digital input active high Engine not running 0V
X26:4 Not used ---
X26:5 Input hydraulic oil filter differential pressure Filter clogged 0V
Digital input active low Filter OK ?V

BOMAG
X26:6 Not used ---
X26:7 Input air conditioning Air conditioning on approx. 12 V
Digital input active high Air conditioning off 0V
X26:8 Input engine air filter Filter clogged 0V
Digital input active low Filter OK ?V
X26:9 Input background illumination Illumination on approx. 12 V
Digital input active high Illumination off 0V
X26:10 Input coolant supply Coolant supply too low 0V
Digital input active low Sufficient coolant supply ?V
X26:11 Not used ---
X26:12 Ground connection 0V (measured against ground)
X27:1 Not used
X27:2 Input fuel level The voltage signal changes with the filling level in the fuel tank
Analog input Fuel tank empty ?? V
Fuel tank full ?? V
X27:3 Not used ---

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PIN data Signal description Nominal values (voltage / current)

collector
X27:4 Voltage supply for monitoring of water separation (PIN X27:9) Voltage supply O.K. approx.12 V
No voltage supply 0V
X27:5 Ground connection 0V (measured against ground)
X27:6 Interface CAN-Bus 1 Wire +, is used for communication with MESX, Measurement not possible!
ESX, LCD-display and BOP.
X27:7 Interface CAN-Bus 1 Wire -, is used for communication with MESX, ESX, Measurement not possible!
LCD-display and BOP.
X27:8 Voltage supply (permanent voltage) Control running approx. 12 V
Control not running 0V
X27:9 Input water separation If a sufficient amount of water has been separated, a low current flows over
Current input the over the contacts and the water in the separator bowl. This input
analyses this current.
No water separated I= 0A
Water separated I∗ 0,03mA
X27:10 Not used ---

BOMAG
X27:11 Not used ---
X27:12 Not used ---

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Service Training WZ – 4 Description of Signals on the Travel Lever

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7 Description of signals on the travel lever
Notes:
Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage
under due consideration of voltage drops in the lines.

PIN Signal description Nominal values (voltage / current)

Technical Manual / Electrics

travel lever
X23:1 Voltage supply (permanent voltage) Electronics functioning approx. 12 V
Electronics not working 0V
X23:2 Ground connection 0V (measured against ground)
X23:3 Output BTS brake Brake opens approx. 12 V
Digital output (max. 4 A) Brake closes 0V
X23:4 Output BTS (not used)
Digital output (max. 4 A)
X23:5 Output voltage supply for additional analog evaluations Nominal voltage = approx. 5,0 V
This output supplies the 24-stage travel range selector switch. This Permissible range: approx. 4,8..5,2 V

BOMAG
voltage is required to connect and evaluate further analog switches to the This voltage must be measured against AGND.
travel lever.
X23:6 Interface CAN-Bus 2 Wire +, is used to communicate with ESX and Measurement not possible!
engine EMR.
X23:7 Interface CAN-Bus 2 Wire -, is used to communicate with ESX and Measurement not possible!
engine EMR.
X23:8 AGND = Analogue ground: Ground potential for additional analog approx. 0 V measured against ground (terminal 31)
evaluations
Reference to PIN X23:5
X23:9 Node address addressing 1 Connection to machine ground (0V)
X23:10 Node address addressing 2 Connection to machine ground (0V)

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PIN Signal description Nominal values (voltage / current)

travel lever
X23:11 Input travel stage selector switch The voltage signal changes with the adjusted travel speed range
Analog input Travel stage min. ?? V
Travel stage max. ?? V
X23:12 Not used ---
X24:1 Not used ---
X24:2 Input high amplitude High amplitude active approx. 12 V
Digital input active high High amplitude inactive 0V
X24:3 Input low amplitude Low amplitude active approx. 12 V
Digital input active high Low amplitude inactive 0V
X24:4 Not used ---
X24:5 Not used ---
X24:6 Input arm rest left (not yet realized) ---
Digital input active high
X24:7 Output voltage supply for additional digital evaluations Voltage supply active approx. 12 V
This output supplies the amplitude selector switch. This voltage is Voltage supply inactive 0V

BOMAG
required to connect and evaluate further digital switches to the travel
lever.
X24:8 Output voltage supply ground potential 0V (measured against ground)
In connection with PIN X24:7 this output enables the control of additional
components (relays, displays etc.)

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Service Training WZ – 4 Description of Signals on the LC-Display

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8 Descriptions of signals on the LC - Display
Notes:
Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage
under due consideration of voltage drops in the lines.

PIN Display Signal description Nominal values (voltage / current)

X28:1 Voltage supply (permanent voltage "ignition on") Electronics functioning approx. 12 V
Technical Manual / Electrics

Electronics not working 0V

X28:2 Ground connection 0V (measured against ground)
X28:3 Interface CAN-Bus 1 Wire +, is used for communication with MESX, Measurement not possible!
ESX, data collector and BOP.
X28:4 Interface CAN-Bus 1 Wire -, is used for communication with MESX, ESX, Measurement not possible!
data collector and BOP.
X28:5 Voltage supply (permanent voltage "Battery +“ for RTC) Electronics functioning approx. 12 V
Electronics not working 0V
X28:6 Not used ---
X29:1 Input lower frequency Adjustment active approx. 12 V

BOMAG
Digital input active high Adjustment inactive 0V
X29:2 Input higher frequency Adjustment active approx. 12 V
Digital input active high Adjustment inactive 0V
X29:3 Input engine speed high idle High idle active approx. 12 V
Digital input active high High idle inactive 0V
X29:4 Input engine speed low idle Low idle active approx. 12 V
Digital input active high Low idle inactive 0V
X29:5 Not used ---
X29:6 Not used ---
X29:7 Output voltage supply for additional digital evaluations Voltage supply active approx. 12 V
This output supplies the engine speed switch and the switch for Voltage supply inactive 0V
frequency adjustment. This voltage is required to connect and evaluate
further digital switches to the LCD.
X29:8 Not used ---

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9 Description of Signals on DIOS-Module

(only for option with attachment plates)

DIOS terminal Signal description Nominal values (voltage / current)

X62:1 Interface CAN-Bus 1 Wire +, is used to communicate with the ESX- Measurement not possible!
control.
X62:2 Interface CAN-Bus 1 Wire -, is used to communicate with the ESX- Measurement not possible!
control.
X62:3 Voltage supply for electronics Ignition ON: approx. 12 V
Ignition OFF: 0V
X62:4 Input proximity switch, plates middle Plates in middle position approx. 12 V
Digital input active high Plates outside middle position 0V
X62:5 Output plates up Up active approx. 12 V
Digital output (max. 4 A) Up inactive 0V
X62:6 Output plates down Down active approx. 12 V
Digital output (max. 4 A) Down inactive 0V
X62:7 Output plates left Sliding to left active approx. 12 V

BOMAG
Digital output (max. 4 A) Sliding to left inactive 0V
X62:8 Output plates right Sliding to right active approx. 12 V
Digital output (max. 4 A) Sliding to right inactive 0V
X62:9 Voltage supply for outputs Ignition ON: approx. 12 V
Ignition OFF: 0V
X62:10 Voltage supply for outputs Ignition ON: approx. 12 V
Ignition OFF: 0V
X62:11 Ground connection 0 V measured against ground
X62:12 Input proximity switch, plates top Plates lifted above sensor 0V
Digital input active high Plates lowered below sensor approx. 12 V
X62:13 Output plates float position 1 Float position active approx. 12 V
Digital output (max. 4 A) Float position inactive 0V
X62:14 Output plates priority Priority active approx. 12 V
Digital output (max. 4 A) Priority inactive 0V
X62:15 Output plates float position 2 Float position active approx. 12 V
Digital output (max. 4 A) Float position inactive 0V
X62:16 Not used ---

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BOMAG
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Service Training Fault Codes on ESX Control

10 Fault codes of the ESX control

10.1 Overview
Fault code Fault description
0000 - General faults / warnings / machine tests
0999
1000 - Fault in travel system
1999
2000 - Fault in steering system
2499
2500 - Fault in remote control
2999
3000 - Faults in work functions (vibration, attachment plates, rotor, chip
4499 spreader)
4500 - Fault in measuring systems
4999
5000 - Fault diesel engine
5499
5500 - Fault hydraulic system
5999
6000 - Fault anti-theft warning system, localization system, access
6999 system, time account, etc.
7000 - Input of machine codes
7499
7500 - Input of codes for measuring technology
7899
7900 - Operating hours, load spectrum, etc.
7999
1
8000 - Severe software error
8999
9000 - Errors of external IO-nodes (joystick, data collector, Dios module,
9999 LC-display, etc.) 1

1
These faults are not broken down hereunder!

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10.2 Description of fault reactions
Fault reaction Description of fault reaction
1 Warning.
Fault code is displayed.

2 Warning.
Fault code is displayed.
Technical Manual / Electrics

Audible signal

3 Function affected, the faulty function is replaced by an emergency function.

Fault code is displayed.
Audible signal

4 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is stopped if this fault occurs.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Fault code is displayed.

BOMAG
Audible signal

5 Partial function faulty, the partial function cannot be overridden by an emergency function.
the diesel engine is shut down.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
Fault code is displayed.
Audible signal

6 Fatal fault. The function of the control can no longer be guaranteed.

Control is switched off.
the diesel engine is shut down, if possible.
The fault code is displayed, the signal light in the monitoring board is permanently on.
No audible signal!

Note: Errors with error reaction 1 and 2 are only warning messages and are NOT stored in the error log.

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10.3 Detailed description of fault codes and their possible causes

10.3.1 General
Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
500 Driving against brake – warning A corresponding input code has been entered X X
The function "Driving against brake" is activated

502 Simulated engine run - warning A corresponding input code has been entered X X
The function "Simulated engine run" is activated

504 Ant- Slip Control (ASC) deactivated - warning A corresponding input code has been entered X X
The function "Anti Slip Control (ASC)" is deactivated

507 Drum drive deactivated - warning A corresponding input code has been entered X X
Test mode "Drum drive deactivated" was activated.

508 Axle drive deactivated - warning A corresponding input code has been entered X X

BOMAG
Test mode "Axle drive deactivated" was activated.

560 Overvoltage 8,5V Connection of voltage level to operating voltage, another X35:23 X X
The voltage level of the 8,5V range is impermissibly voltage potential or control defective
exceeded
(see signal description)
561 Undervoltage 8,5V Connection of voltage level to ground, another voltage potential X35:23 X X
The voltage level of the 8,5V range is impermissibly fallen or control defective
short of
(see signal description)
562 Error "Voltage Override Relay" X X
The voltage level of the 8,5V range is...

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10.3.2 Brake
Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
1001 Brake valve line breakage The connecting line between control output and control X35:61 X X
The required control power cannot be transmitted to the solenoid is interrupted, or
control solenoid. The proportional solenoid is defective
1002 Brake valve Cable breakage in ground line, or X35:61 X X
Signal outside the valid range (see signal description) Connecting cable between valve and ground connection has
Technical Manual / Electrics

come loose
1003 Brake valve Cable breakage in connecting line, or X35:61 X X
Signal outside the valid range (see signal description) Connecting cable between valve and supply has come loose
1004 BTS brake / travel lever (BTS=output driver) Hardware defect on travel lever X35:17 X X
Overheating of the BTS has the effect, that the braking
position of the travel lever is not correctly recognized
1005 BTS brake / plausibility (BTS=output driver) Hardware defect on travel lever, input X35:17 has not the same X35:17 X X
Plausibility conflict in evaluation of travel lever X- and y- voltage as the BTS
axes to the brake contact signal

BOMAG
10.3.3 Travel lever
Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
1025 Travel lever sum error X-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of axis
1026 Travel lever cable breakage X-axis Cable breakage in travel lever -> Replace travel lever. X X
Signal outside the valid range (see signal description)
1027 Travel lever parameterization X-axis Internal fault in travel lever -> Replace travel lever. X X

1028 Travel lever direction evaluation X-axis Internal fault in travel lever -> Replace travel lever. X X
The direction of travel lever movement could not be
determined
1029 Travel lever difference error X-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of travel lever signal
1030 Travel lever software error X-axis Internal fault in travel lever -> Replace travel lever. X X
Software does not work fault free

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Fault Fault description Possible causes Equip. Assignment Input Fault

Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
1031 Travel lever sum error Y-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of axis
1032 Travel lever cable breakage Y-axis Cable breakage in travel lever -> Replace travel lever. X X
Signal outside the valid range (see signal description)
1033 Travel lever parameterization Y-axis Internal fault in travel lever -> Replace travel lever. X X

1034 Travel lever direction evaluation Y-axis Internal fault in travel lever -> Replace travel lever. X X
The direction of travel lever movement could not be
determined
1035 Travel lever difference error Y-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of travel lever signal
1036 Travel lever software error Y-axis Internal fault in travel lever -> Replace travel lever. X X
Software does not work fault free

10.3.4 Travel speed range selector switch

BOMAG
Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
1040 Travel range selector switch "Ground connection" Cable breakage in ground line, or X23:8 X X
Signal outside the valid range (see signal description) Connecting cable between switch and ground connection has
come loose
1041 Travel range selector switch "Supply connection" Cable breakage in connecting line, or X23:5 X X
Signal outside the valid range (see signal description) Connecting cable between switch and supply line has come
loose
1042 Travel speed range selector switch Higher contact resistances have possibly caused a faulty X23:11 X X
Signal outside the valid range (see signal description) signal.
The switch must be replaced.

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10.3.5 Travel system
Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
1070 Output travel pump forward The connecting line from the output of the control to the X35:49 X X
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid
proportional solenoid. is defective
1071 Fault of current regulator forward Faults in valve control Check wiring. X X
1072 Fault of current regulator forward Faults in valve control Check wiring. X X
Technical Manual / Electrics

1073 Output travel pump forward Short circuit of connecting line (control to proportional valve) to X35:49 X X
Supply voltage UB applied to the output to the proportional voltage supply
valve.
1074 Error in teaching the surge current forward Machine mechanically blocked X35:49
Travel system bypass valves out of adjustment

1080 Output travel pumps reverse The connecting line from the output of the control to the X35:64 X X
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid
proportional solenoid. is defective
1081 Fault of current regulator reverse Faults in valve control Check wiring. X X
1082 Fault of current regulator reverse Faults in valve control Check wiring. X X

BOMAG
1083 Output travel pumps reverse Short circuit of connecting line (control to proportional valve) to X35:64 X X
Supply voltage UB applied to the output to the proportional voltage supply
valve.
1084 Error in teaching the surge current reverse Machine mechanically blocked X35:64
Travel system bypass valves out of adjustment
1088 Note! Surge currents for travel pump have NOT been The function "Teaching pump surge currents" for the travel X X Note
learned. See 3.6 pump has not yet been executed.
-> New machine/replacement of control

1100 Output front travel motor The connecting line from the output of the control to the X35:46 X X
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid
proportional solenoid. is defective
1105 Speed sensor pulses front travel motor Check connecting lines and plugs on wheel speed sensor, if X35:34 X X
Incorrect or non-existent signal "Frequency" necessary replace the wheel speed sensor

1106 Direction signal pulses front travel motor Check connecting lines and plugs on wheel speed sensor, if X35:37 X X
Incorrect or non-existent signal "Direction" necessary replace the wheel speed sensor

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Fault Fault description Possible causes Equip. Assignment Input Fault

Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
1107 Output front travel motor Short circuit of connecting line (control to proportional valve) to X35:46 X X
Supply voltage UB applied to the output to the proportional voltage supply
valve.

BOMAG
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1110 Output rear travel motor The connecting line from the output of the control to the X35:47 X X
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid
proportional solenoid. is defective

1115 Speed sensor pulses rear travel motor Check connecting lines and plugs on wheel speed sensor, if X35:12 X X
Incorrect or non-existent signal "Frequency" necessary replace the wheel speed sensor

1116 Speed sensor direction signal rear travel motor Check connecting lines and plugs on wheel speed sensor, if X35:38 X X
Incorrect or non-existent signal "Direction" necessary replace the wheel speed sensor
Technical Manual / Electrics

1117 Output rear travel motor Short circuit of connecting line (control to proportional valve) to X35:47 X X
Supply voltage UB applied to the output to the proportional voltage supply
valve.

1140 Travel system pressure sensor "Signal" The connecting line between control output and pressure X35:31 X X
The current signal is not transmitted (see signal sensor is interrupted, or
specification The pressure sensor is defective
1141 Travel system pressure sensor "Signal range" The pressure sensor is defective X35:31 X X
The current signal is outside the valid range (see signal
specification)

BOMAG
1142 Travel system pressure sensor "no pressure" No pressure connection on sensor or supply line clogged, or X35:31 X X
The electric signal indicates that the travel pressure is No travel pressure built up
permanently missing.

1145 Inclination sensor "Supply connection" Cable breakage in supply line, or connecting cable sensor / X35:?? X X
Signal outside the valid range (see signal description) voltage supply has come loose ..
X35:30
1146 Inclination sensor "Ground connection" Cable breakage in ground line, or connecting cable sensor / X35:1 X X
Signal outside the valid range (see signal description) ground supply has come loose

1300 Seat connect not occupied Cable breakage in signal line or driver's seat not loaded (driver X35:15 X X
not seated!)

1500 Warning "Dangerous condition ASC" Due to counter-rotating drive units the machine was stopped X X
and the brake applied.
After setting the travel lever to brake position the brake can be
released.

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10.3.6 Steering
(Only machine with electric steering)
Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
2060 Output steering valve right The connecting line between control output and proportional X35:20 X
The required control power cannot be transmitted to the solenoid is interrupted, or
proportional solenoid. The proportional solenoid is defective
2061 Output steering valve left The connecting line between control output and proportional X35:21 X
The required control power cannot be transmitted to the solenoid is interrupted, or
proportional solenoid. The proportional solenoid is defective

2065 Error when teaching the surge current for the Drum was not moved, maximum current was reached, steering X35:20
right hand valve is blocked (e.g. articulation lock applied)
2066 Error when teaching the surge current for the left Drum was not moved, maximum current was reached, steering X35:21
hand valve is blocked (e.g. articulation lock applied)
2068 Note! Surge currents for steering pump have NOT been The function "Teaching pump surge currents" for the steering (X) Note
learned. See 3.7 pump has not yet been executed.
(Only machine with electric steering) -> New machine/replacement of control

BOMAG
2170 Steering valve (arm rest) "direction change" Wiring fault or steering sensor in left hand arm rest defective X35:18 X
X35:19
X35:40
X35:41
2171 Steering valve (arm rest) "Pulse coverage" Steering sensor in left hand arm rest defective. X35:18 X
High difference in measuring values between sensor 1 X35:19
and 2 X35:40
X35:41
2172 Steering wheel (arm rest) "Sensor 1 pulse range" Check connecting line to steering sensor 1 or X35:18 X
The detected steering pulses on steering sensor 1 are replace the steering sensor in the left hand arm rest, if X35:19
outside the valid range necessary
(see signal description)
2173 Steering wheel (arm rest) "Sensor 2 pulse range" Check the connecting lines to steering sensor 2, or replace the X35:40 X
The detected steering pulses on steering sensor 2 are steering sensor in the left hand arm rest, if required. X35:41
outside the valid range
(see signal description)
2174 Steering wheel A45 (arm rest) "Sensor 1" Steering sensor in left hand arm rest defective. X35:18 X
X35:19

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Service Training WZ – 4 Description of Fault Codes on Control

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Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
2175 Steering wheel A45 (arm rest) "Sensor 2" Steering sensor in left hand arm rest defective. X35:40 X
X35:41
2176 Steering wheel A45 (arm rest) "Sensor 1 cable Check the connecting lines to steering sensor 1, or replace the X35:18 X
breakage" steering sensor in the left hand arm rest, if required. X35:19
2177 Steering wheel A45 (arm rest) "Sensor 2 cable Check the connecting lines to steering sensor 2, or replace the X35:40 X
breakage" steering sensor in the left hand arm rest, if required. X35:41
Technical Manual / Electrics

2190 Steering "steering angle sensor... initialization" Replace the control X

Internal control fault.
2191 Steering angle sensorB65 "Measuring value" Steering angle sensor on the articulated joint X35:29 X
2192 Steering angle sensor B65 "Supply cable Power supply line to the steering angle sensor interrupted, or X35:23 X
breakage" Steering angle sensor on the articulated joint
2193 Steering angle sensor B65 "Ground cable Ground cable to the steering angle sensor interrupted, or X35:1 X
breakage" Steering angle sensor on the articulated joint
2198 Note! Teaching of steering stops for electric steering The function "Teaching steering stops" for the electric steering (X) Note
NOT yet executed. See 3.7 has not yet been executed.
-> New machine/replacement of control

BOMAG
10.3.7 Driver's seat arm rest sensor
(Only machine with electric steering)
Fault Fault description Possible causes Terminal Assignment Input Fault
Code on ESX DH-4 BVC-4 code for reaction
diagnose
2300 Note! "Arm rest raised" The arm rest has been raised or the magnetic switch under the X35:16 X
left hand arm rest is defective
2301 Signal fault Cable breakage in magnetic switch signal line, or X35:16 X
Signal outside the valid range (see signal description) Magnetic switch under left hand arm rest defective
2302 Supply cable breakage Power supply line to the magnetic switch interrupted, or X35:16 X
Magnetic switch under left hand arm rest defective
2303 Ground cable breakage Ground cable to the magnetic switch interrupted, or X35:16 X
Magnetic switch under left hand arm rest defective

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10.3.8 Vibration
Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
3000 Vibration sensor "No signal" Check connecting lines and plugs to the vibration sensor, or X35:35 X X
The sensor in the vibration motor does not pick up any replace the sensor in the vibration motor, if necessary.
pulses.
3001 Valve vibration pump (low amplitude on DH) Details in 3004 – 3008 X35:48 X X
General fault.
3002 Valve vibration pump (low amplitude on DH) System fault! Replace the control X35:48 X X
Internal system fault.
3003 Valve vibration pump (low amplitude on DH) Faults in control line, or X35:48 X X
"Current range" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3004 Valve vibration pump (low amplitude on DH) The connecting line between control output and proportional X35:48 X X
Line interruption solenoid is interrupted, or
The proportional solenoid is defective
changeover relay / bridge missing

BOMAG
3005 Valve vibration pump (low amplitude on DH) System fault! Replace the control X35:48 X X
Internal system fault.
3006 Valve vibration pump (low amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X X
"Control fault regulating up" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3007 Valve vibration pump (low amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X X
"Control fault regulating down" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3008 Valve vibration pump (low amplitude on DH) System fault! Replace the control X35:48 X X
Internal system fault.
3009 Vibration adaptation control (low amplitude on DH) Wear or damage in vibration system hydraulic circuit. X35:48 X X
"Frequency adaptation"
Limits of adaptation range exceeded
(see signal specification)

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Service Training WZ – 4 Description of Fault Codes on Control

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3011 Valve vibration pump (high amplitude on DH) Details in 3014 – 3018 X35:48 X
General fault.
3012 Valve vibration pump (high amplitude on DH) System fault! Replace the control X35:48 X
Internal system fault.
3013 Valve vibration pump (high amplitude on DH) Faults in control line, or X35:48 X
"Current range" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3014 Valve vibration pump "Cable breakage" The connecting line between control output and proportional X35:48 X
(high amplitude only DH) solenoid is interrupted, or
Technical Manual / Electrics

Line interruption The proportional solenoid is defective

changeover relay / bridge missing
3015 Valve vibration pump (high amplitude on DH) System fault! Replace the control X35:48 X
Internal system fault.
3016 Valve vibration pump (high amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X
"Control fault regulating up" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3017 Valve vibration pump (high amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X
"Control fault regulating down" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal

BOMAG
specification)
3018 Valve vibration pump (high amplitude on DH) System fault! Replace the control X35:48 X
Internal system fault.
3019 Vibration adaptation control (high amplitude on DH) Wear or damage in vibration system hydraulic circuit. X35:48 X
"Frequency adaptation"
Limits of adaptation range exceeded
(see signal specification)

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10.3.9 Attachment plates

Fault Fault description Possible causes Terminal Assignment Input Fault
Code on ESX DH-4 BVC-4 code for reaction
diagnose
3051 Vibration pump, plates, valve Details in 3052 – 3058, this fault always is connected with one X35:22 X
General fault. of the faults listed below
3052 Vibration pump, plates, valve "hysteresis" X35:22 X
3053 Vibration pump, plates, valve "current range" X35:22 X
The control current is outside the valid range (see signal
specification)
3054 Vibration pump, plates, valve "Cable breakage" The connecting line between control output and proportional X35:22 X
Line interruption solenoid is interrupted, or
The proportional solenoid is defective
changeover relay / bridge missing
3055 Vibration pump, plates, valve System fault! Replace the control X35:22 X
Internal system fault.

3056 Vibration pump, plates, valve X35:22 X

"Control fault positive limit"

BOMAG
The control current is outside the valid range (see signal
specification)
3057 Vibration pump, plates, valve X35:22 X
"Control fault negative limit"
The control current is outside the valid range (see signal
specification)
3058 Vibration pump, plates, valve System fault! Replace the control X35:22 X
Internal system fault.

3060 Warning ! Attachment plate lowered and backward The attachment plates are lowered and an attempt is made to X
travel drive backwards

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Service Training WZ – 4 Description of Fault Codes on Control

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10.3.10 Diesel engine
Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
5024 Diesel engine "Coolant level" warning Coolant level too low or sensor defective X26:10 X X
5025 Diesel engine "Coolant level" fault shut-down Coolant level too low or sensor defective X26:10 X X
5026 Diesel engine "Air filter" warning Air filter soiled or sensor defective X26:8 X X
5027 Diesel engine "Air filter" fault shut-down Air filter soiled or sensor defective X26:8 X X
5028 Water separator warning Water or other dirt in fuel filter X27:4 X X
Technical Manual / Electrics

X27:9
5029 Water separator fault shut-down Water or other dirt in fuel filter X27:4 X X
X27:9

10.3.11 Diesel engine EMR

Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
5100 Diesel engine EMR "Warning light" Collective warning X X

BOMAG
see further fault code for more accurate fault diagnose
5101 Diesel engine EMR "red stop light" Collective message for engine shut down X X
see further fault code for more accurate fault diagnose

5110 Diesel engine EMR "Nominal speed value" CAN connection between ESX and EMR interrupted X X
CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.
ESX without voltage supply
Battery charge level too low
5111 Diesel engine EMR "Engine oil filling level" Engine oil filling level too low X X
5112 Diesel engine EMR "Oil pressure" Engine oil pressure too low X31:21 X X
5113 Diesel engine EMR "Charge air pressure" Charge air pressure too low X31:24 X X
5114 Diesel motor EMR "Temperaturein intake line" Charge air temperature too high X31:4 X X
5116 Diesel engine EMR "Coolant temperature" Coolant temperature too high X31:9 X X
5117 Diesel engine EMR "Fuel temperature" Fuel temperature too high X X
5118 Diesel engine EMR "Engine speed" Speed sensor 1 or 2 defective X31:13 X X
Connection between EMR and speed sensor 1 or 2 X31:11
interrupted

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Fault Fault description Possible causes Equip. Assignment Input Fault

Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose

5120 Diesel engine EMR "CAN communication" CAN connection between ESX and EMR interrupted
CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.
ESX without voltage supply
Battery charge level too low
5121 Diesel engine EMR "CAN communication" CAN connection between ESX and EMR interrupted
CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.
EMR without voltage supply.
5122 Diesel engine EMR "Nominal speed value" CAN connection between ESX and EMR interrupted
CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.
ESX without voltage supply
Battery charge level too low
5123 Diesel engine EMR CAN communication CAN communication between EMR and ESX X31:12 X X

BOMAG
X31:13
5124 Diesel engine EMR CAN communication CAN communication between EMR and ESX X31:12 X X
X31:13
5125 Diesel engine EMR CAN communication CAN communication between EMR and ESX X31:12 X X
X31:13
5126 Diesel engine EMR CAN communication CAN communication between EMR and ESX X31:12 X X
X31:13
5130 Diesel engine EMR "Oil pressure sensor" Sensor defective X31:22 X X
Wire breakage in current path X31:20
Current path has short circuit to ground
5131 Diesel engine EMR "Charge air pressure sensor" Sensor defective X31:25 X X
Wire breakage in current path X31:23
Current path has short circuit to ground
5132 Diesel engine EMR "Charge air temperature" Sensor defective X31:25 X X
Wire breakage in current path X31:23
Current path has short circuit to ground
5133 Diesel engine EMR "Coolant temperature sensor" Sensor defective X31:8 X X
Wire breakage in current path
Current path has short circuit to ground
5134 Diesel engine EMR "Speed sensor" Speed sensor 1 or 2 defective X31:10 X X

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Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
X31:12
5140 Diesel engine EMR "unknown fault" Fault diagnostics only possible with DEUTZ diagnostics tool X X
(SERDIA)
Technical Manual / Electrics

BOMAG
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10.3.12 Miscellaneous
Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
5502 "Hydraulic oil filter" warning Hydraulic oil filter soiled or sensor defective X X
5503 "Hydraulic oil filter" fault shut-down Hydraulic oil filter soiled or sensor defective X X
5504 "Oil temperature" warning Hydraulic oil temperature too high or sensor defective X X
5005 "Oil temperature" fault shut-down Hydraulic oil temperature too high or sensor defective X X

10.3.13 Machine type

Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
7011 Warning "Change of machine type" Only change the machine type after applying appropriate X X
This warning is displayed when the machine type is measures; e.g. conversion from D to PD (different rolling
changed. circumference of roller drum)

BOMAG
7012 "Conflict machine type" The machine type has been changed to such an extent, that the X X
This error message is displayed if the set machine does type parameters no longer match the basic parameters → enter
not comply with the basic parameters of the machine. the correct machine code or one of the basic machine
parameters was changed (e.g. different axle)

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11 Input Codes for ESX Control
Display and adjustment functions can generally only be accessed by entering "service code" 9999 beforehand!

11.1 Fault log

without service code!
Technical Manual / Electrics

Input code Description of display function Display values

0700 Function "Show stored faults“ activated Fault codes are displayed one after the other
0701 Function "Show stored faults“ deactivated 0000
0710 Delete stored faults once the fault log is deleted it is returned to 0000

11.2 Value displays

BOMAG
11.2.1 General
Input code Description of display function Display values
0555 Display of "machine control software version ( ESX)" e.g.: "1.13" for software version V 1.13
0556 Display of Firmware version "LCD Display" e.g. "1.36" for version 1.36
0557 Display of Firmware version "Data Collector" e.g. "1.11" for version 1.11
0720 Display of "Machine Code" The machine code is displayed (72xx) (see chapt. 3.6)

11.2.2 Brake
Input code Description of display function Display values
1001 Display of voltage at control output "Valve Brake" Display in V (e.g. 12.6 corresponds with 12,6V)

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11.2.3 Travel lever / driving

Input code Description of display function Display values
1020 Display "Travel lever end positions" 100 = Forward
0 = Neutral
10 = Reverse
1000 = Left
10000 = Right
Combinations are possible, e.g. 1100 for forward
1021 Display "Values for axle forward reverse" 0..1000 = Forward
0..-1000 = Reverse
1022 Display "Values for axle right left" left -> - 1000..0..1000 -> right, i.e. brake gate
1025 Display "Travel lever actuating direction" 100 = Forward
0 = Neutral
1 = Reverse
1026 Display "Travel direction" 0 = Neutral
1 = Forward

BOMAG
2 = Reverse
1027 Display "Travel lever release" 0 = locked
1 = released

11.2.4 Travel speed range selector switch

Input code Description of display function Display values
1040 Display "Speed range / gear" Position of travel range selector switch from 1...24
1041 Display "Voltage value for speed range / gear" Stages 0...4 = 4
Stages 5...9 = 3
Stages 10...14 = 2
Stages 15...19 = 1
Stages 20...24 = 0

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Input code Description of display function Display values
1042 Display "Voltage value for speed range / gear standardized" Stage 1 ≈ 956 Stage 2 ≈ 916 Stage 3 ≈ 875
Stage 4 ≈ 835 Stage 5 ≈ 795 Stage 6 ≈ 756
Stage 7 ≈ 716 Stage 8 ≈ 675 Stage 9 ≈ 637
Stage 10 ≈ 597 Stage 11 ≈ 557 Stage 12 ≈ 517
Stage 13 ≈ 478 Stage 14 ≈ 436 Stage 15 ≈ 396
Stage 16 ≈ 357 Stage 17 ≈ 318 Stage 18 ≈ 279
Stage 19 ≈ 238 Stage 20 ≈ 200 Stage 21 ≈ 160
Stage 22 ≈ 120 Stage 23 ≈ 80 Stage 24 ≈ 40
Technical Manual / Electrics

1044 Display "Speed range / gear" end value Stage 1 = 417 Stage 2 = 833 Stage 3 = 1‘250
Stage 4 = 1‘667 Stage 5 = 2‘089 Stage 6 = 2‘500
Stage 7 = 2‘917 Stage 8 = 3‘333 Stage 9 = 3‘750
Stage 10 = 4‘167 Stage 11 = 4‘583 Stage 12 = 5‘000
Stage 13 = 5‘417 Stage 14 = 5‘833 Stage 15 = 6‘250
Stage 16 = 6‘667 Stage 17 = 7‘500 Stage 18 = 8‘333
Stage 19 = 9‘167 Stage 20 = 10‘000 Stage 21 = 13‘334
Stage 22 = 16‘667 Stage 23 = 20‘000 Stage 24 = 23‘333

11.2.5 Travel pump: Travel direction forward

BOMAG
Input code Description of display function Display values
1070 Display "Actual current value travel pump forward" Display in mA (0..350..1300)
1071 Display "Nominal current value travel pump forward" Display in mA (0..350..1300)

1078 Initial current value (learned surge current) of the valve Display in mA (permitted range 350mA..600mA)
1079 Maximum current value (derived end current) of the valve Display in mA (permitted range 1150mA..1400mA)

11.2.6 Travel pump: Travel direction reverse

Input code Description of display function Display values
1080 Display "Actual current value travel pump reverse" Display in mA (0..400..1300)
1081 Display "Nominal current value travel pump reverse" Display in mA (0..400..1300)

1088 Initial current value (learned surge current) of the valve Display in mA (permitted range 350mA..600mA)
1089 Maximum current value (derived end current) of the valve Display in mA (permitted range 1150mA..1400mA)

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11.2.7 Travel motor front (drum)

Input code Description of display function Display values
1100 Actual pump current Display in mA (0..600..1000)
1101 Nominal pump current Display in mA (0..600..1000)
1105 Travel speed Display in m/min
1106 Pulses of speed sensor Counts the pulses up to 99'999 and starts again at 0
1107 Direction signal of speed sensor 2 = Forward
1 = Standstill and reverse
1108 Travel direction logics 1 = Forward
0 = Standstill
2 = Reverse

11.2.8 Travel motor rear (wheel axle)

Input code Description of display function Display values
1110 Actual pump current Display in mA (600..1000)
1111 Nominal pump current Display in mA (600..1000)

BOMAG
1115 Travel speed Display in m/min
1116 Pulses of speed sensor Counts the pulses up to 99'999 and starts again at 0
1117 Direction signal of speed sensor 2 = Forward
1 = Standstill and reverse
1118 Travel direction logics 1 = Forward
0 = Standstill
2 = Reverse

11.2.9 Adaption values for speed regulation

Input code Description of display function Display values
1128 Pre-control factor forward travel 7000..10000
1129 Pre-control factor reverse travel 7000..10000

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11.2.10 Travel pressure sensor
11.2.11
Input code Description of display function Display values
1140 Pressure in bar 0..600
1141 Raw measuring value (voltage in V) 0..5V
1142 Standardized measuring value 0..1000
1143 Function status (internal logic -> diagnose) 0, 1, 2
Technical Manual / Electrics

11.2.12 Inclination sensor

Input code Description of display function Display values
1145 Value in % 0..80%
1146 Raw measuring value (voltage in V) 0..5V. 2.55V = 0%
1147 Standardized measuring value –1000..0..1000. (0 = 0%)
1148 Function status (internal logic -> diagnose) 0, 1, 2

11.2.13 Travel condition values

BOMAG
Input code Description of display function Display values
1150 Current travel speed (in km/h) 0,00..20,00

11.2.14 Speed limitation

Input code Description of display function Display values
1200 Current setting (in km/h) 0 = No limitation
6, 7, 8, 9, 10, 11,12

11.2.15 Arm rest contact

Input code Description of display function Display values
1300 Function status 1= arm rest up; 2= arm rest down
1301 Raw measuring value (voltage in V) Display in mV
1302 Travel operation status by arm rest contact 1= Driving permitted; 2= Driving disabled

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11.2.16 Adaption values traction control

Input code Description of display function Display values
1500 Pre-control factor front 400..24000
1501 Pre-control factor rear 400..24000

11.2.17 Steering: Steering valve

Input code Description of display function Display values
2100 Display "Nominal current value steering valve right" 0– 1200mA
2101 Display "Actual current value steering valve right" Display in mA
2102 Display "Nominal current value steering valve left" 0– 1200mA
2103 Display "Actual current value steering valve left" Display in mA

2106 Display "Minimum current value steering valve left" Display in mA

2107 Display "Maximum current value steering valve left" Display in mA
2108

BOMAG
Display "Minimum current value steering valve right" Display in mA
2109 Display "Maximum current value steering valve right" Display in mA

11.2.18 Steering: Angle sensor in articulated joint

Input code Description of display function Display values
2110 Raw measuring value (voltage in V) 0...8,5VDC
2111 Standardized measuring value -1000...0...1000
2112 Standardized actual steering angle position -1000...0...1000

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11.2.19 Steering: Steering wheel
Input code Description of display function Display values
2120 Standardized nominal steering angle position -1000...0...1000

2130 Steering wheel sensor 1 track 1 absolute pulses Number of total pulses
2131 Steering wheel sensor 1 track 2 absolute pulses Number of total pulses
2132 Steering wheel sensor 1 total pulses of sensor
2133 Steering wheel sensor 1 sense of rotation 1=steering wheel steers to the right (clockwise); 2=steering
Technical Manual / Electrics

wheel steers to the left

2140 Steering wheel sensor 2 track 1 absolute pulses Number of total pulses
2141 Steering wheel sensor 2 track 1 absolute pulses Number of total pulses
2142 Steering wheel sensor 2 total pulses of sensor
2143 Steering wheel sensor 2 sense of rotation 1=steering wheel steers to the right (clockwise); 2=steering
wheel steers to the left

11.2.20 Vibration
Input code Description of display function Display values

BOMAG
3000 Display "Switch for vibration mode" Off = 0
On = 1
3001 Display "Status of vibration relay“ 0 = Relay K43 not switched
1 = Relay K43 switched
3002 Display "Vibration pump valve current" Display value = mA
The display shows the actual pump current.
3003 Display "Vibration pump valve current" (high amplitude on DH) Display value = mA
The display shows the actual pump current.

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11.2.21 Attachment plates, option (only BW213 BVC)

Input code Description of display function Display values
3050 Display "Attachment plates activated" OFF, i.e. software for plates switched off
ON, i.e. software for plates switched on
3051 Display "Sensor for height shut-down" OFF = Sensor has switched, senses metal, plates raised
ON = Sensor has not switched, senses no metal, plates lowered
3052 Display "Sensor for middle position" OFF = Sensor has not switched, senses no metal
ON = Sensor has switched, senses metal, plates in middle

3053 Display "Logic vibration On-Off“ OFF = Vibration switched off

ON = Vibration switched on
3054 Display "Switch for float position" OFF = Switch switched off
ON = Switch switched on
Attention! Float position is not always activated when switch is in
ON-position!
3055 Display "Contact plates coupled" OFF = Plates are not hydraulically connected with the machine

BOMAG
ON = Plates are connected with the machine
3056 Display "Potentiometer value frequency setting of plates" 0..1000 standard, 0 = min. frequency, 1000 = max. frequency

3057 Control status valve "move up" OFF = Output not triggered
(Pin 5 DIOS module) ON = Output triggered
3058 Control status valve "move down" OFF = Output not triggered
(Pin 6 DIOS module) ON = Output triggered
3059 Control status valve "retract sideways" OFF = Output not triggered
(Pin 8 DIOS module) ON = Output triggered
3060 Control status valve "extend sideways" OFF = Output not triggered
(Pin 7 DIOS module) ON = Output triggered
3061 Control status valve "floating position" OFF = Output not triggered
(Pin 13 + 15 DIOS module) ON = Output triggered
3062 Control status valve "Priority change-over" OFF = Output not triggered
(Pin 14 DIOS module) ON = Output triggered

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11.2.22 Engine
Input code Description of display function Display values
5000 Actual speed (rpm) 0..3000
5001 Nominal speed (rpm) 0..3000
5010 Idle speed (EMR parameter) (rpm) 600..1000
5011 Maximum speed (EMR parameter) (rpm) 1600..3000
Technical Manual / Electrics

5024 Display "Status engine coolant level" 0= Coolant level OK

1= Coolant level too low
5026 Display "Status engine air filter" 0= Air filter OK
1= Air filter soiled
5028 Display "Status of water separator" 0= Water separator OK
1= Water or dirt in fuel filter

5050 Charge air pressure (in bar * 100) 0..300 -> 0..3bar

BOMAG
11.2.23 Hydraulics
Input code Description of display function Display values
5502 Display "Status hydraulic oil filter" 0= Hydraulic oil filter OK
1= Hydraulic oil filter contaminated

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11.3 Test settings

11.3.1 Brake
Input code Description of display function Display values
0500 Activates the function "Driving against the closed brake" 500 and brake control light stays on when shifting the travel lever
out of the brake gate
0501 Deactivates the function "Driving against the closed brake" O K for 3seconds, then 0000

11.3.2 Disable electric supply to wheel and drum drive motors (switch off)
Input code Description of display function Display values
1120 Enable function
1121 Switch off function "Disable electric supply for drum drive motor"
Motor remains in position: max. displacement.
1122 Function "Disable electric supply for drum drive motor"

BOMAG
Motor remains in position: max. displacement.

11.4 Settings / Teach / Emergency functions

11.4.1 Changing the machine code

Input code Description of display function Display values
7010 Change "Machine code" see chapter "Change machine code"

11.4.2 Automatic detection of surge currents in travel system

Input code Description of display function Display values
1090 Activate the function see chapt. "Teach travel system surge currents"
1091 Function "Determine surge currents forward" (only Vers.1.07 and 1.08) see chapt. "Teach travel system surge currents"
1092 Function "Determine surge currents reverse" (only Vers.1.07 and 1.08) see chapt. "Teach travel system surge currents"

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11.4.3 Speed detection, trimming of measuring values
Input code Description of display function Display values
1158 Enable function
1159 Activate the function Pulses per 10m. 4000 - 15000

11.4.4 Speed detection, teaching of distance pulses

Technical Manual / Electrics

Input code Description of display function Display values

1160 Permit teach function
1161 Activate the function: Measurement over a travel distance of 5m Pulses read
1162 Activate the function: Measurement over a travel distance of 10m Pulses read
1163 Activate the function: Measurement over a travel distance of 20m Pulses read
1164 Activate the function: Measurement over a travel distance of 50m Pulses read
1165 Activate the function: Measurement over a travel distance of 100m Pulses read

1168 Reset to basic values "saved"

1169

BOMAG
Storing the learned values "saved"

11.4.5 Detection of wheel rotation

Input code Description of display function Display values
1200 Permit teach function
1201 Teach sense of rotation1 Raise travel speed over 10m/min

1
Only optional function! The logical sense of rotation is automatically adjusted

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11.4.6 Steering: Automatic detection of surge currents on steering valve

Input code Description of display function Display values
2000 Activate function "Teach steering start current" see chapter 3.5
2001 Function "Teach steering start current" see chapter 3.5

11.4.7 Steering: Determining the steering stops

2010 Activate function "Teach steering stops" see chapter 3.7
2011 Deactivate function "Teach steering stops" 0000
2012 Function "Accept right hand steering stop" see chapter 3.7
2013 Function "Accept left hand steering stop" see chapter 3.7

11.4.8 Steering: Emergency function

2050 Steering with joystick buttons "OK". In case of steering wheel failure
2051 Steering wioth steering wheel (uncontrolled) "OK". In case of steering angle potentiometer failure

BOMAG
11.4.9 Steering: Other functions
2060 Activates function „Change steering unit“ see chapter 0
2061 Activate: Electric steering unit see chapter 0
2062 Activate: Hydraulic steering unit see chapter 0

11.4.10 Vibration: Cancellation of the vibration permission in dependence on the travel speed

3047 Activate function "Limitation of vibration permission"

3048 Limitation of vibration permission to travel stage 12
3049 Cancelling the limitation of vibration permission

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11.4.11 Plates
3070 Enabling code "Change plate parameters"
3071 Code "Switch on plate operation" Only required if plates have been retrofitted
3072 Code "Switch off plate operation" Only required if plates have been removed
3075 Code "Plate adjustment without sensors" Attention – danger of collision! Use only in case of a sensor fault!
3076 Code "Plate pump energized without plates attached" Only for initial commissioning!
Technical Manual / Electrics

BOMAG
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Service Training WZ – 4

12 Terminology in connection with ESX

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

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

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

Terminal, cable lug

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

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Short circuit to ground

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

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

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

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

Closed loop control

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

Marking Closed loop control Control

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

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Current and voltage measurement

Ohm’s law:
U = R∗I
U = Voltage
I=
R = Resistance U
I = Current R
R=
U
I

Plausibility check
The control (ESX) runs a plausibility check on all inputs. This means the control checks
permanently whether certain state combinations are permitted; e.g. travel lever position forward
and reverse will cause an fault message, because this condition is normally not possible.

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

PWM – digital output

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

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Table of contents
Foreword A1
Documentation A2
General A3

New developments A5

Technical data and adjustment values B1

Maintenance C1
Maintenance chart C2

DEUTZ diesel engine with EMR D1

Service side D2
Starter side D3
Lubrication oil circuit D4
Coolant circuit D5
Fuel system D6
EMR D10
Trouble shooting D22
Diagnose SERDIA D24
Checking and adjusting the valve clearance D26
Assembly of the plug-in injection pump D28
Engine components D44

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

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

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

Electric - Training

Wiring diagram

Hydraulic diagram

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Foreword and novelties
Reliable construction equipment is of greatest advantage for all parties involved:

• for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.

• in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.

• for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.

It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:

• the location of components in the machine eases maintenance work,

• the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.

• the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.

Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.

This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.

This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.

The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .

The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.

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Documentation
For valid BOMAG single drum roller serie -4 :

BW 213 DH-4

with serialnumber of the machine: 58251, 58252, 58253, 58254,

BW 214 DH-4

with serialnumber of the machine: 58258, 58259,

For the BOMAG machines described in this training manual the following documentation is additionally
available:

Attention!

The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.

1. Operating and maintenance instructions

2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.

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General
The new single drum rollers serie -4 from BOMAG are essentially further developments of their
predecessors, the machines of product range serie -3.

These machines have been successfully and reliably used for years on construction sites all over the
world, especially in earth construction and on sanitary landfill sites.

High compaction power and excellent traction are characteristics, which are of utmost importance for
this type of machine.

All components installed in these machines are manufactured in series production and are subjected to
stringent quality tests. This guarantees a high level of reliability and safety.

As with many other BOMAG products, and here especially with the large single drum rollers of the new
generation, we have decided to use the same successful drive concept with diesel engine (water cooled)
and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the
engine directly to drum, drive wheels and steering.

The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by
slow running radial piston motors.

On construction machines the work place of the operator is of utmost importance. Under such working
conditions the health and safety of the operator must be the greatest concern.

The cabin is very spacious and clearly arranged. The driver’s seat is very comfortable and can be
individually adjusted for every operator, even for his weight.

All control elements and gauges are within the reach and in the sight of the operator.

A monitoring display with light emitting diodes and clear pictograms informs the operator about any
operating faults. The operator is therefore always informed about the present condition of the machine.

The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens,
as well as a heated rear windscreen, offers clear vision to all sides.

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Important characteristics of the new generation of single drum rollers are

• strong ROPS/FOPS according to SAE-standard

• wear free service brake by closed hydrostatic travel circuits

• disc brakes in axle and drum drive motor serve as parking and emergency brakes

• high stability due to low centre of gravity and the use of an articulated joint

• operating safety due to the use of monitoring boards for all important system data

• automatic engine shut-down at too engine temperature, too low hydraulic oil level (when reaching the
lowest permissible level the engine will be shut down after 20 seconds) and too low engine oil
pressure.

The new single drum roller serie -4 are well designed down to the smallest detail, so that they can meet
the toughest demands on large scale construction sites all over the world.

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Novelties
The multi-function travel lever and the display

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Control, operation, data collector,

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Diesel engine with EMR

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Travel System

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Technical data and adjustment values
The following pages contain technical data valid at the date of printing (see front page of this manual).

Attention!

The currently valid technical data and adjustment values can be taken from the BOMAG Intranet
or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.

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Status: 2005-01-28

Product type: BW 213 DH Serie 4

Type No.: 582 51
Serial numbers from: 101 581 51 1001

Engine:
Manufacturer: Deutz
Type: BF4M1013EC EMR
Combustion principle: 4-stroke-Diesel
Cooling: Water
Number of cylinders: 4
Power acc. to ISO 9249: 114 kW
Power data at nominal speed of: 2200 1/min
Low idle speed: 900+/-10 1/min
High idle speed: 2200 +/-10 1/min
Spec. fuel consumption: 235 g/kWh
Valve clearance, inlet: 0,3 mm
Valve clearance, outlet: 0,5 mm
Opening pressure, injection valves: 275 bar
Starter voltage: 12 V
Starter power: 3,1 kW

Travel pump:
Manufacturer: Sauer-Danfoss
Type: 90R 075 (EP)
System: Axial piston-swash plate
Max. displacement: 75 cm3 /U
Max. flow ratio: 165,0 l/min
High pressure limitation: 400 bar
Charge pressure, high idle: 25+/-1 bar

Reduction gear, drum:

Manufacturer: Sauer-Danfoss
Type: CR 31
Transmission ratio: 45,6

Travel motor, rear:

Manufacturer: Sauer-Danfoss
Type: 51D110 (EP)
System: Axial piston-bent axle
Max. displacement (stage 1): 110 cm 3/U
Min. displacement (stage 2): 55,3 cm3 /U
Perm. leak oil quantity: 2 l/min

Drum drive:
Manufacturer: Sauer-Danfoss

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Type: 51C 110 (EP)

System: Axial piston-swash plate
Displacement stage 1: 110 cm 3/U
Displacement stage 2: 31,4 cm3 /U
Perm. leak oil quantity: 2 l/min

Vibration pump:
Manufacturer: Sauer-Danfoss
Type: 90R 075 (EP)
System: Axial piston-swash plate
Max. displacement: 75 cm3 /U
Starting pressure: 365+/-65 bar
Operating pressure, soil dependent: ca.100 bar

Vibration motor:
Manufacturer: Bosch-Rexroth
Type: A2FM 56 HDD
System: Axial piston-bent axle
Displacement: 56 cm3 /U
Frequency: 30-40 Hz
Amplitude: 2,0/0,9 mm

Steering and charge pump:

Manufacturer: Bosch-Rexroth
Type: HY/ZFS11/16
System: Gear pump
Displacement: 16 cm3 /U
Max. steering pressure: 200+/-15 bar

Steering valve:
Manufacturer: Sauer-Danfoss
Type: OSPC 500 ON
System: Rotary valve
DBV - Einstellung (?): 175 bar
Schockventile (?): 240 bar

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

Filling capacities:
Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on
Ethane-diol-basis)
Engine oil: 13 l (SAE 15W-40, API CG-4 (for details see
maintenance manual))

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Hydraulic oil: 60 l (HVLP 46 VI 150)

Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF)
Rear axle: 1,9 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs: 1,85 l (SAE 90 EP, API GL 5)
Rear axle, transmission: 11 l (SAE 90 EP, API GL 5)
Reduction gear, drum: 3,2 l (SAE 90 EP, API GL 5)
AC refrigerant: 1400 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG Öl)

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Maintenance
Single drum rollers are heavy-duty construction machines for extremely difficult tasks in earth
construction. To be able to meet these demands the machines must always be ready to be loaded up
to their limits. Furthermore, all safety installations, protections and guards must always be in place and
fully functional.

Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably
higher functional safety, but also prolongs the lifetime of the machine and of important components.

The time required for thorough maintenance is only minor when being compared with the malfunctions
and faults that may occur if these instructions are not observed.

The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance
interval all the work for shorter preceding intervals must also be performed. During the 2000 hours
interval you must also perform the work described for the service intervals after 50, 250 and 500 hours.

During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and
lubricants (oils, fuels, grease etc.).

The designation specified under No: in the first column of the maintenance chart refers to the
corresponding number of the service work to be performed, as specified in the operating and
maintenance instructions. This also helps to find detailed information on the individual maintenance
tasks.

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Maintenance table

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Deutz diesel engine
The single drum rollers of product range BW 213/214 DH/PDH-4 are powered by a Deutz diesel engine
of series BF4M 1013EC COM2 with electronic engine management (EMR). The engine cooling system
uses an external radiator. The cooling fan is mounted to the engine fan block and is directly driven by
the engine.

This automotive engine is characterized by the following features:

• short and compact design,

• low noise level,

• almost vibration-free running,

• low fuel consumption,

• low exhaust emissions (EPA II),

• high power reserves and

• good access to all service points.

Crankcase and cylinders of this engine are made of alloyed cast iron. This provides strength and
ensures high wear resistance.

The engine is equipped with wet cylinder liners, which can be easily changed in case of a repair.

The forged steel conrods are fitted with compensation weights near the conrod bearing seats. These
weights compensate manufacturing tolerances with respect to weight and centre of gravity.

The pistons are made of an aluminium alloy. The combustion chamber recess is slightly offset from the
middle at its side walls are inclined for 10° towards the inside. All pistons are fitted with three piston rings
and a cast iron ring carrier for the first ring. The pistons are lubricated by an oil mist.

The forged crankshaft is equipped with integrated counterweights.

The block-type cylinder head is made of cast steel. Each cylinder is fitted with one intake and one
exhaust valve. The valve guides are shrunk into the cylinder head. The valve seat rings are made of
high-grade steel and are also shrink fitted.

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Cross-sectional total view

Fig. 1: Deutz BFM 1013

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Service side

3 4
2
5

6
14

9 8
13 12 11 10

Fig. 2: Service side BFM1013

1 Oil filler neck 8 Fuel pump

2 Valve, boost fuel supply 9 Engine mounting
3 Engine solenoid 10 Fuel filter
4 Oil pressure switch 11 Lubrication oil filter
5 Cooling air blower 12 Oil sump
6 Coolant pump 13 Dipstick
7 V-belt pulley 14 Steering/charge pump

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Starter side

3
1

Fig. 3: Starter side

1 Flywheel
2 Ground cable
3 Starter
4 Turbo charger
5 Generator
6 Coolant temperature switch

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Lubrication oil circuit
3 4 5 6 7 8 9 10 11 12 13 14 15

2 1 22 21 20 19 18 17 16

Fig. 4: Lubrication oil circuit

1 Oil sump 12 Piston cooling nozzle

2 Return flow turbo charger to crankcase 13 Camshaft bearing
3 Turbo charger 14 Main oil channel
4 Oil line to turbo charger 15 Lubrication oil cooler
5 Line to mass balance wheel (2 x) 16 Lubrication oil pump
6 Oil pressure sensor 17 Pressure relief valve
7 Valve with pulse lubrication 18 Leak oil return line
8 Push rod, oil supply to rocker arms 19 Lubrication oil filter
9 Line to spray nozzles 20 Suction line
10 Rocker arm 21 Crankshaft bearing
11 Return flow to oil sump 22 Conrod bearing

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Lubrication oil circuit

3 1

5 4

Fig. 5: Lubrication oil circuit

1 Cooler
2 To cooler
3 From cooler
4 Coolant pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder head cooling
8 Ventilation connection between cylinder head and heat exchanger

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Fuelsystem
7

1a

1b

1c

Fuel tank

1d

Fig. 6: Fuel system

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Legend Fig. 6:
1a Manual fuel pump
1b Fuel prefilter
1c Water separator
1d) Water proportion sensor
2 Feed to fuel lift pump
3 Fuel lift pump
4 Connecting line lift pump – main filter (fuel pre-pressure up to 10 bar)
5 Main fuel filter (pressure resistant)
6 Connecting line main filter – supply for injection pump
7 Single injection pump
8 High pressure line
9 Injection nozzle
10 Leakage line
11 Pressure retaining valve - 5 bar
12 Return flow to tank

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Fuel prefilter with water separator

1
2

Fig. 7: Fuel prefilter with water separator

1) Hand pump
2) Breather valve
3 Filter element
4) Water and dirt collecting bowl
5 Drain valve
6 Electric connection for water level sensor

The fuel pre-filter / wate rseparator consists mainly of:

• the dirt / water sediment bowl with water level warning sensor

• and the filter element

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Function:

The fuel lift pump draws fuel through both filters.

The water resistant filter element retains remaining smaller dirt and water particles.

Once the water level reaches the height of the warning connections, the warning light in the dashboard
lights up.

Draining off water or fuel:

If the filter element is clogged before a service is due (indicated by e.g. a power drop), the filter may be
regenerated as follows to keep up operation of the engine:

• Open the bleeding screw (this applies atmospheric pressure to the filter element and releases bigger
dirt particles from the bottom side of the filter, which will then sink down.

• Open the drain valve and let approx. 0.5 l of fuel run out. The fuel above the filter element presses
through the filter element and cleans the underside of the filter element from dirt.

• Close the drain valve.

Draining off bigger dirt particles or sludge:

• Unscrew the water separator housing.

Bleed the system with the manual fuel pump and then tighten the bleeding screw.

Main fuel filter

Attention!

The main fuel filter is subjected to approx. 10 bar fuel pre-pressure from the fuel lift pump. This
pressure is considerably higher than on other engines. For this reason only original filter
elements must be used. Filter elements of similar design or with adequate dimensions are not
necessarily pressure resistant!

A filter element of insufficient pressure resistance will be damaged by the high pressure and will
disintegrate. This causes severe damage to the injection system!

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Electronic engine control EMR II

The Deutz engines in single drum roller BW 213 / 214 DH-4 are equipped with an electronic engine
management (Deutz EMR II).

The most important benefits of this system are:

• shorter response times compared with mechanically controlled engines, i.e. the response times are
significantly better. This improvement is achieved without increasing the acceleration fumes or the
fuel consumption.

• electronic idle speed control enabling a higher starting torque

• no mechanical throttle control (light moving, maintenance free, less susceptible for faults)

• in comparison with the first version of the Deutz-EMR this system has the essential advantage that
faults can be indicated directly by the fault indicator light on the machine in form of a flashing code,
with the necessity of additional software.

The EMR-injection system is based on the approved Deutz-injection system of series 1012/1013 with
individual injection pumps for each cylinder. However, the fuel quantity per stroke is not regulated
mechanically via a throttle cable, but is controlled by the EMR II-system by means of an electromagnetic
actuator acting on the governor rod.

The essential components of the EMR II-system for engine speed control are:

• EMR II control unit [A48] at the left under the operator's stand.

• The control unit processes the input signals from:

• displacement measuring system in the EMR actuator [Y 137] (current position of the injection pump
control rod)

• the coolant temperature sensor [B 113] on the cylinder head

• the rotary speed sensor [B 114] on the camshaft

• the engine oil pressure sensor [B 88] on the oil filter housing

• the charge air pressure and charge air temperature sensor [B 115] connected to the intake manifold

• The cold start device (heating flange) is additionally triggered by the EMR II in dependence on the
coolant temperature

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These input signals are processed, sent as output signals to the EMR actuator Y 137 and there they are
converted to the required fuel quantity per stroke.

In ECO-mode (position "AUTO") the travel lever determines the engine speed setpoint. The control unit
compares this nominal value with the actual speed value detected by the engine speed sensor. If the
nominal value corresponds with the actual value, the signal to the EMR actuator will remain unchanged.

However, if the nominal speed deviates from the actual speed (e.g. when changing the travel lever
position or under higher load), the control unit uses the current turbo charger pressure and the coolant
temperature to determine the necessary change in fuel quantity to achieve the nominal speed value.
The control unit then sends a signal to the EMR actuator to change the control rod position and thereby
the engine speed.

This automatic speed adaptation only takes place in ECO-mode

(i.e. if the throttle control is in "AUTO" position.)

Control unit EMR II

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Plug, engine side [X31] Plug on vehicle [X30]

Control unit

EMR II

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Pin assignment X 31 19 16 8 12 21 25 23 10 3 4 6
Technical Manual / DH/PDH

14 17 18 9 13 22 20 21 11 2 1 5 7

Connecting cable
Engine wiring harness
Control unit EMR II

EMR central plug engine [X57] Pin assignment complies with X 31

BOMAG
EMR engine wiring harness
Connection overview EMR sensors/actuators on engine

EMR-actuator Temperature Speed Pressure Pressure Speed

Y 137 Coolant Flywheel Engine oil Charge air
B 113 B 114 B 88 B 115 B 130
and temp.
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The EMR control unit is located above the central electrics under the operator's stand in the access
area. This is the computer unit of the EMR and it processes the input signals from the sensors to output
signals for the EMR actuator (governor rod).

1
3
2

Pos. Designation Pos. in wiring Deutz Measuring

diagram designation values
1 Control unit EMR II A 48 EMR II
2 Plug, engine side X 31
3 Plug, vehicle side X 30

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Plug assignment X 31 (engine plug on EMR control unit)

Pos. Deutz designation Description

1 Spare Spare
2 not used
3 Output: Digital 4 Switching output heating flange (ground!)
4 empty
5 Input temp. (option) Charge air temperature
6 empty
7 empty
8 GND Reference potential for signal pin 9 coolant
temperature sensor B 113
9 Input: Analogue 7 Analogue input coolant temperature
sensor B 113
10 GND Reference potential Pin 11 crankshaft
speed sensor B 130
11 Input: Speed 2 Digital input rotary speed sensor
crankshaft B 130
12 GND Reference potential Pin 13 camshaft
speed sensor B 114
13 Input: Speed 1 Digital input rotary speed sensor camshaft
B 114
14 STG - PWM-output, signal for EMR-actuator coil
Y 137
15 STG + PWM-output, signal for EMR-actuator coil
Y 137
16 Screen not used
17 RF - common connection for reference and
measuring coil EMR-actuator Y 137
18 RF REF analogue input, measuring signal of
reference coil of EMR-actuator Y 137
19 RF MESS analogue input, measuring signal of
measuring coil of EMR-actuator Y 137
20 GND Reference potential for signal on pin 21, oil
pressure sensor B 88
21 Input: Analogue 4 Analogue input, sensor signal oil pressure
sensor B 88
22 +5V REF + 5 V reference voltage for signal on Pin
21, oil pressure sensor S 88
23 GND Reference potential for signal on pin 24,
boost pressure sensor B 115
24 Input: Analogue 2 Analogue input, sensor signal boost
pressure B 115
25 + 5V LDA + 5 V reference voltage for signal on pin 24
(max. 15mA), boost pressure sensor B 115

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Plug assignment X 30 (vehicle plug on EMR control unit)

Pos. Designation Description

1 U Batt - Vehicle ground through X1:182
2
3
4
5 Output: Digital/ empty
PWM 1
6 Spare Spare
7 NC empty
8 NC empty
9 NC empty
10 L-line to diagnostics plug EMR, X32:L
11 K-line to diagnostics plug EMR, X32:K
12 CAN high X1:180, CAN2-
13 CAN low X1:181, CAN2+
14 U Batt + Power supply, vehicle voltage (ignition
on) from relay K11, X1:179
15
16 Output: Digital/ empty
PWM/Frequency
17 Ground empty
18 Input: digital/PWM empty
1
19 Input: digital / empty
analogue
20 Input: digital / empty
analogue
21 Input: digital/PWM empty
2
22
23
24
25

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EMR actuator Y 137

The EMR actuator is directly connected with the governor rod of the injection pump and moves this rod
by being excited by the signal currents from the EMR control unit. At the same time the actual position
of the actuator is fed back to the EMR control unit. This component is generally a proportional magnet
with integrated path measuring system.

In case of a fault in the path measuring system the engine is shut down and a fault code displayed.

2 Stg+

7
3 RF -

1 Stg+
9
4 RFMeß 6

5 RF Ref

Pin assignment of EMR-actuator looking towards actuator (plug pins mirror inverted)

EMR-actuator

Pos. Designation Pos. in wiring Deutz Measuring

diagram designation values
Pin 1 Signal input actuator coil STG -
Pin 2 Signal input actuator coil STG +
Pin 3 common connection for measuring RF -
and reference coil
Pin 4 Measuring signals measuring coil RF MESS
Pin 5 Measuring signals reference coil RF REF
Pin 6 not used
Pin 7 not used
8 EMR-plug X 57
9 EMR-actuator Y 137

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Temperature sensor B 113

The EMR coolant temperature sensor is mounted to the flywheel end of the engine. The EMR sensor
is the bottom sensor.

The coolant temperature influences the calculated injection quantity of the EMR.
The EMR sensor value is not only used for the EMR itself, but also for the high coolant temperature
control light in the display.

In case of a too high temperature the EMR shuts down the engine and a fault code is displayed.

In case of a sensor failure the display shows a fault code.

Pos. Designation Pos. in wiring Deutz Measuring

diagram designation values
1 EMR temperature sensor for B 113
coolant

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Speed sensors: Camshaft B114 and crankshaft B 130

The sensors for camshaft and crankshaft speeds are installed in the side of the engine block.
These sensors deliver the actual engine speed value for the EMR control unit.

If the engine speed is too high (pushing operation) the governor rod is returned to zero position, until the
speed has dropped to the permissible range.

In case of a sensor failure the engine is shut down and the fault code appears in the display.

With a missing rotary speed signal from standstill the engine will not start, however, no fault message
will be displayed, because the EMR assumes that the engine is at standstill and does therefore not
release any fuel.

The EMR speed sensor has a fixed stop and does not need to be adjusted after installation.

Pos. Designation Pos. in wiring Deutz Measuring

diagram designation values
1 EMR speed sensor camshaft SAE B 114
housing
2 EMR speed sensor crankshaft SAE B 130
housing

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Engine oil pressure sensor B88

The engine oil pressure sensor is mounted on the engine oil filter housing. The oil pressure is
permanently monitored by the EMR.

With a too low engine oil pressure the display shows a fault code.

In case of a too low pressure the EMR shuts down the engine and a fault code is displayed.

In case of a sensor failure the engine keeps on running and the display shows a fault code.

Pin 3 (+ 5 V from EMR)

Pin 2 (Signal)

Pin 1 (AGND)

Ventilation

Pos. Designation Pos. in wiring Deutz Measuring

diagram designation values
1 EMR oil pressure sensor B 88

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Charge air pressure and temperature sensor B 115

The Deutz engine BF4M1013EC (EMR) is fitted with a combination sensor for charge air pressure and
charge air temperature. This sensor measures the pressure and temperature in the intake manifold. The
sensor itself is located on the intake manifold. Charge air pressure and charge air temperature inform
the EMR about the actual load state of the engine.

Pos. Designation Pos. in wiring Deutz Measuring

diagram designation values
1 EMR charge air pressure and B 115
temperature sensor

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Heating flange R 19

Instead of glow plugs this engine is fitted with a heating flange before the intake air manifold, which
heats up the passing air with resistance heated wires when the engine is cold. This system is electrically
supplied via high current relay K14, located to the left next to the engine. This high current relay is
triggered by the EMR-control unit (ground triggering) in dependence on the coolant temperature.

2
1

Pos. Designation Pos. in wiring Deutz Measuring

diagram designation values
1 Heating flange R 19
2 High current relay K14

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Trouble shooting

The display shows the fault codes

For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)

All electric faults are mainly shown by the display

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Possible diagnostics with SERDIA

with fault code 5140: a fault diagnose is only possible via SERDIA

SERDIA is a software program from Deutz which can be used in connection with a laptop computer to
perform more detailed fault analyses, especially reading out of the error log.

This displays information on

• Fault location (e.g. ’sensor’, ’coolant temperature sensor’)

• Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)

• Environmental data / operating data (speed and operating hours at the time of the last fault
occurrence)

• Number of fault locations

• Frequency of fault

• Fault status (active – fault present / passive- fault no longer present)

Fault messages for non-present / rectified faults can be deleted with SERDIA.

Further display possibilities:

• Function test: With the engine shut down the control outputs and the travel of the governor rod can
be activated.

• Assignment of inputs/outputs Display of the current input/output assignment of the EMR-control

• Representation of measuring values: There are a lot of measuring values available which can be
used if no EMR II fault is present (starting performance, engine sawing, lack of power).

Operation of SERDIA is described in a separate operation manual.

Connection of SERDIA

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Possible diagnostics with SERDIA

with fault code 5140: a fault diagnose is only possible via SERDIA

SERDIA is a software program from Deutz which can be used in connection with a laptop computer to
perform more detailed fault analyses, especially reading out of the error log.

This displays information on

• Fault location (e.g. ’sensor’, ’coolant temperature sensor’)

• Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)

• Environmental data / operating data (speed and operating hours at the time of the last fault
occurrence)

• Number of fault locations

• Frequency of fault

• Fault status (active – fault present / passive- fault no longer present)

Fault messages for non-present / rectified faults can be deleted with SERDIA.

Further display possibilities:

• Function test: With the engine shut down the control outputs and the travel of the governor rod can
be activated.

• Assignment of inputs/outputs Display of the current input/output assignment of the EMR-control

• Representation of measuring values: There are a lot of measuring values available which can be
used if no EMR II fault is present (starting performance, engine sawing, lack of power).

Operation of SERDIA is described in a separate operation manual.

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For this purpose the PC or Laptop is connected to the diagnostic interface with a special interface cable.

This connection is located

in the electric junction box.

Replacement of system
components

• Replacement of the EMR II-control unit:

Each control unit is clearly designated to the engine, in accordance with the respective application.
In case of a replacement the control unit therefore needs to be completed with the engine specific
data set. When ordering a new control unit you must not only specify the part-number, but also the
engine serial number (see sticker on EMR-control unit).

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

• Replacement of the EMR actuator (Y137)

On engines of types 1013 and 2012 the actuators can be replaced without any additional
programming of the control unit.

• Replacement of other EMR-components

All other EMR-components (sensors etc.) must not be repaired, but should only be replaced if they
are faulty. Programming of the control unit is not required

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Checking and adjusting the valve clearance

Excessive or insufficient valve clearance can cause failure of the engine as a result of mechanical and
thermal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the
intervals specified in the operating and maintenance instructions.

Note: The valve clearance must be checked and adjusted when the engine is cold.

Intake valve: = 0.3 mm

Exhaust valve= 0.5 mm

• Turn the crankshaft until both valves on cylinder 1 are overlapping (the exhaust valve is not yet
closed, the intake valve starts to open).

Flywheel
side

1 2 3 4

Fig. 1: Crankshaft position 1

• Check and adjust the valve clearance by following the black marking in the adjustment schematics.
For control purposes mark the respective rocker arm with chalk.

Flywheel
side

1 2 3 4

Fig. 2: Crankshaft position 2

• Turn the crankshaft one full turn (360°) further. Check

and adjust the valve clearance by following the black marking in the adjustment schematics.

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Explanation of pictograms

During the following work the following pictograms are used for the reason of simplicity:

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plug-in injection pump

Deutz diesel engines of product range 2012 are equipped with plug-in injection pumps of series PF 33
from Bosch.

The concept of the plug-in fuel injection pumps enables the realization of high injection pressures in
connection with extremely short injection lines, which contributes to a high hydraulic stiffness of the
injection system. This in turn provides the prerequisite for low exhaust emission values (soot) in
combination with a low fuel consumption.

Plug-in fuel injection pumps have the following plunger dimensions:

• Stroke 12 mm

• Diameter 9 mm

Cavitation in the injection lines and injection overrun, which is normally associated with high pressures,
is prevented by a return flow nozzle arranged after the pressure valve
The constant volume relief is 50 mm³.

Assembling the plug-type injection pumps

The adjustment of the injection pump timing (FB) affects:

• the fuel consumption,

• the power

• the exhaust emission

of the engine.

On engines of series 2012 the start of delivery is adjusted without tolerance. The start of delivery is
entered in degree of crank angle measured from the top dead centre of the piston and depends on
application, power and speed setting of the engine.

The plug-in injection pump is in position of start of delivery when the plunger just closes the fuel supply
bore in the plunger sleeve.

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On engines with inline injection pumps the engine drive is turned to start of delivery position and closing
of the fuel supply bore is determined by means of a high pressure pump. Occurring tolerances are
compensated in the coupling of the injection pump drive, whereby the injection pump camshaft is turned
to start of delivery position against the fixed engine drive.

The injection pump cams on engines of series 2012 are arranged on the camshaft of the engine. For
this reason the conventional adjustment method for the start of delivery cannot be used.

The start of delivery of the injection pump must be adjusted using the new method.

For this the conventional adjustment method is subdivided into length measurements of individual
engine parts and calculations.

The permissible manufacturing tolerances for the components

• cylinder crankcase,

• camshaft,

• plunger

• plug-in injection pump

are measured and eliminated by the adjustment of the start of delivery.

However, in cases of interest for BOMAG engineers the engine will not be overhauled completely, but
individual injection pumps will be replaced.

Crankcase, camshaft and plunger remain unchanged.

This results in a certain installation measurement for the engine drive, which is stamped on the engine
type plate.

In column „EP“ it is stamped as „CODE“ for each cylinder.

Note:
If an injection pump and/or nozzle is replaced, the respective high pressure line between pump and
nozzle must also be replaced..

1. Remove crankcase ventilation and cylinder

head cover.

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Fig. 3:

2. Remove the engine solenoid

Fig. 4:

3. Insert the pressing device, WILBÄR No. 100

830 carefully into the groove in the governor
rod and tighten.

Fig. 5:

4. Turn the knurled fastening screw to press the

governor rod to stop position.

Note:

Tighten the knurled fastening screw by hand.

Fig. 6:

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5. Set the cylinder of the injection pump to be
replaced to ignition top dead centre (valves
overlapping). Then turn the crankshaft
approx. 120° against the sense of rotation.

Note:

View on flywheel

Fig. 7:

6. Remove injection line and injection pump.

Fig. 8:

7. Take the compensation shim carefully out with

the rod magnet.

Fig. 9:

Determine the thickness of the new compensation shim:

Determination of the compensation shim thickness when replacing plug-in fuel injection pumps

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On the engine type plate column - EP – contains a code for the plug-in fuel injection pump for each
cylinder.

295

Each line represents 1 cylinder

e.g. 1st line = cylinder 1
2. line = cylinder 2 etc.

Fig. 10: Injection pump code BFM 2012

The EP-code is used to determine the installation measurement to be corrected „Ek“ from table 1.

EK EP EK EP EK EP EK EP
(mm) code (mm) code (mm) code (mm) code
119,250 230 119,850 254 120,450 278 121,050 302
119,275 231 119,875 255 120,475 279 121,075 303
119,300 232 119,900 256 120,500 280 121,100 304
119,325 233 119,925 257 120,525 281 121,125 305

119,350 234 119,950 258 120,550 282 121,150 306

119,375 235 119,975 259 120,575 283 121,175 307
119,400 236 120,000 260 120,600 284 121,200 308
119,425 237 120,025 261 120,625 285 121,225 309

119,450 238 120,050 262 120,650 286 121,250 310

119,475 239 121,075 263 120,675 287 121,275 311
119,500 240 120,100 264 120,700 288 121,300 312
119,525 241 120,125 265 120,725 289 121,325 313

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119,550 242 120,150 266 120,750 290 121,350 314
119,575 243 120,175 267 120,775 291 121,375 315
119,600 244 120,200 268 120,800 292
119,625 245 120,225 269 120,825 293

119,650 246 120,250 270 120,850 294

119,675 247 120,275 271 120,875 295
119,700 248 120,300 272 120,900 296
119,725 249 120,325 273 120,925 297

119,750 250 120,350 274 120,950 298

119,775 251 120,375 275 120,975 299
119,800 252 120,400 276 121,000 300
119,825 253 120,425 277 121,025 301

Fig. 11: Injection pump code table BFM 2012

Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from
table 1.

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During the manufacture of the plug-in fuel injection pump the high pressure method is used to determine
the wear in the fuel supply bore. In this position – injection pump plunger in start of fuel delivery position
- the distance between pump contact face and plunger foot contact face is measured.

Measurement "A" in 1/100 mm has been written on the pump with an electric marker.

64

Fig. 12: Plunger code inscription

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A=XXX

Fig. 13: Individual injection pump

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Measurement "A" specifies by how many 1/100 mm the gap between contact area on cylinder
crankcase and plunger foot is longer than the hydraulic base measurement Lo.

Lo
A = XX

A/100

Fig. 14: Presentation of measurement „A“

• Lo = 117,5 mm - BFM 2012

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Ek Lo+A/100

Z
Ts

Fig. 15: Drive in start of delivery position after determination of „Ts“

The plug-in fuel injection pump is now positively connected with the drive, which has been set to start
of delivery by inserting a compensation shim "Z" of calibrated thickness..

The illustration explains that according to calculation:

(Ek) - (Lo + A/100)

there is a gap „Ts“ between injection pump plunger foot and roller plunger. This gap has to be
compensated with a compensation shim "Z" of appropriate (calculated) thickness.

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Theoretical Compensation Theoretical Compensation

thickness shim thickness shim
„Ts“ thickness „Ss“ „Ts“ 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 - 3.850 3.8
2.35 - 2.449 2.4
Table 1: Shims 2012

For the determination of the theoretical shim thickness „Ts“ it is also necessary to determine
measurement Lo + A/100 of the new fuel injection pump, which must then be subtracted from the
corrected injection pump measurement Ek.

Ts = Ek - (Lo + A/100) [mm]

The real compensation shim thickness „Ss“ is determined with the help of table 2.

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Exemplary calculation for BFM 2012

EP-code read off engine type plate: 295

• see table 1

corrected injection pump measurement „Ek“: 120,875 mm

Lo = 117,5 mm (fixed measurement)

Value for A/100 read off new injection pump A/100 = 42

• Ts = Ek - (Lo + A/100)
Ts = 120,875 mm - (117,5 + 42/100 mm)
Ts = 2.995 mm

see also table 1

Ts = 3,0 mm

8. P?lace the new calculated compensation shim

on the roller plunger.

Fig. 16:

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9. Turn the injection pump control lever to
approx. middle position.

Fig. 17:

10. Apply some oil to the locating bore in the

crankcase and the O-rings on the injection
pump. Carefully insert the injection pump
control lever into the governor rod.

Fig. 18:

11. Attach the flange.

Note:

The chamfer must face towards the injection

pump body

Fig. 19:

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12. Slightly oil the screws and tighten them
evenly with 5Nm.

Fig. 20:

13. Loosen the screws again for 60°.

Fig. 21:

14. Carefully turn the injection pump with and

open end spanner in anti-clockwise direction
against the noticeable stop

Fig. 22:

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15. Tighten the screws again for 60° and
continue in stages with tightening torques of
7 Nm, 10 Nm and 30 Nm.

Note:

Start with the outer screw, viewed from the

flywheel. (see arrow).

Fig. 23:

16. Back out the knurled screw of the pressing

device, remove the pressing device.

17. Reinstall the engine solenoid with a new O-

ring.

18. Reinstall the cylinder head cover. Tightening

torque: 9 +/-1 Nm.

Note:

If necessary replace the gasket.

Fig. 24:

19. Slightly oil the O-ring of the crankcase ventilation. Reassemble the crankcase ventilation. Tightening
torque 9 +/- 1Nm

Note: If necessary replace the gasket.

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Explanation of pictograms

During the following work the following pictograms are used for the reason of simplicity:

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Tools

The following tools can be ordered from the respective supplier (in brackets) under the stated part-
number.

For tools from Hazet and Bosch you should consult your nearest representative, orders to Wilbär should
be addressed to:

Co. Wilbär
P.O. box 140580
D - 42826 Remscheid

Fig. 1

• Pressing device for governor rod 100 830 (Wilbär)

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Auxiliary drive, diesel engine

1
3

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

diagram
1 EMR - central plug X 57
2 Steering and charge pump 09
3 Fuel pre-filter with hand pump

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Starter side, diesel engine

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

diagram
4 Vacuum switch on air filter B 03 Switching point
50mbar

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Exhaust and starter side, diesel engine

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

diagram
5 High current relay for heating flange K 14

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Travel system

15

Charge pressure filter

Charging
from

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

diagram
10 Travel pump, electr.- prop. 90R075 10
12 Drum drive motor electr.-prop. 12
51C110
13 Axle drive motor, electr.-prop. 13
51D110
14 Axle 14
15 Reduction gear CR 31

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

• travel pump with control and safety elements,

• Drum drive motor with reduction gear;

• axle drive motor,

• charge pump (also for vibration circuit),

• hydraulic oil filter (in charge circuit),

• hydraulic oil cooler with thermostat

• hydraulic lines.

Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump. The travel pump is the first pump section, flanged directly to the flywheel side
of the diesel engine.

The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to 425 bar (∆p = 400 bar between low and high
pressure sides).

A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain
oil quantity out of the closed circuit when the machine is driving (∆p between the two sides of the closed
circuit). Leakage in the individual components of the circuit are replaced by the charge circuit through
the boost check valves in the travel pump.

The charge pump inside the vibration pump draws hydraulic oil out of the tank and delivers it through
the hydraulic oil filter to the boost check valves in travel and vibration pump. The return flow from the
steering system also flows through the hydraulic oil filter and is then available for the closed circuit
charging system. The charge circuit also provides the oil for the control functions in the closed circuits
for travel and vibration drive and to release the parking brakes.

Both travel motors and the travel and vibration pumps are electrically proportionately controlled.

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Travel pump

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

4
1 2

Charging

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

diagram
1 Travel pump, electr.- prop. 90R075 10
2 Charge pressure relief valve
3 Control, electr.-prop.
4 Multi-function valve

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

7 1

6
5
Fig. 1: Travel pump

1 Electric prop. control 5 Cylinder block

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

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

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

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

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Cross-sectional view of travel pump

2
4
5
1 3

9
10
8
11

Fig. 2: Cross-sectional view of travel pump

1 Retainer for swash plate 7 Swash plate bearing

2 Sliding block 8 Swash plate guide
3 Control piston 9 Swash plate
4 Servo arm 10 Swashing lever
5 Servo valve
6 Feedback device

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View of the rotating group

4 3
5

Fig. 3: Travel pump, view of the rotating group

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

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Description of function

2 3 4 5 6
1

8 6 7

Fig. 4: Function of travel pump

1 Drive shaft 5 Cylinder block

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

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

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

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

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

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

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

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Tandem pump, connections and adjustment points

38

Thermostat
housing

Fig. 5: Connections and adjustment points

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1 Rear vibration pump connecting plate, turned by 90° !!!
2 Proportional solenoid (vibration pump)
3 Multi-function valve 400 bar (charging and pressure limitation), travel system
4 Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
5 Multi-function valve 400 bar (charging and pressure limitation), travel system
6 Pump flange
7 Port L, leak oil to vibration pump
8 Electr.-prop. control (travel pump)
9 Pressure test port, pilot pressure
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 bar
12 not on EP-pumps
13 Port L2, leak oil to tank
14 Pressure test port MB, high frequency
15 Pressure test port MA, low frequency
16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 Charge pump (only in vibration pump)
19 Port L2, (connection to vibration pump)
20 not on EP-pumps
21 Filter block for charge circuit
22 Multi-function valve 400 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between hydraulic oil tank and charge pump
24 Multi-function valve 400 bar (charging and pressure limitation), vibration low frequency
25 Charge pressure relief valve, vibration pump (fixed setting 40 bar)
26 Filter block for charge circuit
27 Port L1, leak oil port to travel pump
28 Pressure test port MB, high pressure reverse
29 Charge oil from filter
30 Pressure test port MA, high pressure forward
31 High pressure port A, high pressure forward
Thermostat housing:
32 Port C, from solenoid valve for brake/speed range selection
33 Leak oil port D, leak oil from axle drive motor
34 Leak oil port A, leak oil from travel pump
35 Leak oil port G, leak oil from drum drive motor
36 Leak oil port F, leak oil from vibration motor
37 Leak oil port B, leak oil to oil cooler

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servo control

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

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

Servo cylinder

Control piston

Sliding block

Servo arm

Control piston in pump

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

• when shutting the engine down,

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

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Multi-function valves

High pressure limitation

Pumps of series 90 are equipped with a follower valve, which activates a pressure override and a
pressure relief valve, one after the other.

1 2

3
A

6 5

B
4

Fig. 6: Multi-function valves

1 to the control 6 Drive shaft

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

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

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

2 3
4
5
1

6
9 7
8
10
11

Fig. 7: Multi-function valve, details

1 Reducing fitting 7 Check valve

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

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

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

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

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Charge pressure relief valve

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

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

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

When parking the machine on level ground with the engine running, the pressures in both

sides of the closed circuit are identical (charge pressure).

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Axle drive motor

The axle drive motor is a swash plate controlled Sauer-Danfoss axial piston motor of series 51 D 110
with an electrical proportional control for variable displacement.
HD-Pump Brake valve
Charge pressure

5
4
2

Leak
oil

HD-Pump

Fig. 1Hydraulic diagram, axle drive motor

1 Motor drive
2 Control piston
3 Proportional control with proportional solenoid
4 Flushing valve with flushing pressure limitation valve
5 Axle with brake
6) Rotary speed sensor (flange sensor)

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.

5 7 8

6
9

11
10
4
2

Fig. 2: Axle drive motor,

1 Control piston 7 Cylinder block

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

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Function

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

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

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

Control

The motor is electric-proportionally controlled.

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

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

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

The displacement is changed by a control piston, which is tightly connected with the valve segment.

The front travel motor (drum drive) also is an axial travel motor 51C110
from Sauer-Danfoss.

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Flushing valve

Fig. 8Cross-section of flushing valve

1 Flushing spool
2 Flushing pressure relief valve

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

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

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

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Manual releasing of brake on axle drive

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

Fig. 9: Manual releasing of rear axle brakes

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

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

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

Attention!

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

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

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Drum drive motor 51C110 with reduction gear CR 31

The drums on the DH-4 and PDH-4 versions are driven by a swash plate operated Sauer axial piston
motor 51C110. This motor is almost identical with the rear axle motor. Another detailed description at
this point is therefore not necessary.

2
3 4
1

10 8
9

Fig. 10: Reduction gear CR 31

1 Travel motor 6 Sun gear

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

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

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Brake control

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

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

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

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

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Manual drum drive brake release (in the reduction gear)
Brake releasing device
in operation position

Brake releasing device in

position “brake manually
released”

For manual brake release both screws on the drum drive reduction gear (marked with arrow) must be
turned in uniformly, until the drum is able to rotate freely.

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Travel circuit with drum drive motor 51C110 and CR 31 (position of
components)

2
9
Travel lever
forward

3
8

4
7 5

n
6 ti o
ec 1 Travel pump
l dir 2 Vibration pump
a ve
Tr 3 Hydraulic oil filter
4 Rear axle
High pressure 5 Axle drive motor
6 Reduction gear
Low pressure
7 Drum drive motor
Charge pressure 8 Hydraulic oil tank
Leak oil 9 Travel lever

Fig. 11: Travel circuit with 51 C 110 and CR 31

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Brake control BW 213 (with Sauer motor 51C110 and CR 31)

Brake valve

Charge pressure
Brake releasing pressure
Leak oil

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Test and adjustment points, travel system

Charge pressure filter and travel pump

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

diagram
1 charge oil filter 07
2 Charge oil filter pressure differential B21 ∆p 3,5 bar
switch
3 Pressure test port, charge pressure MA 26+/-3 bar
4 Travel pump - pressure test port 10 / A / MD max. 426 bar
Travel pressure forward
5 Test port travel pump forward A 10 / A

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Travel pump

2
2
3

1
1

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

diagram
1 Travel pump - pressure test port 10 / B / MC max.426 bar
Travel pressure reverse
2 Prop. solenoid travel forward Bl.004 / Y17 / X16 12V / 0,4-1,2 A
3 Prop. solenoid travel reverse Bl.004 / Y16 / X15 12V / 0,4-1,2 A

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Travel and vibration pump

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

diagram
1 Test port travel pump reverse B 10 / B
2 Pressure test port, charge pressure MA 26+/-3 bar

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Travel motor (drum drive)

3 4

5
2 1
3
2
4 1

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

diagram
1 Pressure travel forward 12 - A
2 Pressure travel reverse 12 - B
3 Port X X1 approx. 26bar
4 Prop. solenoid Y30 12V / 0,4-1,2 A
5 Speed flange sensor PPU B59

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Service Training
Travel motor (axle drive)

2
1

3
5

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

diagram
1 Prop. solenoid Y 31 12V / 0,4-1,2 A
2 Port X X1 approx. 26bar
3 Travel pressure sensor B 112 26 -426 bar
4 High pressure travel pump forward 13 - B
and further to drum drive motor
5 High pressure travel pump reverse 13 - A
and further to drum drive motor
6 Speed sensor (flange sensor) B 60

BW 213 / 214 DH / PDH-4

- E 29 -

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Service Training
Speed sensor and travel pressure sensor

NEW : Speed flange sensors in both travel motors and a travel

pressure sensor at the front left hand side under the operator's platform!

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

diagram
1 Speed flange sensor PPU axle B60
motor
1 Speed flange sensor PPU drum B59
drive motor
2 Travel pressure sensor in frame, B112
front left under operator's platform

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- E 30 -

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Brake valve

3 4
1

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

diagram
1 Brake valve Y 04 08 0V closed 12V
open

BW 213 / 214 DH / PDH-4

- E 31 -

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Travel lever

Multi-function travel lever

For a detailed description of the travel lever buttons

please refer to the page on "Electrics" (Service Training Electrics)

BW 213 / 214 DH / PDH-4

- E 32 -

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Service Training
Trouble shooting

The display shows the fault codes

For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)

All electric faults are mainly shown by the display

The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.

BW 213 / 214 DH / PDH-4

- E 33 -

008 913 76 BOMAG 319

4.3 Technical Manual / DH/PDH

Service Training
Procedure:

The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.

Maschine fährt mit Fahrhebel in Stellung 'Neutral'

Max.Fahrgeschwindigkeit wird nicht erreicht
Maschine fährt nur in eine Fahrtrichtung
Maschine fährt nicht (vor und zurück)
FEHLERSUCHE FAHRANTRIEB

Hydrauliköl wird zu heiss

BW 213/214 DH/PDH-4
SYMPTOME

MÖGLICHE URSACHEN
Bremsventil (elektrisch/mechanisch/hydraulisch) 1
Bremse Achse/Bandagenmotor (mechanisch/hydraulisch) 2 2 3
Fahrpropverstellung /defekt/Verkabelung 1
Speisepumpe / Speisedruckbegrenzungsventil(e)
2 3
verschmutzt/defekt
Pumpenansteuerung (Servoverstellung) 2 1 2 3
Druckabschneidung/ Hochdruckbegrenzung Fahrpumpe
3 2 3 3
verschmutzt/verstellt/defekt
Fahrhebel 1 2
Nullage Fahrpumpe 3 3
Fahrpumpe(n) defekt 3 3 2
Stellventil Fahrmotoren (elektrisch / mechanisch / hydraulisch) 1 2
Spülventil Fahrmotoren hängt 3
Fahrmotor(en) defekt 3 3
Hydraulikölkühler verschmutzt (intern/extern) 1
Thermostat (Hydraulik) verschmutzt/verklemmt/defekt 2
Kupplung Dieselmotor-Pumpe 2
Dieselmotor 1
Drehzahl-Flanschsensoren im Fahrmotor (Verkabelung) 1 1 2

FEHLERSUCHE

BW 213 / 214 DH / PDH-4

- E 34 -

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Service Training
Vibration

3
4

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

diagram
1 Vibration pump 75 cm³ 11
2 Integrated charge pump 17 cm³
3 Multi-function valves with high
pressure limitation and boost check
valve function
4 Proportional control

BW 213 / 214 DH / PDH -4 -F1-

008 913 76 BOMAG 321

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Service Training
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
5 Vibration motor with flushing valve 15

The vibration system on these single drum rollers works with different frequencies and tow amplitudes.
This enables perfect adaptation of the machine to various types of soil and different applications.

The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit.

The main components of this circuit are

vibration pump,

Vibration motor

and the pressure resistant hydraulic hoses.

Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the
diesel engine.

By operation of a proportional valve the pilot oil is guided to one of the control piston sides. This actuates
the pump from neutral position to one of the two possible maximum displacement positions.

When changing the swashing angle through the neutral position to the opposite side, the flow direction
of the oil and the sense of rotation of the vibration motors will change.

Since the engine speed is variable in "Position AUTO", the pump displacement must always be
proportionately adapted in order to maintain the vibration frequency at a constant level.

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

The eccentric weights on the vibrator shaft are fitted with additional change-over weights.

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Service Training

Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract
from the basic weights.

Basic weight + change-over weight = high amplitude

Basic weight - change-over weight = low amplitude

The displacement of the pump may be different to both flow directions. This results in different exciter
shaft speeds for the different senses of rotation of the motor.

The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled
with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.

Sense of rotation of exciter shaft

BW 213 / 214 DH / PDH -4 -F3-

008 913 76 BOMAG 323

4.3 Technical Manual / DH/PDH

Service Training

Vibration pump

The vibration pump is a swash-plate controlled axial piston pump with variable displacement of type 90
R 075 EP from Sauer-Danfoss. The pump is fitted with all control and safety elements needed for
operation in a closed hydraulic circuit.

5 4

2 6 3

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

diagram
1 Vibration pump 75 cm³ 11
2 Integrated charge pump 17 cm³
3 Multi-function valves with high
pressure limitation and boost check
valve function
4 Prop. solenoids X 6 and X 7
5 servo control
6 Safety valve in charge circuit

BW 213 / 214 DH / PDH -4 -F4-

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Service Training
Function

1 2

5 4 3

Cross-section of vibration pump

1 Servo piston

2 Working pistons

3 Charge pump

4 Valve plate

5 Roller bearing

6 Swash plate

BW 213 / 214 DH / PDH -4 -F5-

008 913 76 BOMAG 325

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Service Training

1
2
5

4 3

Cross-section of vibration pump

1 Control

2 Servo piston

3 Friction free swash plate bearing

4 Attachment plate

5 Spool valve

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Service Training

The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.

The slipper pads rest against the sliding surface of the swash plate and are at the same time held on
the sliding surface by a retaining device.

During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.

During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into
the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he
closed circuit.

Control

The electro-hydraulic displacement control converts the electric proportional input signal into a load
controlling output signal.

The vibration pump has an integrated charge pump, an internal gear pump with a displacement of 17
cm³ per revolution

The vibration pump is equipped with an integrated charge pressure relief valve, which is set to a
pressure of 40 bar. This valve only has a safety function in the charge circuit.

BW 213 / 214 DH / PDH -4 -F7-

008 913 76 BOMAG 327

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Service Training
Multi-function valve

As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.

1 From the charge pump

2 Closed circuit

3 High pressure relief valve with integrated boost check valve

Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 426 bar
(pressure difference between high and low pressure side = 400 bar + charge pressure = 26 bar).

The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit.

BW 213 / 214 DH / PDH -4 -F8-

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Service Training
Vibration motor

The vibration motor is a Bosch-Rexroth axial piston motor of series A2FM 56 with fixed displacement in
bent axle design. Since the motor can be subjected to pressure from both sides, it is most suitable for
the use in closed hydraulic circuits.

BW 213 / 214 DH / PDH -4 -F9-

008 913 76 BOMAG 329

4.3 Technical Manual / DH/PDH

Service Training
When switching the vibration on the motor must first start to move the resting vibration shaft. This
resistance causes a hydraulic starting pressure, which is limited to 426 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).

Hard ground = High operating pressure

Loose ground = Low operating pressure

A MA

3 1

B MB

Circuit diagram of vibration motor

1 Vibration motor

2 Flushing valve

3 Flushing pressure relief valve

BW 213 / 214 DH / PDH -4 - F 10 -

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Service Training
Flushing valve

The vibration motor is equipped with an integrated flushing valve. This flushing valve is located inside
the bolted on connecting block. When switching the vibration on a pressure difference will appear
between the two sides of the closed circuit. The higher pressure moves the valve spool of the flushing
valve against the neutral setting spring, so that oil can flow out of the low pressure side.

1
A

Flushing valve

1 Flushing spool

2 Flushing pressure relief valve

The flushing valve is fitted with a downstream 16 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.

This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.

BW 213 / 214 DH / PDH -4 - F 11 -

008 913 76 BOMAG 331

4.3 Technical Manual / DH/PDH

Service Training
Speed sensor

The fixed displacement vibration motor A2FM56 is equipped with a Bosch-Rexroth speed sensor
HDD1L16 or HDD2L16 with an installation depth of 16 mm, which uses the Hall-effect.

Fixed displacement motor

A2FM56

Connection in wiring diagram, vibration speed sensor B16 on page 006

BW 213 / 214 DH / PDH -4 - F 12 -

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Service Training
Drum

4
14

5 9

7 13
6
10
3 8 11

12

Fig. 1 Cross-section of drum

1 Drum shell 8 Change-over weight

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

BW 213 / 214 DH / PDH -4 - F 13 -

008 913 76 BOMAG 333

4.3 Technical Manual / DH/PDH

Service Training
Test and adjustment points, vibration system

Vibration pump
7 8

6 6 72
1
8
6 5
7

5 1
5 4
3 4 1
2
3
4 2 3
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
1 Pressure test port, vibration 11 - B - ME Starting pressure
pressure low amplitude 330 -400 bar
2 Pressure test port, vibration 11 - A - MF Starting pressure
pressure high amplitude 330 -400 bar
3 High pressure port low amplitude 11 - B max. 426 bar
4 High pressure port high amplitude 11 - A max. 426 bar
5 Multi-function valve with high 11 - B
pressure limitation low amplitude
6 Multi-function valve with high 11 - A
pressure limitation high amplitude
7 Solenoid valve, low amplitude Y07 / X 8 11 - B 12V / 0,4 - 1,2A
8 Solenoid valve, high amplitude Y07 / X 7 11 - A 12V / 0,4 - 1,2A

BW 213 / 214 DH / PDH -4 - F 14 -

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Service Training
Vibration motor

5 3

1
1 2
2

4
3

2 31

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

diagram
1 High pressure port high amplitude 15 - A
2 High pressure port, low amplitude 15 - B
3 Flushing valve 15
4 Leakage and flushing 15 - L1 approx. 2.5 l..
Flushing quantity

BW 213 / 214 DH / PDH -4 - F 15 -

008 913 76 BOMAG 335

4.3 Technical Manual / DH/PDH

Service Training

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

diagram
1 Speed-sensor B 16 15

BW 213 / 214 DH / PDH -4 - F 16 -

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Service Training
Trouble shooting

The display shows the fault codes

For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)

All electric faults are mainly shown by the display

The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.

BW 213 / 214 DH / PDH -4 - F 17 -

008 913 76 BOMAG 337

4.3 Technical Manual / DH/PDH

Service Training
Procedure:

The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.

Erregerwellendrehzahl nicht korrekt

Keine Vibration (Speisedruck OK)
Vibration nur in einer Amplitude
FEHLERSUCHE VIBRATION
BW 213/214 DH/PDH-4

SYMPTOME

MÖGLICHE URSACHEN
Vibrationschalter (Amplitudenvorwahl) 1 1
Fahrhebel, Taster Vibration (an/aus), Verkabelung 1
Elektrik defekt / Verkabelung 2 2
Pumpenansteuerung (elektrisch / hydraulisch) 1 1
Druckabschneidung/ Hochdruckbegrenzung Vibrationspumpe
2
verschmutzt/verstellt/defekt
Speisepumpe / Speisedruckbegrenzungsventil
2
verschmutzt/defekt
Frequenzeinstellung Vibrationspumpe 2
Vibrationspumpe defekt 2 2
Kupplung zwischen Dieselmotor und Fahrpumpe defekt
Erregerwellenlager defekt 3
Vibrationsmotorkupplung defekt 2
Vibrationsmotor defekt 2 1
Dieselmotor 1 1 1
Drehzahlsensor (Verkabelung) 1 1 1
Spülventil Vibmotor hängt 2

FEHLERSUCHE

BW 213 / 214 DH / PDH -4 - F 18 -

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Service Training
Steering
Single drum rollers of series BW 213 / 214 DH-4 are equipped with a hydrostatically operated articulated
steering system.

The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.

to charge
system
1
7
6
5
3

2
4

from steering pump

Fig. 1Steering hydraulics

1 Rating pump
2 Distributor valve
3 Steering pressure relief valve (∆p =175 bar)
4 Check valve (pre-loaded to 0.5 bar)
5 Anti-cavitation valve
6 Shock valves (240 bar)
7 Steering cylinders

The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.

When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.

The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.

BW 213 / 214 DH / PDH -4 -G1-

008 913 76 BOMAG 339

4.3 Technical Manual / DH/PDH

Service Training
Charge pump

The charge pump for travel circuit and vibration works also as steering pump The pump is an external
gear pump with fixed displacement.

The oil flow generated by the charge pump is joined together with the return flow from the steering valve
before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and vibration
pump.

BW 213 / 214 DH / PDH -4 -G2-

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Service Training
Steering pump

The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.

9 9 6 1 7

8
2

4 5

Fig. 2Steering pump

1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals

BW 213 / 214 DH / PDH -4 -G3-

008 913 76 BOMAG 341

4.3 Technical Manual / DH/PDH

Service Training
Working principle of the gear pumps

The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. 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 created between the tooth flanks, the inside wall of the housing and
the faces of the bearing plates.

When the pump is running the chambers transport hydraulic oil from the suction side to the pressure
side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The
tooth chambers transport the fluid to the outlet of the pump 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.

For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.

This pressure field is always under the actual system pressure.

BW 213 / 214 DH / PDH -4 -G4-

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Service Training
Steering valve

The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and
shock valves.

9 2

5
8

Fig. 3Cross-sectional view of steering valve

1 Neutral setting springs

2 Housing
3 Inner spool
4 Outer spool
5 Universal shaft
6 Ring gear
7 Gear
8 Check valve
9 Pressure relief valve
When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating
pump. The rating pump guides the oil flow through the distributor valve to the corresponding
sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the
rotation angle of the steering wheel.
This oil flow to the steering cylinders articulates the machine and causes a steering movement.

BW 213 / 214 DH / PDH -4 -G5-

008 913 76 BOMAG 343

4.3 Technical Manual / DH/PDH

Service Training

240 bar

∆p = 175 bar

240 bar

0,5 bar

Fig. 4Steering valve, hydraulic diagram

The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.
The charge pressure value must be added to this pressure, because the oil leaving the steering system
is fed into the charge circuit for the closed travel circuits.

The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks
which may occur, e.g. when driving over obstructions, and protect the system against overloads.

Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.

A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case
of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would
act as pumps and press the oil back to the pump.

BW 213 / 214 DH / PDH -4 -G6-

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Technical Manual / DH/PDH 4.3

Service Training
Articulated joint

Front and rear frames of the single drum rollers BW 177 D-4 are connected by an oscillating articulated
joint. This ensures that drum and wheels are at all times in contact with the ground, even when driving
extreme curves.

Fig. 5Articulated joint

BW 213 / 214 DH / PDH -4 -G7-

008 913 76 BOMAG 345

4.3 Technical Manual / DH/PDH

Service Training
The rear console is tightly bolted to the rear frame.

The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.

The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.

The steering cylinder anchor point is welded to the front console.

When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.

All bearings on the articulated joint are maintenance free and do not require any lubrication.

Notes on assembly:

When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.

Please follow the instructions in the repair manual for the articulated joint.

BW 213 / 214 DH / PDH -4 -G8-

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Service Training
Test and adjustment points steering points

3 4
1

2
2

Steering pump

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

diagram
1 Steering pump (and charge pump) 09
2 Steering pressure test port MB 200 +/-10 bar

BW 213 / 214 DH / PDH -4 -G9-

008 913 76 BOMAG 347

4.3 Technical Manual / DH/PDH

Service Training
Vibration and noise damper

The damper is located in the steering/charge circuit directly after the steering and charge pump.

It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.

The damper is mounted to the front plate of the rear frame, between both steering cylinders.

BW 213 / 214 DH / PDH -4 - G 10 -

348 BOMAG 008 913 76

Technical Manual / DH/PDH 4.3

Service Training
Trouble shooting

The display shows the fault codes

For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)

All electric faults are mainly shown by the display

The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.

BW 213 / 214 DH / PDH -4 - G 11 -

008 913 76 BOMAG 349

4.3 Technical Manual / DH/PDH

Service Training
Procedure:

The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.

FEHLERSUCHE LENKUNG
Endanschläge werden nicht erreicht

BW 213/214 DH/PDH-4
Lenkung schwergängig
Keine Lenkfunktion
SYMPTOME

MÖGLICHE URSACHEN
Lenkorbitrol 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2

BW 213 / 214 DH / PDH -4 - G 12 -

350 BOMAG 008 913 76

5 Air conditioning system

008 913 76 BOMAG 351

5.1 Notes on safety for the air conditioning system

5.1 Notes on safety for the air con- according to paragraph 32. . In this case
periodically recurring inspections consist of external
ditioning system examinations, normally on containers in opera-
tion . The refrigerant container must be vis-
Air conditioning system ually examined twice every year in connection with
the inspection. Special attention must thereby
be paid to signs of corrosion and mechanical dam-
i Note age. If the pressure vessel is in no good condi-
In some countries the legislator demands minimum tion, it should be replaced for safety reasons, thus
requirements concerning the qualification of the main- to make sure that sufficient precautions have been
tenance personnel. In the Federal Republic of Germa- applied to protect the operator and third par-
ny refrigeration and air conditioning equipment must ties. .
only be serviced by persons who are in the posses- l
Wear safety goggles! Put on your safety goggles.
sion of a so-called qualification certificate.
This will protect your eyes against coming into con-
tact with refrigerant, which could cause severe
! Danger damage by freezing.
Do not open refrigerant containers which contain l
Wear safety gloves and an apron! Refrigerant are
refrigerant! excellent solvents for greases and oils. In contact
l
When opening refrigerant containers the contents with skin they will remove the protective grease film.
may escape in liquid or vaporous state. The higher However, degreased skin is very sensitive against
the pressure in the container, the fiercer this proc- cold temperatures and germs.
ess will take place. The height of the pressure de- l
Do not allow liquid refrigerants to come into contact
pends on two conditions. 1. Which type of with skin! Refrigerant takes the heat required for
refrigerant is in the container. The following applies: evaporation from the environment. Very low tem-
The lower the boiling point, the higher the pressure. peratures may be reached. The results may be local
2. The height of the temperature. The following ap- frost injuries (boiling point of R134a -26.5°C at am-
plies: The higher the temperature, the higher the bient pressure).
pressure. l
Do not inhale higher concentrations of refrigerant
l
In a refrigerant container there must be a steam vapours! Escaping refrigerant vapours will mix with
space above the liquid space. The liquid expands the ambient air and displace the oxygen required for
with increasing temperature. The steam filled space breathing.
becomes smaller. From a certain time on the con- l
Smoking is strictly prohibited! Refrigerants may be
tainer will be filled with just liquid. After this only a
decomposed by a glowing cigarette. The resulting
minor temperature increase is enough to generate
substances are highly toxic and must not be in-
very high pressures in the container, because the
haled.
liquid would like to expand, but there is no more
room. The related forces are high enough to cause l
Welding and soldering on refrigeration equipment!
the container to burst. In order to avoid overfilling of Before starting welding or soldering work on vehi-
a container the pressure gas directive clearly spec- cles, (in the vicinity
ifies how many kilograms of refrigerant may be filled of air conditioning components) all refrigerant must
into the container per litre volume. be drawn out and the rests removed by blowing out
the system with nitrogen. The decomposition prod-
l
In case of occurring mechanical damage or corro-
ucts created from the refrigerant under the influence
sion on the refrigerant container, the container must
of heat not only are highly toxic, but also have a
be replaced, in order to prevent it from bursting and
strong corrosive effect, so that pipes and system
causing further damage.
components may be attacked. The substance is
l
Since the fluid container is pressurized, the manu- mainly fluorohydrogen.
facture and testing of these pressure vessels is gov- l
Pungent smell! In case of a pungent smell the afore
erned by the pressure vessel directive. (New edition
mentioned decomposition products have already
from April 1989). This directive classifies the pres-
been created. Extreme care must be exercised not
sure vessels into the test groups in dependence on
to inhale these substances, as otherwise the respi-
their permissible operating pressure "p" in bar, its
ratory system, the lungs and other organs may be
volume "l" in litres and the pressurized product p x
harmed.
l. On the basis of these prerequisites
the fluid containers must be classified as per testing l
When blowing out components with compressed air
group II. Paragraph 10 of the pressure vessel direc- and nitrogen the gas mixture escaping from the
tive demands that these pressure containers must components must be extracted via suitable exhaust
be periodically inspected and tested by a specialist, facilities (workshop exhaust systems).

352 BOMAG 008 913 76

Notes on repair of the air conditioning system 5.2
5.2 Notes on repair of the air con- l
Compressor oil / refrigeration oil is highly hydro-
scopic. Oil cans must strictly be kept closed until
ditioning system use. Oil rests should not be used, if the can had
been opened over a longer period of time.
Air conditioning system l
All O-rings as well as pipe and hose fittings must be
oiled withcompressor oil / refrigeration oilibefore as-
i Note sembly.
In some countries the legislator demands minimum l
When replacing a heat exchanger, e.g. evaporator
requirements concerning the qualification of the main- or condenser, any compressor oil / refrigeration oil
tenance personnel. In the Federal Republic of Germa- lost by exchanging the components, must be re-
ny refrigeration and air conditioning equipment must placed with fresh oil.
only be serviced by persons who are in the posses- l
A too high compressor oil / refrigeration oil level ad-
sion of a so-called qualification certificate. versely affects the cooling performance and a too
l
In case of a repair on the refrigeration system you low oil level has a negative effect on the lifetime of
should first evacuate the air conditioning system for the compressor.
at least 45 minutes to remove any moisture from the l
If a air conditioning unit needs to be opened, the
system, before you start to refill. Moisture bonded in dryer must be replaced in any case.
the compressor oil / refrigeration oil (PAG oil) can
only be removed from the system by changing the
l
Always use new O-rings when reassembling the
oil. unit.
l
During repair work on refrigerant lines and compo-
l
Always use two spanners when connecting pipes or
nents, these must be kept closed as far as possible, hoses, to prevent the pipe end from being dam-
in order to prevent the invasion of air, moisture and aged.
dirt, because the operational reliability of the system l
Tighten screw fittings with the specified torque.
can only be assured if all components in the refrig- l
Check the connections of pipes, fittings or compo-
erant circuit are clean and dry from inside.
nents thoroughly; do not use if damaged.
l
Make sure that no dirt or foreign parts can enter into l
Do not leave the refrigerant circuit unnecessarily
the compressor or the air conditioning system. The
open to the atmosphere. Do not attempt to repair
area around the refrigerant hoses should be
bent or burst pipes.
cleaned with a gasoline free solvent.
l
Compressor valves must only be opened after the
l
All parts to be reused should be cleaned with a
system has been properly sealed.
gasoline free solvent and blow-dried with clean
compressed air or dried with a lint-free cloth. l
The use of leak detection colouring matter is not
permitted, because its chemical composition is un-
l
Before opening all components should have
known and its effect on compressor oil and rubber
warmed up to ambient temperature, to avoid that
elements is not predictable. The use of leak detec-
damp air is drawn into the component by the differ-
tion colouring matter makes any warranty claims
ence in temperatures.
null and void.
l
Damaged or leaking parts of the air conditioning l
Tools used on refrigeration circuits must be of ex-
must not be repaired by welding or soldering, but
cellent condition, thus to avoid the damage of any
must generally be replaced.
connections.
l
Do not fill up refrigerant, but extract existing refrig- l
The dryer is to be installed last, after all connections
erant and refill the system.
in the refrigerant circuit have been tightened.
l
Different types of refrigerant must not be mixed. l
After completion of repair work screw locking caps
Only the refrigerant specified for the corresponding
(with seals) on all connections with valves and on
air conditioning system must be used.
the service connections. Start up of the air condi-
l
Refrigerant circuits with refrigerant type R134a tioning system. Observe the filling capacity.
must only be operated with the compressor oil / re- l
Before start up of the air conditioning system after a
frigeration oil approved for the compressor.
new filling: - Turn the compressor approx. 10 revo-
l
Used compressor oil / refrigeration oil must be dis- lutions by hand using the clutch or V-belt pulley of
posed of as hazardous waste. the magnetic clutch. - Start the engine with the com-
l
Due to its chemical properties compressor oil / re- pressor/control valve switched off. - Once the idle
frigeration oil must never be disposed of together speed of the engine has stabilized switch on the
with engine or transmission oil.

008 913 76 BOMAG 353

5.2 Notes on repair of the air conditioning system

compressor and run it for at least 10 minutes at idle

speed and maximum cooling power.
l
Never operate the compressor over longer periods
of time with high engine speeds without a sufficient
amount of refrigerant in the system. This could
probably cause overheating and internal damage.

354 BOMAG 008 913 76

Physical basics 5.3
Physical basics A - heat absorption
5.3 Physical basics

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.

008 913 76 BOMAG 355

5.3 Physical basics

Pressure and boiling point i Note

The boiling point is the temperature at which fluid At absolute pressure 0 bar correspond with an abso-
changes to gaseous state. lute vacuum. The normal ambient pressure (overpres-
Changing the pressure above a fluid also changes the sure) corresponds with 1 bar absolute pressure. On
boiling point. It is a well known fact, that e.g. the lower the scales of most pressure gauges 0 bar corre-
the pressure applied to water, the lower the boiling sponds with an absolute pressure of 1 bar (indicated
point. by the statement -1 bar below the 0).
When looking at water, the following values do apply:
l
Atmospheric pressure, boiling point 100°C
l
Overpressure 0.4 bar, boiling point 126°C
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
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:
A - compression
B- condensation
Fig. 3
C- relaxation
Steam pressure curve for refrigerant R134a D- evaporation.
The steam pressure curve is a means for explaining
the operation principle of an air conditioning system.
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.
4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
(e.g. alcohol on skin)

356 BOMAG 008 913 76

Refrigerant R134a 5.4
5.4 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:

Physical properties of R134a:
- 26.5 °C
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. °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.

Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the

008 913 76 BOMAG 357

5.5 Compressor oil / refrigeration oil

liquid container has absorbed approx. 8 gr. of water, 5.5 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.

358 BOMAG 008 913 76

Working principle of the air conditioning system 5.6
5.6 Working principle of the air
conditioning system

All air conditioning systems are based on the same

principle. They extract heat from the surrounding en-
vironment. Everybody knows the effect: if a sweating
body is exposed to wind it will cool down, because
heat is extracted. For this purpose a refrigerant circu-
lates in a closed circuit inside the vehicle. This refrig-
erant thereby continuously changes its physical state
between liquid and gaseous.

Fig. 1
An engine driven compressor (1) draws in gaseous re-
frigerant from the evaporator (5) and compresses it.
During this process the temperature of the refrigerant
increases tremendously.
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front
of the vehicle radiator, so that a sufficient air flow is as-
sured. In the condenser (2) the gas is cooled down
and consequently liquefied.
In the dryer / liquid container (3) the refrigerant is then
collected and freed of moisture and contaminants.
The expansion valve (4) regulates the flow rate from
the dryer / liquid container (3) back to the evaporator
(5) and the circuit starts again.

008 913 76 BOMAG 359

5.7 Refrigeration diagram

5.7 Refrigeration diagram

Fig. 1
1 High pressure - gaseous
2 High pressure - liquid
3 Low pressure - gaseous
4 Compressor
5 Compressor pressure switch (not used)
6 Vacuum switch
7 Evaporator
8 Expansion valve
9 Inspection glass
10 Filter dryer
11 Fluid container
12 Condenser
13 Manual shut-off valve (not used)
14 Overpressure switch
15 Defroster thermostat

360 BOMAG 008 913 76

Description of components 5.8
5.8 Description of components Reason of oil Amount of oil
loss lost
Compressor Loss when approx. 15 gr
emptying
Defective A/C approx. 30 gr
hose
Hose change approx. 15 gr
Replacement of approx. 30 gr
condenser
Replacement of approx. 30 gr
evaporator
Replacement of approx. 30 gr
liquid container
Replacement of approx. 15 gr
expansion
valve

! Caution
Fig. 1
Please bear in mind, that the new compressor is
The compressor is mounted to the engine and has the delivered with a filling of 207 gr. compressor oil.
duty to build up the refrigerant pressure required for To avoid excessive oil in the A/C-system and thus
the function of the system. Coupling and decoupling is a poor cooling effect, the oil level in the A/C-sys-
accomplished by an electromagnetically controlled tem must be adjusted accordingly.
mechanical clutch, which is integrated in the V-belt
pulley of the compressor. The quantity depends on the amount of oil that
may have been lost in connection with the possi-
Compressor data ble replacement of other components.
Displacement: 155 cm² The compressor oil quantity must be 10% of the
Weight: 6,9 kg refrigerant quantity in the complete system.
max. rpm: 6000 With a refrigerant filling of 1100 gr. the system re-
quires a compressor oil / refrigerant oil filling of
Sense of rotation: cw
100 gr.
Refrigerant: R134a
Procedure:
Oil quantity (scope of delivery): 207 gr
Drain and measure the compressor oil from the
Oil: PAG SP-20 (H14-003-404) old compressor.
Drain the compressor oil from the new compres-
! Caution sor and only fill in the exact quantity that had been
The compressor oil level must be checked after drained out of the old compressor. The compres-
replacing a system component or if a leak in the sor oil from the new compressor can be used for
system is suspected. Use only refrigeration oil this purpose.
PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator i Note
or condenser, any compressor oil / refrigeration Topping up compressor oil / refrigeration oil is possi-
oil lost by exchanging the components, must be ble on a pressureless compressor directly into the oil
replaced with fresh oil. pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
The actual quantity depends on the amount of oil
into the pressure side of the refrigeration system dur-
that may have been lost in connection with the
ing the evacuation process.
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.

008 913 76 BOMAG 361

5.8 Description of components

Condenser Dryer / filter / fluid container / inspection

glass

Fig. 1
The condenser is located in front of the the radiator for Fig. 1
the machine. It emits heat energy from the system into
the surrounding air and liquefies the gaseous refriger- Dryer / filter
ant. The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve.
Moisture that has entered during assembly of the re-
i Note
frigerant circuit is absorbed by a dryer in the fluid con-
The fins must be free of dirt and damage.
tainer.
At evaporation temperatures below zero the refriger-
! Caution ant will deposit previously absorbed moisture on the
When replacing a heat exchanger, e.g. evaporator expansion valve, where this water turns into ice and
or condenser, any compressor oil lost by ex- thus adversely affects the controllability of the expan-
changing the components, must be replaced with sion valve. Moreover, moisture in the refrigerant cir-
fresh oil. 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.

i Note
Since the absorbing capacity of this filter/dryer is lim-
ited, it must be changed within certain service inter-
vals. We recommend to replace it 1 x per years,
before the start of the season.

! Caution
The filter/dryer must generally be replaced when-
ever opening the refrigerant circuit, because
moisture will enter in such a case.
This requires emptying the air conditioning sys-
tem!
Installation position:
The arrow marks on the filter/dryer must point in
flow direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!

362 BOMAG 008 913 76

Description of components 5.8
Safety valve
i Note
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.

Fig. 2 ! Danger
The fluid container is equipped with a safety valve. In case of mechanical damage or corrosion on
Opening pressure 32 +/- 4 bar this pressure container this collector unit must be
replaced, to avoid bursting and further damage.
Tightening torque 10 - 35 Nm

Inspection glass

Fig. 3
During operation the refrigerant must flow through the
inspection glass without air bubbles. In most cases
the presence of air bubbles is a sign for a too low re-
frigerant level in the system. Apart from this, the refrig-
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
down to a level, at which gaseous refrigerant could
flow through the rising tube to the inspection glass.
This results in abnormally high temperatures in and on
the fluid lines (between refrigerant container and ex-
pansion valve), as well as very high pressures in the
pressure side.
However, incorrect evacuation or filling may also be
the reason for air entering into the system and since
air cannot be condensed, one will not be able to get
rid of these bubbles by topping up refrigerant. In this
case the air conditioning system needs to be evacuat-
ed and refilled.

008 913 76 BOMAG 363

5.8 Description of components

Expansion valve Evaporator

Fig. 1
The evaporator is mounted inside the HKL-module in
Fig. 1 the cabin. It consists of a heat exchanger (inside air -
The expansion valve is mounted inside the HKL-mod- refrigerant), with refrigerant flowing to a pipe system
ule in the cabin. The expansion valve always allows a with cooling flanges.
small amount of the high pressure liquefied refrigerant As with the condenser, correct operation of all fans
to flow into the evaporator, which has a much lower and cleanliness of the fins must be assured.
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state. Air conditioning systems have a circulation air filter
The heat required for this evaporation process is tak- mounted in the air flow in front of the evaporator,
en from the ambient air through the lamellas and sup- which should be cleaned or changed by the operator
plied to the refrigerant. This is the so-called cooling after each third trip, depending on the amount of dirt.
effect. A condensation water filter is mounted in the air flow
The thermostatic expansion valve operates with an after the evaporator. This filter has the function to col-
external pressure compensation. This type of expan- lect the water that has condensed from the air in the
sion valve works with high accuracy, because it uses evaporator block and to discharge this water into the
pressure and temperature at the evaporator outlet and water pan With a defective condensation water filter
adjusts and overheating of approx. 7 K. The already condensation water may flow into the inside of the ve-
installed expansion valves and the ones delivered as hicle.
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor ! Caution
damage you should only use original expansion
When replacing a heat exchanger, e.g. evaporator
valves, because adjusting expansion valves takes a
or condenser, any compressor oil lost by ex-
lot of time and care.
changing the components, must be replaced with
fresh oil.
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+

364 BOMAG 008 913 76

Description of components 5.8
Defroster thermostat Pressure switch

Fig. 1
After a minimum pressure is reached in the low pres-
Fig. 1 sure side or a maximum pressure in the high pressure
side, the pressure switch will switch of the magnetic
The feeler of a defroster thermostat to switch off the
clutch of the compressor, thus to avoid destruction of
magnetic clutch in case of icing up or to switch the
system components by excessive pressure or draw-
clutch back on after defrosting, is mounted on the
ing in external gases and foreign matter as a result of
evaporator. The correct adjustment of the defroster
too low pressure.
thermostat as well as the correct feeler assembly
should be checked during maintenance. Working pressure:
Switching point on: + 1°C (+/- 1°C) Low pressure off: 1.5 +/- 0.5 bar
Switching point off: + 5.5°C (+/- 1°C) Low pressure on: 3.5 bar
Overpressure off: 25.0 +/- 1.5 bar
i Note Overpressure on: 18.0 +/- 1.5 bar
It is very important that the feeler is mounted down-
stream of the evaporator, but before the pressure sen-
sor, in countercurrent direction, with full length and
insulated against the outside temperature.

008 913 76 BOMAG 365

5.8 Description of components

Pipes and hoses

Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.

Recommended tightening torques for O-ring

sealed fittings

Thread Spanner width Torque

5/8“ 17 or 19 13,6 - 20,3 Nm
3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
1 1/16“ 32 40,7 - 47,5 Nm
M30X2 36 105,0 - 115,0
Nm
M36X2 41 165.0 - 175.0
Nm
Bending radii for air conditioning hoses

Hose type Nominal width Bending radi-

us
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

366 BOMAG 008 913 76

Checking the compressor oil level 5.9
Checking the compressor oil level / refrig- Insert the oil dipstick.
5.9 Checking the compr esso r oil level
l

eration oil level l

Pull out the dipstick and count the notches covered
by oil.
! Caution l
Drain off oil or fill up as specified in the table.
The compressor oil level must be checked after
replacing a system component or if a leak in the Environment
system is suspected. Use only compressor oil / re-
Used compressor oil / refrigeration oil must be
frigeration oil PAG SP-20 (H14-003-404).
disposed of as hazardous waste.
l
Run the compressor for 10 minutes at engine idle
speed. Fastening an- Oil dipstick in
l
In order to avoid any compressor oil losses you gle (degree) increments
should slowly drain all refrigerant from the air condi- 0 5-7
tioning system. 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.
Fig. 1
l
Measure the fastening angle (Fig. 1) of the com-
pressor (oil plug at top)
l
Remove the oil filler plug.

Fig. 2
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

008 913 76 BOMAG 367

5.10 Checking the magnetic clutch

5.10 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.

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

368 BOMAG 008 913 76

Inspection and maintenance work 5.11
5.11 Inspection and maintenance 5.12 Measuring the pressure in the
work refrigerant circuit
l
Visual inspection of the complete system for dam-
age.
l
Check the compressor mounting bracket on the ve-
hicle engine for tight fit and damage. i Note
l
Check the condition, alignment and tightness of the The temperature of the components in the refrigerant
V-belt. circuit must be the same as the ambient temperature.
l
Check the routing of refrigerant hoses and cables in If individual components in the refrigerant circuit are
the area of the vehicle engine and transmission, as warmer or colder, the pressure will differ from the val-
well as on the chassis for chafing and rectify any de- ues in the table.
tected faults. Ensure sufficient clearance to hot
Steam pressure curve for refrigerant R134a
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.
l
Check the electric control panel. If discolorations on
conductors are found, these should be replaced
and possibly also the corresponding relays.
l
Switch on the cooling system and check the refrig-
erant level.
l
Filter/dryer and filter/dryer/fluid container combina- Fig. 3
tions must always be replaced after opening the re- A- liquid
frigerant circuit. If these are in service for more than B- gaseous
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer Temperature Pressure in
should be replaced in regular intervals. in C° bar
l
Measure the temperature on the evaporator: Meas- -45 -0,61
ure the intake air temperature - Measure the blow -40 -0,49
out air temperature - The temperature difference -35 -0,34
should be at least 8-10 K. -30 -0,16
-25 0,06
l
Measuring the pressure in the refrigerant circuit -20 0,32
-15 0,63
-10 1
-5 1,43
0 1,92
5 2,49
10 3,13
15 3,90
20 4,70
25 5,63
30 6,70
35 7,83
40 9,10
45 10,54
50 12,11

008 913 76 BOMAG 369

5.13 Check condition and tension of refrigerant compressor V-belt,

Temperature Pressure in 5.13 Check condition and tension

in C° bar of refrigerant compressor V-
55 13,83
60 15,72
belt, replace the V-belt
65 17,79
70 20,05 Danger
!
75 22,52
Danger of injury!
80 25,21
85 28,14 Work on the V-belt must only be performed with
90 31,34 the engine shut down.

The pressure in the refrigerant circuit is Checking the V-belt

lower than the value in the table
Refrigerant level in the circuit too low ?
l
Check for leaks in the refrigerant circuit with a leak
detector
l
Check the overpressure relief valve.

Has the overpressure relief valve responded ?

l
Check the control for the refrigerant fans.
l
Check refrigerant pipes and hoses for restriction
caused by too tight bending radii.
Fig. 4
l
Check refrigerant lines and hoses for external dam-
age.
l
Inspect the entire circumference of the V-belt (Fig.
4) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
i Note
l
Check with thumb pressure whether the V-belt can
If no fault is found:
be depressed more than 10 to 15 mm (0.4 – 0.6
Blow out refrigerant circuit with compressed air and ni- inches) between the V-belt pulleys, retighten if nec-
trogen. essary.
Replace the filter dryer.
Tensioning the V-belt

Fig. 5
l
Slightly slacken the fastening screws 1, 2 and 3
(Fig. 5).
l
Press the compressor in direction of arrow, until the
correct V-belt tension is reached.
l
Retighten all fastening screws.

370 BOMAG 008 913 76

Servicing the air conditioning 5.14
Changing the V-belt 5.14 Servicing the air conditioning*
l
Slightly slacken the fastening screws 1, 2 and 3.
l
Press the compressor against the direction of arrow Cleaning the condenser
completely against the engine.
l
Take the old V-belt off. ! Caution
l
Fit the new V-belt to the V-belt pulleys. A soiled condenser results in a considerable re-
duction of air conditioning power.
l
Tension the V-belt as previously described.
Under extremely dusty conditions it may be nec-
essary to clean the condenser several times per
Caution
!
day.
Check the V-belt tension after a running time of 30
minutes. If, during operation of the air conditioning system,
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.

Danger
!

Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.

!Caution
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
ment.

Fig. 6
l
Clean the condenser fins (Fig. 6) with compressed
air or a cold water jet.

Checking the refrigerant level

l
Start the engine.
l
Switch the air conditioning on.

* Optional equipment

008 913 76 BOMAG 371

5.14 Servicing the air conditioning

i Note
The refrigerant level is correct.

Fig. 7
l
Turn the rotary fan switch (Fig. 7) to position "2",
middle fan stage.
l
Open the air outlet openings on both control units. Fig. 10
l
If the white float (Fig. 10) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
the service department.

i Note
The refrigerant level is not correct.
l
Refrigerant must be filled up, if necessary the air
conditioning system must be checked for leaks.

Checking the moisture level of the drying

agent

Fig. 8
l
Turn the rotary switch for the air conditioning ther-
mostat (Fig. 8) clockwise. The air flow cools down.

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

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.
Fig. 9
l
Check whether the white float (Fig. 9) inside the in- ! Caution
spection glass of the drier/collector unit floats right Have the drier/collector unit replaced by the serv-
at the top. ice department every year before the operating
season.

372 BOMAG 008 913 76

Drying and evacuation 5.15
Checking the condition of the drier/col- 5.15 Drying and evacuation
lector unit
Evacuation of air conditioning systems using R-type
refrigerants not only has the purpose of emptying the
! Caution system of all air before filling in refrigerant, but also to
According to the regulation for pressure reser- verify the leak tightness over a longer lifetime in the
voirs all pressure reservoirs must be repeatedly achieved vacuum. However, the most important factor
inspected by a specialist. In this sense repeated in this work step is the drying of the system.
inspections are external examinations, normally Any water residues in the refrigerant circuit will com-
on pressure reservoirs in operation. In connection bine with the refrigerant, which will lead to the previ-
with this inspection the drier/collector unit must ously described consequential damage.
be visually examined twice every year. During
Vacuum pumps with a capacity of more than 100 l/min
these inspections special attention must be paid
and a final pressure of less than 30 micron, i.e. 0.039
to corrosion and mechanical damage. If the reser-
mbar should be used to evacuate the refrigeration
voir is not in proper condition it must be replaced
system.
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris- The refrigerant compressor is not suitable for the pur-
ing from the handling and operation of pressure pose of evacuation, because it is not able to achieve
reservoirs. a sufficient final vacuum and, apart from this, may be
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
Danger
!
It is common practice to evacuate the refrigeration
Danger of injury! system to a final vacuum of 1 Torr, i.e. 1.33 mbar.
In case of mechanical damage or corrosion on An exact time for evacuation and drying cannot be
this drier/collector unit this unit must be replaced, predicted. It can only be determined by means of a
to avoid bursting and further damage. vacuum meter. However, if there is no vacuum meter
at hand it is generally better to evacuate 1 hour longer
than 1 hour too less.

Function drying:
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced,
water will already evaporate, e.g. under a pressure of
10 mbar, at an ambient temperature of almost 7°C,
but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in
the system, the evacuation process is supported by
the co-called vacuum breaking (filling the circuit with
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
Fig. 12 circuit, which can then be easily discharged together
l
Check the drier/collector unit (Fig. 12) for mechani- with the nitrogen.
cal damage or rust.

008 913 76 BOMAG 373

5.16 Emptying in case of repair

5.16 Emptying in case of repair 5.17 Leak test

For repair work the air conditioning systems must very
often be emptied of all refrigerant. ! Caution
Especially with expensive refrigerants and larger The use of leak detection colouring matter is not
amounts of oil it may be necessary to keep the refrig- permitted, because its chemical composition is
erant for later use. unknown and its effect on compressor oil and rub-
For later use these refrigerants must be drawn out ber elements is not predictable. The use of leak
with suitable equipment and intermediately stored in detection colouring matter makes any warranty
collecting containers. claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
Environment
er valve (approx. 22 bar). After this all connections in
Contaminated refrigerant must be disposed of en- the air conditioning system are checked with the help
vironmentally of a suitable leak detection spray. A leak is thereby in-
Releasing refrigerant into the atmosphere is pro- dicated by means of foam bubbles.
hibited (see restrictive injunction concerning A leak test is required if a pressure drop is noticed.
CFC, day of enforcement 01. 08. 1991, § 8)
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.
! Danger Small leaks with only very low amounts of refrigerant
For draining refrigeration systems you should not escaping can be detected, e.g. with an electronic leak
simply use any delivery containers, but only ap- tester. Such equipment is able to detect leaks of less
propriate pressure bottles, which must be special- than 5 gr. per year.
ly marked and should comply with the pressure The leak tester used must be specially designed for
gas directive. the refrigerant composition in the air conditioning sys-
When transferring refrigerant you must make sure tem. For example, leak detectors for refrigerant R12
that the bottle does not contain more than the per- are not suitable for R134a, because the refrigerant
mitted amount of refrigerant in litres and has suf- R134a is free of chlorine atoms, meaning that this leak
ficient gas space for expansion (filling factor: 0,7). detector will not respond.
In order to reduce the evacuation period in case of
short repairs, you may fill the refrigerant circuit with
approx. 0.5 bar nitrogen when opening. This ensures
that nitrogen will flow out of the refrigerant circuit while
it is open and no air or moisture can enter. However,
the necessity for vacuum generation and a dryer
change remains.

374 BOMAG 008 913 76

Filling instructions 5.18
5.18 Filling instructions

Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).

! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.

i Note
White frost on the suction line is no measure for as-
sessing the filling.

008 913 76 BOMAG 375

5.18 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 Overpressure switch
5 Compressor pressure switch (not used) 15 Defroster thermostat
6 Vacuum switch 16 Vacuum meter
7 Evaporator 17 Low pressure gauge
8 Expansion valve 18 High pressure gauge
9 Inspection glass 19 Pressure reducing valve

376 BOMAG 008 913 76

Filling instructions 5.18
20 Vacuum pump 17 Open the valve on the refrigerant bottle and open
21 Nitrogen bottle the black and red hand wheels on the pressure
gauge bar. Fill refrigerant into the system, until a
22 Refrigerant bottle
pressure equilibrium between suction and pres-
23 Pressure gauge bar sure side is reached (reading of pressure gaug-
es).
Filling instructions 18 Close the red hand wheel.
1 Connect the service adapter with the blue hand 19 Perform a leak test with the electronic leak detec-
wheel in the suction side. tor.
2 Connect the service adapter with the red hand 20 Start the engine and switch on the system.
wheel in the pressure side (the hand wheels on 21 Open the blue hand wheel and continue filling in
the service adapters must be fully backed out - left refrigerant until the inspection glass is free or air
hand stop) bubbles (in fluid container/dryer combinations the
3 Connect the blue suction hose below the blue white pearl should float in the upper third of the in-
hand wheel on the pressure gauge bar to the blue spection glass). Then close the refrigerant bottle.
service adapter. 22 Close the blue hand wheel on the pressure gauge
4 Connect the red pressure hose below the red bar.
hand wheel on the pressure gauge bar to the red 23 Preparing the test run: -Close windows and doors
service adapter. -Fan on full speed stage -Mount measuring feel-
5 Connect the yellow hose below the yellow hand ers to air discharge and air intake.
wheel on the manometer bar to the 2-stage vacu- 24 Run the system for approx. 20 minutes with medi-
um pump. um engine speed.
6 Connect the last hose below the black hand wheel 25 The temperature difference between air discharge
on the nitrogen bottle via the pressure reducing and air intake should be (depending on type of air
valve. condition) 8-10°C. The ambient temperature
7 Check on the pressure gauge bar that all hand thereby is approx. 20°C. (These data are only ref-
wheels are closed. erence values, which may be influenced by possi-
8 Turn the hand wheels on both service adapter ble insolation)
clockwise. This opens the valves (right hand 26 Switch off system and engine and check for leaks
stop). again.
9 Open the valve on the nitrogen bottle (only via 27 Turn out (left hand stop) and remove the hand
pressure reducer); pressure approx. 20 bar. wheels on both service adapters.
10 Open the black and red hand wheels on the pres- 28 Fit all valves with dust caps.
sure gauge bar and fill nitrogen into the system, 29 Perform a leak test.
until a pressure of approx. 3.5 to 5.0 bar is indicat-
ed on the suction side. 30 Mark the system with the corresponding type
plates and information decals, such as type of oil
11 Then open the blue hand wheel and raise the and refrigerant.
pressure in the suction side (max. 10 bar). Check
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.
16 Switch off the vacuum pump, watch the pressure
gauges to see whether the vacuum is maintained.

008 913 76 BOMAG 377

5.18 Filling instructions

378 BOMAG 008 913 76

5.19 Heating control / air conditioning control

008 913 76 BOMAG 379

5.19 Heating control / air conditioning control

380 BOMAG 008 913 76

Heating control / air conditioning control 5.19

008 913 76 BOMAG 381

5.19 Heating control / air conditioning control

382 BOMAG 008 913 76

Heating control / air conditioning control 5.19

008 913 76 BOMAG 383

5.19 Heating control / air conditioning control

384 BOMAG 008 913 76

6 Replacing the cab window panes

008 913 76 BOMAG 385

6.1 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

386 BOMAG 008 913 76

Special tools 6.2
6.2 Special tools
1. Locking handle for fastening element

BOMAG part-no.: 055 705 84

Fig. 1
2. Suction lifter

commercial

Fig. 2

008 913 76 BOMAG 387

6.3 Auxiliary materials

6.3 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

388 BOMAG 008 913 76

Auxiliary materials 6.3
6. Silicone sealant

BOMAG part-no.: 009 700 36

Fig. 4

008 913 76 BOMAG 389

6.4 Removing and installing the window pane

6.4 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

390 BOMAG 008 913 76

Removing and installing the window pane 6.4
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

008 913 76 BOMAG 391

6.4 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

392 BOMAG 008 913 76

Removing and installing the window pane 6.4
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.
End of Import

Fig. 14

008 913 76 BOMAG 393

6.4 Removing and installing the window pane

394 BOMAG 008 913 76

7 Drum

008 913 76 BOMAG 395

7.1 Special tools

7.1 Special tools

1. Disassembly device for side plate

BOMAG part-no.: 007 211 55

Fig. 1
2. Assembly device for side plate

BOMAG part-no.: 971 079 21

Fig. 2
3. Assembly device for coupling hub abd flanged
hub

Fig. 3
4. Pressing plate for cylinder roller bearing

Fig. 4

396 BOMAG 008 913 76

Special tools 7.1
5. Pressing plate for travel bearing

Fig. 5
6. Pressing bushing for radial seal

Fig. 6
7. Lifting device for exciter unit

BOMAG part-no.: 007 215 08

Fig. 7

008 913 76 BOMAG 397

7.2 Repair overview for drum

Fig. 1

398 BOMAG 008 913 76

Repair overview for drum 7.2
1 Drum 13 Flanged hub
2 Cylinder roller bearing 14 Vibrator shaft
3 Coupling 15 Coupling
4 Vibration motor 16 Vibrator shaft
5 Rear shell 17 Change-over weight
6 Grooved ball bearing 18 Cylinder roller bearing
7 Spacer block 19 Basic weight
8 Rectangular rubber buffer 20 Flanged housing
9 Side plate 21 Flange
10 Spacer ring 22 Cylinder roller bearing
11 Grooved ball bearing 23 Cover
12 Mechanical seal

008 913 76 BOMAG 399

7.2 Repair overview for drum

400 BOMAG 008 913 76

Repair overview for drum 7.2

008 913 76 BOMAG 401

7.2 Repair overview for drum

402 BOMAG 008 913 76

Repair overview for drum 7.2
Fig. 2

008 913 76 BOMAG 403

7.2 Repair overview for drum

404 BOMAG 008 913 76

Repair overview for drum 7.2

008 913 76 BOMAG 405

7.2 Repair overview for drum

406 BOMAG 008 913 76

Removing and installing the drum 7.3
7.3 Removing and installing the drum

i Note
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (Fig. 1).

Fig. 1

i Note
However, the drum can also be removed without
having to disassemble the side plate, if it is lifted
up and out of the frame (Fig. 2).

Fig. 2
Removing the drum

i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.

Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
1. Mark the hydraulic hoses (Fig. 3) on the travel
motor and disconnect them from the ports.
2. Close all hydraulic hoses and motor ports with
suitable plugs.
3. Remove the guard plate (1).

Fig. 3

008 913 76 BOMAG 407

7.3 Removing and installing the drum

4. Unplug the plugs from solenoid valve and speed

sensor (Fig. 4) on travel motor side.
5. Close the connections with plugs.

Fig. 4
6. Mark the hydraulic hoses on the vibration motor
(Fig. 5) and disconnect them from the ports.
7. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 5

! Danger
Danger of squashing! Do not stand or step
under loads being loaded.
Always secure the machine against unintend-
ed rolling!
8. Unscrew bolts 1 (Fig. 6) and nuts and remove the
front scraper (2).
9. Unscrew bolts 3 and nuts and remove the front
scraper (4).

Fig. 6
10. Support the front cross-member safely with suita-
ble trestles or wooden blocks (Fig. 7).

Fig. 7

408 BOMAG 008 913 76

Removing and installing the drum 7.3
11. Support the rear cross-member safely with suita-
ble trestles or wooden blocks (Fig. 8).

Fig. 8
12. Disassemble bracket 1 (Fig. 9) for the hydraulic
hoses.
13. Pull the wiring loom off the speed sensor plug (ex-
citer shaft speed).

Fig. 9
14. Fasten the lifting gear to the side plate on the vi-
bration motor side.
15. Unscrew bolts 1 (Fig. 10) from the spacer blocks
on vibration and travel motors.

Fig. 10
16. Force out plug 1 (Fig. 11) and unscrew the bolts
(2) from the front and rear cross-members.

!Danger
Danger of squashing! Do not stand or step
under loads being loaded.
17. Take off the side plate.

Fig. 11

008 913 76 BOMAG 409

7.3 Removing and installing the drum

18. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 12).

! Danger
Danger of squashing! Do not stand or step
under loads being loaded.

Fig. 12
19. Check all rubber buffers (Fig. 13), replace if nec-
essary (see corresponding chapter).

Fig. 13
20. Check rectangular rubber buffers (Fig. 14), re-
place if necessary.

Fig. 14

410 BOMAG 008 913 76

Removing and installing the drum 7.3
Installing the drum
! Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
1. Place the drum into the frame and align it parallel
to the frame (Fig. 15).

Fig. 15

i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
2. Attach the side plate, insert the bolts 2 (Fig. 16)
into rear and front cross-members and tighten
with 463 Nm.
3. Close the screw holes with plugs (1).

Fig. 16
4. Fasten the spacer blocks on travel and vibration
motor sides with bolts 1 (Fig. 17) and nuts to the
side plates.

Fig. 17
5. Connect hydraulic hoses (Fig. 18) to the connec-
tions on travel motor and vibration motor accord-
ing to the marking.

Fig. 18

008 913 76 BOMAG 411

7.3 Removing and installing the drum

6. Connect the wiring loom with the speed sensor

plug (vibration sensor).
7. Fasten bracket 1 (Fig. 19) for the hydraulic hoses.

Fig. 19
8. Plug the plugs from solenoid valve (Fig. 20) and
speed sensor on travel motor side.

Fig. 20
9. Connect hydraulic hoses (Fig. 21) to the connec-
tions on travel motor according to the marking.
10. Install the guard plate (1).

Fig. 21
11. Assemble the front scraper 2 (Fig. 22), fasten
with bolts (1), washers and nuts.
12. Assemble the rear scraper (4), fasten with bolts
(3), washers and nuts.

i Note
13. Observe the adjustment measurement 30-35 mm

Fig. 22

412 BOMAG 008 913 76

Removing and installing the drum 7.3
! Caution
Before resuming operation of the machine:
Bleed the hydraulic system and check for
function and leaks.
Adjust the pretension of the rubber buffers.
14. Measure distance „X“ between spacer piece 1
(Fig. 23) and side plate.
15. Calculate the thickness of the compensation
plates.

Nominal value:

Fig. 23
Distance "X" + 2 mm
16. Turn one screw (3) into the welded nut (2) at top
and bottom and open a sufficient gap to insert the
compensation plates.
17. Insert the compensation plates 4 (Fig. 24). Insert
screws (1), slide on washers (3), turn on and
tighten nuts (2).
18. Unscrew the screws from the welded nuts.

Fig. 24

008 913 76 BOMAG 413

7.4 Repairing the drum

7.4 Repairing the drum

Removing the travel motor

! Danger
Danger of squashing!
Do not stand or step under suspended loads.
1. Attach the lifting tackle to travel drive 3 (Fig. 3).
2. Unscrew all nuts (1) from the rubber buffers.
3. Take drive disc (2) with travel drive off the rubber
buffers and lay it down.

Fig. 1
4. Unscrew fastening screws 3 (Fig. 5) and take off
support legs (4).
5. Unscrew fastening screws 1 and take off drive
disc (2).

Fig. 2

Disassembling the exciter unit (travel

motor side)
1. Unscrew both socket head cap screws from the
flange (Fig. 3).

Fig. 3

414 BOMAG 008 913 76

Repairing the drum 7.4
2. Mount bracket 1 (Fig. 11) for the lifting device to
the flange.
3. Unscrew screws (2) from the flange.

i Note
Do not unscrew the thin drawn screws.

Fig. 4
4. Slide the lifting device over the bracket.
5. Force the exciter unit off with two forcing screws
(Fig. 5).

Fig. 5

! Danger
Danger of squashing!
Do not stand or step under suspended loads.
6. Pull the exciter unit out of the drum (Fig. 6).
7. Take the coupling element off the coupling half.

Fig. 6

008 913 76 BOMAG 415

7.4 Repairing the drum

Disassembling the exciter unit (travel

motor side)
1. Unscrew fastening screws 1 (Fig. 7) for the fan.
2. Loosen clamping screw (2).
3. Pull the coupling hub off the shaft.

Fig. 7
4. Unscrew all other fastening screws 1 (Fig. 8) from
the flange.
5. Press the flange off the flanged housing with forc-
ing screws (2).

Fig. 8

Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
6. Lift the flange off the flanged housing (Fig. 9).
7. Take the O-ring out of the groove in the flanged
housing.

Fig. 9

416 BOMAG 008 913 76

Repairing the drum 7.4
8. Unclip the circlip from the groove in the flange
(Fig. 10).

Fig. 10
9. Press the cylinder roller bearing with forcing
screws out of the flange (Fig. 11).

Fig. 11
10. Take the exciter unit (Fig. 12) out of the flanged
housing.

Fig. 12
11. Knock the radial seal (Fig. 13) out of the flanged
housing.

Fig. 13

008 913 76 BOMAG 417

7.4 Repairing the drum

12. Unclip the circlip from the groove in the flanged

housing (Fig. 14).

Fig. 14
13. Press the cylinder roller bearing with forcing
screws out of the flanged housing (Fig. 15).

Fig. 15
14. Extract inner ring 1 (Fig. 16) for the radial seal
and inner bearing races (2).

! Danger
Danger of burning!
Wear safety gloves.

i Note
If the rings are very tight, heat them up with a
torch.

Fig. 16
15. Unclip the circlip from the basic weight (Fig. 17).

Fig. 17

418 BOMAG 008 913 76

Repairing the drum 7.4
16. To change shaft 1 (Fig. 18) knock out dowel pins
(2 and 3) and press the shaft out of the basic
weight.

i Note
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).

Fig. 18

Disassembling the exciter unit (vibra-

tion motor side)
1. Unscrew fastening screw 1 (Fig. 19).
2. Take rectangular rubber buffer (2) with spacer
block (3) off the side plate.

i Note
Remove both rectangular rubber buffers.

Fig. 19
3. Unscrew fastening screws 1 (Fig. 20).
4. Force cover (2) together with the attached vibra-
tion motor off the side plate with forcing screws.

Fig. 20

008 913 76 BOMAG 419

7.4 Repairing the drum

5. To change the vibration motor loosen clamping

screw 1 (Fig. 21) and pull off coupling half (2).

Fig. 21
6. Unscrew fastening screws 1 (Fig. 22).
7. Take the vibration motor off the cover.

Fig. 22
8. Remove the coupling element (Fig. 23).

Fig. 23
9. Fasten the lifting device.
10. Unscrew fastening screws 1 (Fig. 24).

! Caution
The four short fastening screws (2) must re-
main screwed in (the two others are not visi-
ble).

Fig. 24

420 BOMAG 008 913 76

Repairing the drum 7.4
11. Press the exciter unit out of the drum with forcing
screws (Fig. 25).

i Note
The second forcing screw is covered by the side
plate.

Fig. 25

!Caution
Danger of squashing!
Do not stand or step under suspended loads.
12. Pull the exciter unit out of the drum (Fig. 26).

Fig. 26

Removing, dismantling the side plate

1. Take off V-ring 1 (Fig. 27).
2. Unclip circlip (2).

Fig. 27
3. Attach the disassembly device to the side plate
(Fig. 28) and force off the side plate.

Fig. 28

008 913 76 BOMAG 421

7.4 Repairing the drum

4. Lift the side plate of the flanged hub (Fig. 29).

Fig. 29
5. Knock the grooved roller bearing out of the side
plate (Fig. 30) and take out the spacer ring.

Fig. 30
6. Unclip the circlip from the side plate (Fig. 31).

Fig. 31
7. Take the mechanical seal off the flanged hub
(Fig. 32).

Fig. 32

422 BOMAG 008 913 76

Repairing the drum 7.4
Dismantling the exciter unit (vibration
motor side)
1. Unscrew the fastening from the coupling hub.
2. Pull coupling hub (2) off the shaft using a pulling
device (Fig. 33).

Fig. 33
3. Loosen hose clamp 1 (Fig. 34).
4. Pull coupling hub (2) off the shaft.

Fig. 34
5. Unscrew all other fastening screws 1 (Fig. 35)
and press the flanged hub off the flanged housing
with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged
housing.

Fig. 35

008 913 76 BOMAG 423

7.4 Repairing the drum

8. Unclip the circlip from the groove in the flanged

hub (Fig. 36).

Fig. 36
9. Knock the cylinder roller bearing out of the flang-
ed hub (Fig. 37).

Fig. 37

Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
10. Lift the exciter unit out of the flanged housing (Fig.
38).

Fig. 38
11. Knock the radial seal (Fig. 39) out of the flanged
housing.

Fig. 39

424 BOMAG 008 913 76

Repairing the drum 7.4
12. Unclip the circlip from the groove in the flanged
housing (Fig. 40).

Fig. 40
13. Press the cylinder roller bearing with forcing
screws out of the flanged housing (Fig. 41).

Fig. 41
14. Extract inner rings 1 (Fig. 42) for the radial seals
and inner bearing races (2) from the shaft.

! Danger
Danger of burning!
Wear protective gloves.

i Note
If the rings are very tight, heat them up with a
torch.

Fig. 42
15. Unclip the circlip from the basic weight and re-
move the cover (Fig. 43).

i Note
The shafts cannot be pressed out. If damaged
they must be replaced with basic weight and cov-
er.
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).

Fig. 43

008 913 76 BOMAG 425

7.4 Repairing the drum

Assembling the exciter unit (vibration

motor side)
! Caution
Ensure strict cleanliness.

i Note
If the shafts are damaged they must be inserted
into the basic weight or the cover as follows.

! Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
Fig. 44 nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.

! Caution
Close the bores on the short shaft with a
screw.
1. Cool the shaft down in liquid nitrogen.
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
44).
3. Secure shaft 1 (Fig. 45) with dowel pins (2 and 3).

! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.

i Note
Unscrew the screw from the shaft.

Fig. 45

! Caution
Close the bores on the short shaft with a
screw.
4. Cool the shaft down in liquid nitrogen.
5. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
46).

Fig. 46

426 BOMAG 008 913 76

Repairing the drum 7.4
6. Secure shaft 2 (Fig. 47) with dowel pins (1 and 3).

! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.

i Note
Unscrew the screw from the shaft.

Fig. 47
7. Insert the fitting key into the keyway in the respec-
tive shaft (Fig. 48).

Fig. 48
8. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 49).

Fig. 49 ! Danger
Danger of burning!
Wear safety gloves.
9. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 50).

Fig. 50

008 913 76 BOMAG 427

7.4 Repairing the drum

! Danger

Danger of burning!
Wear safety gloves.
10. Heat the inner ring up to approx. 50° C and slide
it onto the short shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 51).

Fig. 51

! Danger
Danger of burning!
Wear safety gloves.
11. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 52).

Fig. 52

!Danger
Danger of burning!
Wear safety gloves.
12. Heat the inner ring up to approx. 50° C and slide
it onto the longer shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 53).

Fig. 53
13. Press cylinder roller bearing 1 (Fig. 54) with
pressing plate (2) into the flanged housing until it
bottoms.

Fig. 54

428 BOMAG 008 913 76

Repairing the drum 7.4
14. Insert the circlip into the groove in the flanged
housing (Fig. 55).

Fig. 55
15. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 56).
16. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.

Fig. 56

!Caution
Danger of squashing!
Do not stand or step under suspended loads.
17. Insert the exciter unit with the longer shaft for-
ward into the flanged housing (Fig. 57).

Fig. 57
18. Press cylinder roller bearing 1 (Fig. 58) with
pressing plate (2) into the flanged hub until it bot-
toms.

Fig. 58

008 913 76 BOMAG 429

7.4 Repairing the drum

19. Insert the circlip into the groove in the flanged hub
(Fig. 59).

Fig. 59
20. Attach the flanged hub to the flanged housing
(Fig. 60).

! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
21. Unscrew eye bolts (1) and replace them with
short screws.
22. Turn short screws (2) into the tapped bores in the
flanged housing (four screws) and tighten them.

Fig. 60
23. Apply some grease to the sealing lip of radial seal
1 (Fig. 61).
24. Insert the radial seal into the flanged hub with the
sealing lip facing down and press it down against
the stop with pressing bushing (2).

Fig. 61 ! Danger
Danger of burning!
Wear protective gloves.
25. Heat the coupling hub up to approx. 80 °C and
slide it onto the shaft against the stop (Fig. 62).

Fig. 62

430 BOMAG 008 913 76

Repairing the drum 7.4
26. Apply some grease to the sealing lip of radial seal
1 (Fig. 63).
27. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).

Fig. 63
28. Cover the thread of screw 1 (Fig. 64) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
29. Slide on the new U-seal ring (2), turn in and tight-
en the screws.

Fig. 64 ! Danger

Danger of burning!
Wear safety gloves.
30. Heat coupling hub 1 (Fig. 65) with marking letter
“L“ up t approx. 80° C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).

Fig. 65

008 913 76 BOMAG 431

7.4 Repairing the drum

Assembling and installing the side

plate
1. Fill grooved ball bearing 1 (Fig. 66) on both sides
with grease.
2. Press the grooved ball bearing completely in us-
ing pressing plate (2).

Fig. 66
3. Insert the circlip into the groove in the side plate
(Fig. 67).

Fig. 67
4. Apply a thick coat of grease to the spacer ring on
both sides and insert it into the side plate (Fig.
68).

Fig. 68

432 BOMAG 008 913 76

Repairing the drum 7.4
5. Fill grooved ball bearing 1 (Fig. 69) on one sides
with grease.
6. Insert the grooved ball bearing with the grease
side forward and press it completely in with
pressing plate (2).

i Note
Grease the other side after installing the exciter
unit.

Fig. 69
7. Insert the oiled loop-ring into the mechanical seal
(Fig. 70).
8. Clean the sliding surfaces of the mechanical seal
and cover them with oil.

Fig. 70
9. Lay one half of the radial seal on the flanged hub
with the sliding surface pointing up (Fig. 71).

Fig. 71
10. Lay the second half of the mechanical seal down
with the sliding face pointing down (Fig. 72).

Fig. 72

008 913 76 BOMAG 433

7.4 Repairing the drum

11. Bolt the threaded section of the assembly device

to the flanged hub (Fig. 73).

Fig. 73 ! Caution
Danger of squashing! Do not stand or step
under suspended loads.
12. Lay the side plate on the flanged hub (Fig. 74).

Fig. 74
13. Attach bushing 2 (Fig. 75) of the assembly device
and turn on nut (1).

Fig. 75
14. Pull the side plate with the assembly device onto
the flanged hub.

! Caution
During assembly make sure that the mechan-
ical seal slides correctly into the side plate
and the loop rings are not damaged (Fig. 76).

Fig. 76

434 BOMAG 008 913 76

Repairing the drum 7.4
15. Remove the assembly device.
16. Insert the circlip into the groove in the flanged hub
(Fig. 77).

Fig. 77

Assembling the exciter unit (travel

motor side)
!Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.

! Caution
Ensure strict cleanliness.
1. Cool the shaft down in liquid nitrogen.
Fig. 78
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
78).
3. Secure shaft 1 (Fig. 79) with dowel pins (2 and 3).

! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.

Fig. 79

008 913 76 BOMAG 435

7.4 Repairing the drum

4. Insert the circlip into the groove in the basic

weight and on the cover (Fig. 80).

Fig. 80

! Danger
Danger of burning!
Wear safety gloves.
5. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 81).

Fig. 81

! Danger
Danger of burning!
Wear safety gloves.
6. Heat the inner ring up to approx. 50° C and slide
it onto the shaft against the shoulder with the wid-
er chamfer facing towards the outside (Fig. 82).

Fig. 82

! Danger
Danger of burning!
Wear safety gloves.
7. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 83).

Fig. 83

436 BOMAG 008 913 76

Repairing the drum 7.4
8. Press cylinder roller bearing 1 (Fig. 84) with
pressing plate (2) into the flanged housing until it
bottoms.

Fig. 84
9. Insert the circlip into the groove in the flanged
housing (Fig. 85).

Fig. 85
10. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 86).
11. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.

Fig. 86 ! Caution
Danger of squashing! Do not stand or step
under suspended loads.
12. Insert the exciter unit into the flanged housing
(Fig. 87).

Fig. 87

008 913 76 BOMAG 437

7.4 Repairing the drum

13. Press cylinder roller bearing 1 (Fig. 88) with

pressing plate (2) into the flange until it bottoms.

Fig. 88
14. Insert the circlip into the groove in the flange (Fig.
89).

Fig. 89
15. Lift the flange onto the flanged housing and align
it the bores (Fig. 90).

! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.

Fig. 90
16. Turn the screws into the tapped bores of the
flanged housing and tighten them (Fig. 91).

Fig. 91

438 BOMAG 008 913 76

Repairing the drum 7.4
17. Apply some grease to the sealing lip of radial seal
1 (Fig. 92).
18. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).

Fig. 92
19. Cover the thread of screw 1 (Fig. 93) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
20. Slide on the new U-seal ring (2), turn in and tight-
en the screws.

Fig. 93
21. Insert the fitting key into the keyway of the shaft
(Fig. 94).

Fig. 94 ! Danger
Danger of burning!
Wear safety gloves.
22. Slide the fan with assembly disc over the shaft.
23. Heat coupling hub 1 (Fig. 95) with marking letter
“R“ up to approx. 80° C and slide it over the shaft
against the shoulder.
24. Turn in and tighten clamping screw (2).
25. Assemble the fan to the coupling hub.

Fig. 95

008 913 76 BOMAG 439

7.4 Repairing the drum

Assembling the exciter unit (travel

motor side)
1. Check coupling elements , replace if necessary.
2. Insert the coupling element into the coupling hub
(Fig. 96).

! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
3. Fasten the lifting device to the exciter unit.

Fig. 96 ! Caution
Danger of squashing! Do not stand or step
under suspended loads.
4. Insert the vibrator unit into the drum (Fig. 97).

Fig. 97 i Note
Insert the exciter unit so that oil filler plug 1 (Fig.
98) is in line with bore (2) in the drum.

Fig. 98

440 BOMAG 008 913 76

Repairing the drum 7.4
5. Turn in and tighten screws 2 (Fig. 99).
6. Remove bracket (1) for the lifting device.

Fig. 99
7. Cover the thread of screws (Fig. 100) with a
screw retention agent (e.g. Loctite green 270).
8. Slide on the new U-seal ring, turn in and tighten
the screws.

Fig. 100

Installing the travel motor

1. Assemble drive disc 2 (Fig. 101) and support (4)
with screws (3).

Fig. 101

! Danger
Danger of squashing!
Do not stand or step under suspended loads.
2. Attach the drive disc 2 (Fig. 102) with the assem-
bled travel drive (3) to the rubber buffers. Turn on
and tighten the nuts (1).

Fig. 102

008 913 76 BOMAG 441

7.4 Repairing the drum

Installing the exciter unit (vibration

motor side)

! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.

! Danger
Danger of squashing! Do not stand or step
under suspended loads.
1. Fasten the lifting gear to the exciter unit and insert
it into the drum (Fig. 103).

Fig. 103

! Caution
Ensure correct engagement of coupling and
alignment of shaft (Fig. 104).
If the shafts are not correctly in line determine
the cause, if necessary measure the drum.

Fig. 104
2. Turn in and tighten screws 1 (Fig. 105).
3. Remove the lifting gear.
4. Fit cover (2) to the drum.

Fig. 105

442 BOMAG 008 913 76

Repairing the drum 7.4
5. Check the end float of the exciter shafts (Fig.
106).

Nominal value: 0.6...1.8 mm

Fig. 106
6. Attach disc 1 (Fig. 107), turn in and tighten the
fastening screws (2).

Fig. 107
7. Lay a new V-ring over the journal of the flanged
hub (Fig. 108).
8. Fill the grooved ball bearing with grease.

Fig. 108
9. Check coupling element, replace if necessary.
10. Insert the coupling element into the coupling hub
(Fig. 109).

Fig. 109

008 913 76 BOMAG 443

7.4 Repairing the drum

11. Fasten the vibration motor 1 (Fig. 110) to the cov-

er (5) so that the hydraulic connections and the
ventilation bore are opposite each other.
12. Turn in fastening screw (2) with ball disc (3) and
ball socket (4) and tighten.

Fig. 110
13. Slide on coupling half 2 (Fig. 111) and secure with
clamping screw (1).

Fig. 111
14. Attach the cover 2 (Fig. 112) with the installed vi-
bration motor, turn in and tighten the screws (1).

Fig. 112
15. Install rectangular rubber buffers 2 (Fig. 113) with
attached spacer block (3) and screws (1) to the
side plate.

i Note
Assemble both rectangular rubber buffers.

Fig. 113

444 BOMAG 008 913 76

Repairing the drum 7.4

008 913 76 BOMAG 445

7.5 Dismantling, assembling the change-over weights

7.5 Dismantling, assembling the change-

over weights

Dismantling the change-over weight

1. Unscrew all screws (Fig. 3).

Fig. 1
2. Force the cover off the basic weight with forcing
screws (Fig. 5).

Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.

Fig. 2
3. Take the change-over weight out of the basic
weight (Fig. 6).

Fig. 3

446 BOMAG 008 913 76

Dismantling, assembling the change-over weights 7.5
4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.

Fig. 4

Assembling the change-over weights

! Caution
Ensure strict cleanliness.
1. Install new O-rings 1 and 2 (Fig. 5) with grease.

Fig. 5
2. Insert the change-over weight into the basic
weight (Fig. 6).

Fig. 6
3. Fill silicon oil 47 V 1000 cst up to the upper edge
of the change-over weight (approx. 2,5 litres) into
the basic weight (Fig. 13).

Fig. 7

008 913 76 BOMAG 447

7.5 Dismantling, assembling the change-over weights

4. Attach the cover (Fig. 14), so that the raised are-

as are in line.
5. Turn in screws with screw retention agent (e.g.
Loctite blue 243) and tighten with 120 Nm.
6. Check the end float of the shaft.

i Note
There must be play.

Fig. 8

448 BOMAG 008 913 76

Changing the rubber buffers and adjusting the pretension 7.6
7.6 Changing the rubber buffers and ad-
justing the pretension
Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buff-
ers and rectangular buffers are relieved of any
load (Fig. 1).
2. Loosen all fastening screws.

Fig. 1
3. Turn one screw each into the welded nuts (Fig. 2)
on the spacer blocks.

Fig. 2
4. Remove the compensation shims 1 (Fig. 3).

Fig. 3

008 913 76 BOMAG 449

7.6 Changing the rubber buffers and adjusting the pretension

5. Unscrew the screws (Fig. 4) from the welded

nuts.

Fig. 4
Changing the rubber buffers
6. Unscrew nut 1 (Fig. 3) and remove the washer.
7. Unscrew screws (2).
8. Take off rubber buffer (3).
9. Attach the new rubber buffer to the drive disc and
align the bores to the tapped bores in the drum.
10. Turn in and tighten the fastening screws.
11. Assemble the washer, turn on and tighten the nut.

Fig. 5
Adjusting the pre-load
12. Measure distance „X“ between spacer piece and
side plate (Fig. 6).
13. Calculate the thickness of the compensation
plates.

Nominal value:
Distance „X“ + 2 mm

Fig. 6
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 7).

Fig. 7

450 BOMAG 008 913 76

Changing the rubber buffers and adjusting the pretension 7.6
15. Insert the compensation shims 1 (Fig. 8).

Fig. 8
16. Unscrew the screws (Fig. 9) from the welded
nuts.

Fig. 9
17. Tighten the fastening screws (Fig. 10).
18. Lower the frame again.

Fig. 10

008 913 76 BOMAG 451

7.6 Changing the rubber buffers and adjusting the pretension

452 BOMAG 008 913 76

8 Oscillating articulated joint

008 913 76 BOMAG 453

8.1 Special tools

8.1 Special tools

1. Pressing mandrel for rocker bearings

Fig. 1
2. Pressing sleeve for outer race of rocker bearing

Fig. 2
3. Pressing sleeve for inner race of rocker bearing

Fig. 3
4. Guide journal

Fig. 4

454 BOMAG 008 913 76

Special tools 8.1
5. Clamping device

Fig. 5
6. Disassembly device

Fig. 6

008 913 76 BOMAG 455

8.2 Repair overview oscillating articulated joint

1 Housing 12 Rear shell

2 Seal ring 13 Rear shell
3 Rear shell 14 Intermediate ring
4 Self-aligning bearing 15 Self-aligning bearing
5 Bolt 16 Intermediate ring
6 Shim/supporting disc 17 Self-aligning bearing
7 Belleville springs 18 Beam
8 Self-aligning bearing 19 Friction bearing
9 Console 20 V-ring
10 Belleville springs 21 Seal ring
11 Shim/supporting disc

456 BOMAG 008 913 76

Repair overview oscillating articulated joint 8.2

008 913 76 BOMAG 457

8.2 Repair overview oscillating articulated joint

458 BOMAG 008 913 76

Removing and installing the oscillating articulated joint 8.3
8.3 Removing and installing the oscillat-
ing articulated joint
1. Jack up the frame (Fig. 1) at the back and secure
it with trestles or wooden blocks.

Fig. 1
2. Support the rear frame near the oscillating articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.

Fig. 2
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).

Fig. 3

008 913 76 BOMAG 459

8.3 Removing and installing the oscillating articulated joint

4. Unscrew fastening screws 1 (Fig. 4) and take off

axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).

Fig. 4

! Danger
Danger of accident!
7. Support the oscillating articulated joint in the mid-
dle with a suitable jack or a similar device.
8. Unscrew fastening screws 1 (Fig. 5) and take off
with disc (2).

Fig. 5
9. Unscrew nuts 3 (Fig. 6) and take off the clamping
washers (2).
10. Pull out the fastening screws (1).
11. Slightly raise the front frame and lower the oscil-
lating articulated joint to the ground.
12. Pull out the oscillating articulated joint.

Fig. 6
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).

Fig. 7

460 BOMAG 008 913 76

Dismantling the oscillating articulated joint 8.4
8.4 Dismantling the oscillating articulated
joint
1. Unscrew the nuts from hexagon screw 1 (Fig. 1)
and pull out the hexagon screw.
2. Unscrew the screws (2) for the cover.

Fig. 1
3. Take off the cover with Belleville springs, shim
and backing disc (Fig. 2).
4. Disassemble also the cover from the opposite
side.

iNote
No Belleville springs, shim and backing disc are
under this cover.

Fig. 2
5. Drive the console with a plastic hammer to one
side against the end stop (Fig. 3).

i Note
The outer race of the rocker bearing is thereby
stripped off.

Fig. 3

008 913 76 BOMAG 461

8.4 Dismantling the oscillating articulated joint

6. Force inner race 1 (Fig. 4) of the rocker bearing

off the bolt.
7. Take of supporting disc (2).
8. Drive the console to the opposite side and re-
move the rocker bearing in the same way.

Fig. 4
9. Unscrew fastening screws 1 (Fig. 5).
10. Press bolt (3) out of the console with forcing
screws (2).

i Note
Remove the bolt on the opposite side in the same
way.

Fig. 5
11. Lift console 1 (Fig. 6) off housing (2).

Fig. 6
12. Take the seal rings out of the console (Fig. 7).

Fig. 7

462 BOMAG 008 913 76

Dismantling the oscillating articulated joint 8.4
13. Remove the cover from the housing.
14. Take off shims 1 (Fig. 8), backing disc (2) and
Belleville springs (3).

Fig. 8
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).

Fig. 9
16. Take the intermediate ring out of the housing
(Fig. 10).

Fig. 10
17. Place the plate 1 (Fig. 11) on the beam.
18. Attach the puller (2) to the housing (3) and sepa-
rate the carrier from the rocker bearings.

Fig. 11

008 913 76 BOMAG 463

8.4 Dismantling the oscillating articulated joint

19. Pull the housing off the beam (Fig. 12).

Fig. 12
20. Drive the outer race of the friction bearing out of
the housing (Fig. 13).

Fig. 13
21. Drive the friction bearing out of the housing (Fig.
14).

Fig. 14
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.

Fig. 15

464 BOMAG 008 913 76

Dismantling the oscillating articulated joint 8.4
23. Check rocker bearings, if necessary press out of
the housing (Fig. 16).

Fig. 16

008 913 76 BOMAG 465

8.5 Assembling the oscillating articulated joint

8.5 Assembling the oscillating articulated

joint
1. If previously disassembled, press the rocker
bearing fully into the housing with a pressing
mandrel (Fig. 1).

i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly

! Caution
Do not use any grease.

Fig. 1
2. Slide the new V-ring on the beam against the stop
with the lip facing up (Fig. 2).

Fig. 2
3. Lay the seal ring into the beam (Fig. 3).
4. Fill the space between V-ring and seal ring with
multi-purpose grease.

Fig. 3

466 BOMAG 008 913 76

Assembling the oscillating articulated joint 8.5
5. Press the friction bearing fully into the housing
with the chamfered side pointing towards the out-
side (Fig. 4).

Fig. 4
6. Slide the housing over the beam (Fig. 5).

i Note
The journal on the housing must be centrally in
the recess of the beam.

Fig. 5
7. Press the seal ring carefully towards the inside,
until it sits in the recess of the housing (Fig. 6).

Fig. 6
8. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.

! Caution
Do not use any grease.
9. Press the outer rocker bearing race 1 (Fig. 7) in
until it bottoms with the wider outer rim forward
using pressing sleeve (2).

Fig. 7

008 913 76 BOMAG 467

8.5 Assembling the oscillating articulated joint

10. Press inner rocker bearing race 1 (Fig. 8) in until

it bottoms, using pressing sleeve (2).

Fig. 8
11. Insert the intermediate ring (Fig. 9).

Fig. 9
12. Press inner rocker bearing race 1 (Fig. 10) in until
it bottoms, using pressing sleeve (2).

Fig. 10

i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly

! Caution
Do not use any grease.
13. Press the outer rocker bearing race 1 (Fig. 11) in
until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).

Fig. 11

468 BOMAG 008 913 76

Assembling the oscillating articulated joint 8.5
14. Press in intermediate ring 1 (Fig. 12) until it bot-
toms.
15. Attach cover (2) with the machined edge forward.
16. Turn in screws (3) and tighten crosswise.

Fig. 12
Determining the shim thickness
17. Determine the shim thickness, for this purpose
stand the cross-member on a wooden board with
an ∅ 18 mm bore.

! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
Fig. 13 tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.

i Note
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thick-
ness.
Calculation example:
4,7 mm - 4,0 mm = 0,7 mm
measured value: 4,7 mm
fixed value: 4,0 mm
Shim thickness: 0,7 mm
20. Remove the tensioning device.

008 913 76 BOMAG 469

8.5 Assembling the oscillating articulated joint

21. Insert shim 2 (Fig. 14) of appropriate thickness

and backing disc (1) into the cover.

Fig. 14
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).

Fig. 15
23. Assemble cover 2 (Fig. 16) with Belleville springs,
shim and backing disc.
24. Turn in screws (1) and tighten crosswise.

Fig. 16
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).

Fig. 17

470 BOMAG 008 913 76

Assembling the oscillating articulated joint 8.5
26. Lift console 1 (Fig. 18) over the housing (2).

Fig. 18
27. Turn four guide pins into the housing bores (Fig.
19).

Fig. 19

i Note
Perform the following eight work steps on both
sides.
28. Slide the bolt over the guide pins (Fig. 20) and
drive in until it bottoms.

Fig. 20

! Caution
When driving in the bolt make sure that the
seal ring is not pressed out through the back
of the console (Fig. 21).

Fig. 21

008 913 76 BOMAG 471

8.5 Assembling the oscillating articulated joint

29. Unscrew the guide pins .

30. Turn in the screws and tighten with 75 Nm (Fig.
22).

Fig. 22
31. Slide the backing discs over the bolt (Fig. 23).

Fig. 23
32. Drive the inner rocker bearing race on against the
end stop with the wider outer rim forward (Fig.
24).

Fig. 24
33. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.

! Caution
Do not use any grease.
34. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.

Fig. 25

472 BOMAG 008 913 76

Assembling the oscillating articulated joint 8.5
35. Attach cover 1 (Fig. 26) to the bottom side of the
console.
36. Turn in and tighten screws (2).

Fig. 26
Determining the shim thickness
37. Determine the shim thickness, for this purpose in-
sert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.

! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.

Fig. 27
38. Measure the distance from outer rocker bearing
race to console surface (Fig. 28) and write it
down, e.g. 3.4 mm.

i Note
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thick-
ness.
Calculation example:
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
Fig. 28 fixed value: 2,2 mm
Shim thickness: 1.2 mm
39. Remove the tensioning device.

008 913 76 BOMAG 473

8.5 Assembling the oscillating articulated joint

40. Insert shims 2 (Fig. 29) of appropriate thickness

and backing disc (1) into the cover.

Fig. 29
41. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 30).

Fig. 30
42. Assemble cover 1 (Fig. 31) with Belleville springs,
shims and supporting discs.
43. Turn in screws (2) and tighten crosswise.

Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.

Fig. 32

474 BOMAG 008 913 76

Assembling the oscillating articulated joint 8.5
45. Assemble the washer, turn on and tighten the nut
with 120 Nm (Fig. 33).

Fig. 33

008 913 76 BOMAG 475

8.5 Assembling the oscillating articulated joint

476 BOMAG 008 913 76

9 Suppliers documentation

008 913 76 BOMAG 477

478 BOMAG 008 913 76
9.1 Travel pump / vibration pump series 90R

008 913 76 BOMAG 479

9.1 Travel pump / vibration pump series 90R

480 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 481

9.1 Travel pump / vibration pump series 90R

482 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 483

9.1 Travel pump / vibration pump series 90R

484 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 485

9.1 Travel pump / vibration pump series 90R

486 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 487

9.1 Travel pump / vibration pump series 90R

488 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 489

9.1 Travel pump / vibration pump series 90R

490 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 491

9.1 Travel pump / vibration pump series 90R

492 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 493

9.1 Travel pump / vibration pump series 90R

494 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 495

9.1 Travel pump / vibration pump series 90R

496 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 497

9.1 Travel pump / vibration pump series 90R

498 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 499

9.1 Travel pump / vibration pump series 90R

500 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 501

9.1 Travel pump / vibration pump series 90R

502 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 503

9.1 Travel pump / vibration pump series 90R

504 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 505

9.1 Travel pump / vibration pump series 90R

506 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 507

9.1 Travel pump / vibration pump series 90R

508 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 509

9.1 Travel pump / vibration pump series 90R

510 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 511

9.1 Travel pump / vibration pump series 90R

512 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 513

9.1 Travel pump / vibration pump series 90R

514 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 515

9.1 Travel pump / vibration pump series 90R

516 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 517

9.1 Travel pump / vibration pump series 90R

518 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 519

9.1 Travel pump / vibration pump series 90R

520 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 521

9.1 Travel pump / vibration pump series 90R

522 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 523

9.1 Travel pump / vibration pump series 90R

524 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 525

9.1 Travel pump / vibration pump series 90R

526 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 527

9.1 Travel pump / vibration pump series 90R

528 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 529

9.1 Travel pump / vibration pump series 90R

530 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 531

9.1 Travel pump / vibration pump series 90R

532 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 533

9.1 Travel pump / vibration pump series 90R

534 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 535

9.1 Travel pump / vibration pump series 90R

536 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 537

9.1 Travel pump / vibration pump series 90R

538 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 539

9.1 Travel pump / vibration pump series 90R

540 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 541

9.1 Travel pump / vibration pump series 90R

542 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 543

9.1 Travel pump / vibration pump series 90R

544 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 545

9.1 Travel pump / vibration pump series 90R

546 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 547

9.1 Travel pump / vibration pump series 90R

548 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 549

9.1 Travel pump / vibration pump series 90R

550 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 551

9.1 Travel pump / vibration pump series 90R

552 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 553

9.1 Travel pump / vibration pump series 90R

554 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 555

9.1 Travel pump / vibration pump series 90R

556 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 557

9.1 Travel pump / vibration pump series 90R

558 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 559

9.1 Travel pump / vibration pump series 90R

560 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 561

9.1 Travel pump / vibration pump series 90R

562 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 563

9.1 Travel pump / vibration pump series 90R

564 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 565

9.1 Travel pump / vibration pump series 90R

566 BOMAG 008 913 76

Travel pump / vibration pump series 90R 9.1

008 913 76 BOMAG 567

9.1 Travel pump / vibration pump series 90R

568 BOMAG 008 913 76

9.2 Vibration motor A2FM

008 913 76 BOMAG 569

9.2 Vibration motor A2FM

570 BOMAG 008 913 76

Vibration motor A2FM 9.2
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 91 001-03-R/05.03
Konstantmotor A2FM/E ersetzt / replaces 04.00

Fixed Displacement Motor A2FM/E

Baureihe / Series 61

Reparaturanleitung / Repair Instructions

008 913 76 BOMAG 571

9.2
2 Bosch Rexroth AG | Mobile Hydraulics A2F | RDE 91motor
Vibration 001-03-R/05.03
A2FM

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 Seite/ CONTENTS

Page

A2F A2F

Schnittbild 3-6 Sectional view

Allgemeine Reparaturhinweise 7 General repair instructions
Dichtsätze und Baugruppen 8-9 Seal kits and sub-assemblies
Triebwelle abdichten 10 Sealing of the drive shaft
Anschlußplatte abdichten 11-14 Sealing of the cover plate
Triebwerk ausbauen 15-16 Removal the rotary group
Überprüfungshinweise 17-18 Inspection guidelines
Triebwerk einbauen 19-21 Installing rotary group
Anziehdrehmomente 22-24 Tightening torques
Sicherheitsbestimmungen 25 Safety regulations

572 BOMAG 008 913 76

RDE 91 001-03-R/05.03
Vibration motor A2FM| A2F Mobile Hydraulics | Bosch Rexroth AG 9.23
Schnittbild
Sectional view

A2FM Pos.B

Pos.D

Pos.A

Meßpunkte: Measuring points:

Siehe Serviceinfo See service information

008 913 76 BOMAG 573

9.2
4 Bosch Rexroth AG | Mobile Hydraulics A2F | RDE 91motor
Vibration 001-03-R/05.03
A2FM

Schnittbild
Sectional view

A2FM mit Spülventil /

A2FM with flushing valve

574 BOMAG 008 913 76

RDE 91 001-03-R/05.03
Vibration motor A2FM| A2F Mobile Hydraulics | Bosch Rexroth AG 9.25
Schnittbild
Sectional view

A2FE

008 913 76 BOMAG 575

9.2
6 Bosch Rexroth AG | Mobile Hydraulics A2F | RDE 91motor
Vibration 001-03-R/05.03
A2FM

Schnittbild
Sectional view

A2FE

576 BOMAG 008 913 76

Vibration motor A2FM 9.2

008 913 76 BOMAG 577

9.2 Vibration motor A2FM

578 BOMAG 008 913 76

Vibration motor A2FM 9.2

008 913 76 BOMAG 579

9.2 Vibration motor A2FM

580 BOMAG 008 913 76

Vibration motor A2FM 9.2

008 913 76 BOMAG 581

9.2 Vibration motor A2FM

582 BOMAG 008 913 76

Vibration motor A2FM 9.2

008 913 76 BOMAG 583

9.2 Vibration motor A2FM

584 BOMAG 008 913 76

RDE 91 001-03-R/05.03
Vibration motor A2FM| A2F Mobile Hydraulics | Bosch Rexroth AG 9.2
15

Triebwerk ausbauen
Removal the rotary group

Lagersatz / Bearing set

Demontage der Anschlußplatte.

Steuerplatte abheben.
Zylinder am Mittelzapfen mit Schraube befestigen.

Removal of the connection plate.

Lift off the control plate.
Secure the cylinder to the centre pin using a screw.

Gewindestift,Zylinderschraube /
Threaded pin,socket head screw

NG / Size (mm)

10; 12; 16 M3 x 35
23; 28; 32 M5 x 45
45 M5 x 50
56; 63 M5 x 55
80; 90 M5 x 60
107; 125; 131 M6 x 70
160; 180 M6 x 85

008 913 76 BOMAG 585

9.2 Vibration motor A2FM

586 BOMAG 008 913 76

Vibration motor A2FM 9.2

008 913 76 BOMAG 587

9.2 Vibration motor A2FM

588 BOMAG 008 913 76

Vibration motor A2FM 9.2

008 913 76 BOMAG 589

9.2 Vibration motor A2FM

590 BOMAG 008 913 76

Vibration motor A2FM 9.2

008 913 76 BOMAG 591

9.2 Vibration motor A2FM

592 BOMAG 008 913 76

Vibration motor A2FM 9.2

008 913 76 BOMAG 593

9.2 Vibration motor A2FM

594 BOMAG 008 913 76

Vibration motor A2FM 9.2

008 913 76 BOMAG 595

9.2
26 Bosch Rexroth AG | Mobile Hydraulics A2F | RDE 91motor
Vibration 001-03-R/05.03
A2FM

596 BOMAG 008 913 76

RDE 91 001-03-R/05.03
Vibration motor A2FM| A2F Mobile Hydraulics | Bosch Rexroth AG 9.2
27

008 913 76 BOMAG 597

9.2 Vibration motor A2FM

Bosch Rexroth AG
Mobile Hydraulics
Produktbereich Axialkolbenmaschinen
Werk / Plant 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 Bosch Rexroth AG, © 2003 by Bosch Rexroth AG,

Mobile Hydraulics, 89275 Elchingen Mobile Hydraulics, 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 Bosch Rexroth AG reproduziert oder
any form or by any means, without the unter Verwendung elektronischer
prior written authorization of Bosch Systeme gespeichert, verarbeitet,
Rexroth AG. In the event of vervielfältigt oder verbreitet werden.
contravention of the above provisions, Zuwiderhandlungen verpflichten zu
the contravening party is obliged to 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
remembered that our products are zu beachten, dass unsere Produkte
subject to a natural process of wear einem natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.

Printed in Germany
RDE 91 001-03-R/05.03

598 BOMAG 008 913 76

9.3 Travel drive series 51

008 913 76 BOMAG 599

9.3 Travel drive series 51

600 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 601

9.3 Travel drive series 51

602 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 603

9.3 Travel drive series 51

604 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 605

9.3 Travel drive series 51

606 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 607

9.3 Travel drive series 51

608 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 609

9.3 Travel drive series 51

610 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 611

9.3 Travel drive series 51

612 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 613

9.3 Travel drive series 51

614 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 615

9.3 Travel drive series 51

616 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 617

9.3 Travel drive series 51

618 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 619

9.3 Travel drive series 51

620 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 621

9.3 Travel drive series 51

622 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 623

9.3 Travel drive series 51

624 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 625

9.3 Travel drive series 51

626 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 627

9.3 Travel drive series 51

628 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 629

9.3 Travel drive series 51

630 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 631

9.3 Travel drive series 51

632 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 633

9.3 Travel drive series 51

634 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 635

9.3 Travel drive series 51

636 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 637

9.3 Travel drive series 51

638 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 639

9.3 Travel drive series 51

640 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 641

9.3 Travel drive series 51

642 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 643

9.3 Travel drive series 51

644 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 645

9.3 Travel drive series 51

646 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 647

9.3 Travel drive series 51

648 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 649

9.3 Travel drive series 51

650 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 651

9.3 Travel drive series 51

652 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 653

9.3 Travel drive series 51

654 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 655

9.3 Travel drive series 51

656 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 657

9.3 Travel drive series 51

658 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 659

9.3 Travel drive series 51

660 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 661

9.3 Travel drive series 51

662 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 663

9.3 Travel drive series 51

664 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 665

9.3 Travel drive series 51

666 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 667

9.3 Travel drive series 51

668 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 669

9.3 Travel drive series 51

670 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 671

9.3 Travel drive series 51

672 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 673

9.3 Travel drive series 51

674 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 675

9.3 Travel drive series 51

676 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 677

9.3 Travel drive series 51

678 BOMAG 008 913 76

Travel drive series 51 9.3

008 913 76 BOMAG 679

9.3 Travel drive series 51

680 BOMAG 008 913 76

9.4 Transmission CR

008 913 76 BOMAG 681

9.4 Transmission CR

682 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 683

9.4 Transmission CR

684 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 685

9.4 Transmission CR

686 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 687

9.4 Transmission CR

688 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 689

9.4 Transmission CR

690 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 691

9.4 Transmission CR

692 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 693

9.4 Transmission CR

694 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 695

9.4 Transmission CR

696 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 697

9.4 Transmission CR

698 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 699

9.4 Transmission CR

700 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 701

9.4 Transmission CR

702 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 703

9.4 Transmission CR

704 BOMAG 008 913 76

Transmission CR 9.4

008 913 76 BOMAG 705

9.4 Transmission CR

706 BOMAG 008 913 76

9.5 Axle DANA 193

008 913 76 BOMAG 707

9.5 Axle DANA 193

708 BOMAG 008 913 76

Axle DANA 193 9.5

008 913 76 BOMAG 709

9.5 Axle DANA 193

710 BOMAG 008 913 76

Axle DANA 193 9.5

008 913 76 BOMAG

1 711
9.5 Axle DANA 193

PRINTED IN ITALY
Copyright By DANA ITALIA S.p.A.
Vietata la riproduzione anche parziale di testo ed illustrazioni
Realizzazione a cura dell'Ufficio Post Vendita della DANA ITALIA S.p.A.
Impaginazione: TEMAS s.r.l. - Gallarate (Va)
Stampa: Agosto 1999 (N.L. 7416)

Data subject to change without notice. We decline all responsability for the use of non-original components, or accessories which have
not been tested and submitted for approval.
Dati soggetti a modifiche senza impegno di preavviso. Si declina ogni responsabilitaÁ per l'utilizzo di componenti non originali o accessori
non collaudati ed approvati.
AÈnderungen ohne vorherige AnkuÈndingung vorbehalten. Es wird jede Verantwortung fuÈr die Verwendung von Nichtoriginalteilen oder
nicht abgenommenem und genehmigtem ZubehoÈr abgelehnt.
Los datos pueden ser modificados sin aviso previo. Se declina toda responsabilidad en el caso de uso de componentes no originales o
bien de accesorios no ensayados y aprobados.
Le constructeur se reÂserve le droit d'apporter des modifications aÁ sa production, sans pour cela eÃtre tenu d'en donner preÂavis. Nous
deÂclinons toute responsabilite pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.

712 BOMAG
2 008 913 76
Axle DANA 193 9.5

INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX

INTRODUCTION ..........................................................5 DIFFERENTIAL UNIT

GB MAINTENANCE AND LUBRICANTS . Removal and disassembly ....................................................44
. Definition of viewpoints............................................7 . Assembly and installation .....................................................54
. Data plate ..............................................................................7 REDUCTION GEAR AND BEVEL PINION
. Maintenance points ................................................................7 . Disassembly.........................................................................68
. Maintenance intervals.............................................................8 . Installation and adjustment ...................................................74
. Adjustment and checks ..........................................................8
. Conversion tables...................................................................9 SPECIAL TOOLS ......................................................................82
. Tightening torques .................................................................9
. Screw-locking, sealing, and lubricating materials ...................10
NOTES ON SAFETY PRECAUTIONS ........................................13
CHECKING WEAR AND REPLACING THE BRAKING DISKS
. Disassembling the braking units............................................14
. Assembling the braking units ................................................20
. Mechanical and manual release of the axle ...........................28
PLANETARY REDUCTION AND AXLE SHAFT
. Disassembly.........................................................................30
. Assembly .............................................................................38

INTRODUZIONE .......................................................5 GRUPPO DIFFERENZIALE

ITA . Rimozione e smontaggio.......................................................44
MANUTENZIONE E LUBRIFICANTI
. Definizione viste ..................................................7 . Assemblaggio ed installazione ..............................................54
. Targa matricola ......................................................................7 RIDUTTORE E PIGNONE CONICO
. Punti di manutenzione ............................................................7 . Smontaggio..........................................................................68
. Intervalli di manutenzione .......................................................8 . Installazione e registrazione..................................................74
. Registrazione e controlli .........................................................8 ATTREZZI SPECIALI.................................................................82
. Tabelle di conversione............................................................9
. Coppie di serraggio ................................................................9
. Materiali per bloccaggio viti, tenuta e lubrificazione................10
NOTE RIGUARDANTI LA SICUREZZA ......................................13
CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO
. Smontaggio gruppi di frenatura .............................................14
. Assemblaggio dei gruppi di frenatura ....................................20
. Sbloccaggio meccanico manuale dell'assale..........................28
RIDUTTORE EPICICLOIDALE E SEMIASSE
. Smontaggio..........................................................................30
. Assemblaggio ......................................................................38

VORAUSSETZUNG .................................................5 DIFFERENTIAL

D . Abmontieren und zerlegen ....................................................44
WARTUNG UND SCHMIERSTOFFE
. Definition der Ansichten......................................7 . Montieren und installieren.....................................................54
. Kennummernschild.................................................................7 REDUZIERER UND KEGELRAD
. Wartungsstellen .....................................................................7 . Abmontieren ........................................................................68
. Wartungsintervalle..................................................................8 . Installieren und einstellen .....................................................74
. Einstellungen und Kontrollen ..................................................8 SONDERWERZZEUGE ..............................................................82
. Umrechnungstabellen.............................................................9
. Anziehdrehmomente...............................................................9
. Material zur Blockierung von Schrauben und
fuÈr Dichtungen und Schmiermittel .........................................10
BEMERKUNGEN ZUR SICHERHEIT...........................................13
VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN
AUSWECHSELN
. Bremsaggregate abmontieren ...............................................14
. Bremsaggregate montieren ...................................................20
. Achse mechanisch manuell entsichern ..................................28
PLANETENGETRIEBE UND HALBACHSE
. Abmontieren ........................................................................30
. Montieren ............................................................................38

008 913 76 BOMAG

3 713
9.5 Axle DANA 193
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX

PROLOGO................................................................ 5 GRUPO DIFERENCIAL

ESP MANTENIMIENTO Y LUBRICANTES . Remocion y desmontaje ....................................................... 44
. Definicion vistas................................................... 7 . Montaje e instalacion ........................................................... 54
. Matricula ............................................................................... 7 REDUCTOR Y PINÄON CONICO
. Puntos de manutencion.......................................................... 7 . Remocion ............................................................................ 68
. Intervalos de manutencioÁn...................................................... 8 . Instalacion y ajuste .............................................................. 74
. Ajuste y controles .................................................................. 8 HERRAMIENTAS ESPECIALES................................................. 82
. Tablas de conversion ............................................................. 9
. Pares de torsion .................................................................... 9
. Materiales para el bloqueo, estanqueidad y lubricacion ......... 10
NORMAS CONCERNIENTES A LA SEGURIDAD ....................... 13
CONTROL DEL DESGASTE Y SUSTITUCION DE LOS
DISCOS DEL FRENO
. Montaje de los grupos de frenado......................................... 14
. Desmontaje de los grupos de frenado................................... 20
. Desbloqueo manual de los axal ............................................ 28
REDUCTOR EPICICLOIDAL Y SEMIEJES
. Desmontaje ......................................................................... 30
. Montaje ............................................................................... 38

INTRODUCTION ....................................................... 5 GROUPE DIFFERENTIEL

F ENTRETIEN ET LUBRIFIANTS . Depose et demontage .......................................................... 44
. DeÂfinition vues ..................................................... 7 . Assemblage et installation .................................................... 54
. Plaque d'immatriculation ........................................................ 7 REDUCTEUR ET PIGNON CONIQUE
. Points d'entretien................................................................... 7 . Depose................................................................................ 68
. Intervalle de service ............................................................... 8 . Installation et reglage ........................................................... 74
. Reglages et controles............................................................. 8 OUTILS SPECIAL ..................................................................... 82
. Tableaux de conversion ......................................................... 9
. Couples de serrage................................................................ 9
. MateÂriaux pour le blocage vis, eÂtancheÂite et lubrification........ 10
NOTES EN MATIERE DE SECURITE......................................... 13
CONTROLE D'USURE ET SUBSTITUTION DES
DISQUES DE FREINAGE
. Desassemblage des groupes de freinage .............................. 14
. Assemblage des groupes de freinage ................................... 20
. Deblocage mecanique manuel de l'essieu............................. 28
REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU
. Demontage.......................................................................... 30
. Assemblage......................................................................... 38

714 BOMAG
4 008 913 76
Axle DANA 193 9.5
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION

The efficiency and continued operation of mechan- martelli in plastica o rame, leve appropriate estrattori e chiavi
GB ical units depend on constant, correct maintenance specifiche, al fine di facilitare il lavoro salvaguardando nel
and also on efficient repair work, should there be a contempo le superfici lavorate e la sicurezza degli operatori.
break-down or malfunction. The instructions contained in this Prima di procedere al disassemblaggio delle parti e scaricare
manual have been based on a complete overhaul of the unit. l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte,
However, it is up to the mechanic to decide whether or not it is asportando incrostazioni ed accumuli di grasso.
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick PREMESSA: Tutti gli organi meccanici smontati, devono
and sure guide which, with the use of photographs and essere accuratamente puliti con prodotti appropriati, quindi
diagrams illustrating the various phases of the operations, ripristinati o sostituiti nel caso presentino danni, usura,
allows accurate work to be performed. incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ
All the information needed for correct disassembly, checks and di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
assembly of each individual component is set out below. In conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
order to remove the differential unit from the vehicle, the maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la
manuals provided by the vehicle manufacturer should be sostituzione degli organi di tenuta ogni qualvolta si proceda alla
consulted. In describing the following operations it is presumed revisione o riparazione dei componenti. Al momento del
that the unit has already been removed from the vehicle.
montaggio, gli anelli di tenuta devono essere lubrificati sui
IMPORTANT: In order to facilitate work and protect both bordi di tenuta. Nel caso della coppia conica, la sostituzione di
working surfaces and operators, it is advisable to use proper uno dei suoi ingranaggi comporta anche la sostituzione
equipment such as: trestles or supporting benches, plastic or dell'altro. In fase di montaggio sono da rispettare scrupolosa-
copper hammers, appropriate levers, pullers and specific mente i giochi, i precarichi e le coppie prescritte.
spanners or wrenches. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma
VALIDITA
Before going on to disassemble the parts and drain the oil, it is
di matricola. Al fine di una corretta interpretazione, le validitaÁ
best to thoroughly clean the unit, removing any encrusted or
sono indicate come:
accumulated grease.
= fino alla matricola
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate = dalla matricola
products and restored or replaced if damage, wear, cracking or
seizing have occurred. Se non sono indicate validitaÁ, le operazioni di smontaggio ed
In particular, thoroughly check the condition of all moving parts assemblaggio sono comuni a tutte le versioni.
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
wear. In any case, it is advisable to replace the seals every time interventi sui gruppi ponte differenziali e cambi di velocitaÁ la
a component is overhauled or repaired. During assembly, the SPICER CLARK-HURTH, ha ritenuto opportuno compilare
sealing rings must be lubricated on the sealing edge. In the queste istruzioni di manutenzione e riparazione. I disegni delle
case of the crown wheel and pinion, replacement of one attrezzature specifiche eventualmente necessarie per l'esecu-
component requires the replacement of the other one. During zione di interventi di manutenzione e riparazione possono
assembly, the prescribed pre-loading, backlash and torque of essere acquistati direttamente presso il costruttore; i ricambi
parts must be maintained. possono essere ordinati tramite il costruttore della macchina o
direttamente presso la DANA ITALIA S.p.A..
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number Die Leistung und Lebensdauer der mechanischen
D Teile haÈngt nicht nur von einer staÈndigen und
= from the part number on richtig durchgefuÈhrten Wartung sondern auch von
einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses
When no classification is given, disassembly and assembly Handbuch zu erstellen sind wir von einer allgemeinen U È ber-
operations are the same for all versions. pruÈfung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of werden muÈssen oder nicht. Das Handbuch ist schnell und
all specific tools required for maintenance and repair work can einfach nachzuschlagen und ermoÈglicht es anhand der Abbild-
be found at the end of this manual ; spare parts may be ordered ungen und der Zeichnungen, die die verschiedenen VorgaÈnge
either from the vehicle manufacturer or directly from the darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
Service Centers or Authorised Distributors of DANA ITALIA mationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung
S.p.A.. und Montage der Einzelteile noÈtig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den HandbuÈchern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, daû die
Il rendimento e la continuitaÁ degli organi meccanici Fahrzeugachse schon abmontiert worden ist.
ITA dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento, WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
nell'eventualitaÁ di guasti o anomalie. verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der
Nel proporre questo manuale si eÁ considerata l'ipotesi di una Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werk-
revisione generale del gruppo ma eÁ il meccanico a valutare la zeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeig-
necessitaÁ di montare solo i singoli componenti nel caso di nete Abzieher und SchluÈssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O Èl
riparazione. Il manuale eÁ una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni abgelassen wird, muû die Achse sorgfaÈltig gereinigt und
prospettici che illustrano le varie fasi delle operazioni. Di Verkrustungen und Fettablagen abgetragen werden.
seguito sono riportate tutte quelle informazioni ed avvertenze VORAUSSETZUNG: Alle abmontierten mechanischen Teile
necessarie al corretto disassemblaggio, alle relative verifiche muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt
ed all'assemblaggio dei singoli componenti. Per la rimozione oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen
del ponte differenziale dal veicolo, eÁ necessario consultare i usw. ausgewechselt werden. Insbesondere muû der einwand-
manuali forniti dal costruttore del veicolo. Nel descrivere le freie Zustand aller beweglichen Teile (Lager, ZahnraÈder,
operazioni seguenti, si presuppone che il ponte sia giaÁ stato Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O È lab-
rimosso dal veicolo. dichtungen), die am meisten beansprucht werden und ver-
schleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die
IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare Abdichtungselemente immer auszuwechseln, wenn eine U È ber-
attrezzature idonee quali cavalletti o banchi di sostegno, holung oder eine Reparatur der Teile vorgenommen wird. Bei
008 913 76 BOMAG
5 715
9.5 Axle DANA 193
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION

der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos de
Spiele, Vorspannungen und Drehmomente strengstens ein- las herramientas especificas necesarias para la ejecucioÂn de las
gehalten werden. intervenciones de mantenimiento figuran al final del manual; los
recambios se pueden pedir al fabricante de la maÂquina o
È LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern directamente al Service Center o a Distribuidores autorizados de
GU DANA ITALIA S.p.A..
die Einheiten gehoÈren. Der Einfachheit halber sind die
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer

= ab Kennummer Le rendement et la continuite des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapidite d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂcessite de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
DANA ITALIA S.p.A. bezogen werden. toutes les informations et preÂcautions neÂcessaires pour un
deÂmontage correct et les veÂrifications et assemblage de
chaque composant. En ce qui concerne le deÂplacement du
pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels
El rendimiento y la duracioÂn de los oÂrganos mecaÂnicos
fournis par le constructeur du veÂhicule. En deÂcrivant les
ESP depende, ademaÂs que del constante y correcto opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mantenimiento, tambieÂn de la intervencioÂn inmediata enleve du veÂhicule.
en caso de averõÂas o anomalõÂas.
Al proponer este manual, ha sido considerada la suposicioÂn de una IMPORTANT: Pour faciliter le travail en sauvegardant en
revisioÂn general del grupo, pero es el mecaÂnico quien tiene que meÃme temps les surfaces usineÂes et la seÂcurite des opeÂra-
valorar la necesidad de montar cada uno de los componentes en teurs, il est preÂconise d'utiliser des installations approprieÂes
caso de reparacioÂn. El manual es una guõÂa raÂpida y segura que telles que des eÂtais ou banc de support, maillets en plastique
permite intervenciones precisas por medio de fotografõÂas y de ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
planos que muestran las distintas fases de las operaciones. A
continuacioÂn figuran todas las informaciones y advertencias Avant de proceÂder au deÂmontage des parties et vidanger
necesarias para ejecutar un montaje correcto, para las comproba- l'huile, il vaut mieux nettoyer soigneusement le pont, en
ciones y el montaje de cada uno de los componentes. Para enlevant incrustations et blocs de gras.
remover el puente diferencial del vehõÂculo hay que consultar los
manuales de los fabricantes del vehõÂculo. En la descripcioÂn de las PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
operaciones siguientes se supone que el puente ya ha sido sacado doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
del vahõÂculo. approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
IMPORTANTE: Para facilitar el trabajo salvaguardando al mismo particulier, de toutes les parties en mouvement (paliers,
tiempo las superficies mecanizadas y la seguridad de los
operadores, se aconseja que se usen equipos y herramientas engrenages, couple conique, arbres) et l'eÂtancheÂite des
adecuados como caballetes y bancos de soporte, martillos de bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
plaÂstico o de cobre, palancas adecuadas, extractores y llaves sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
especõÂficas. substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
Antes de desmontar las partes y descargar el aceite, es effectue une reÂvision ou une reÂparation des composants. Au
conveniente que se haga una limpieza minuciosa del puente moment du montage, les bagues d'eÂtancheÂite doivent eÃtre
sacando las incrustaciones y acumulaciones de grasa. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
conique, la substitution de l'un de ses engrenages comporte
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados eÂgalement la substitution de l'autre. En phase de montage, il
tienen que ser limpiados minuciosamente con productos adecua-
dos y restaurados o sustituidos en el caso de que presenten danÄos, faut respecter scrupuleusement les jeux, les preÂcharges et les
desgaste, rajaduras, agarrotamientos, etc. En particular, compro- couples prescrits.
bar la integridad de todas las partes en movimiento (cojinetes,
engranajes, par coÂnico, ejes) y de estanqueidad (anillos OR, VALIDITE: Le manuel fournit la validite des groupes sous
detenedor de aceite) sujetas a mayores solicitaciones y desgaste. forme de matricule. Pour une meilleure interpreÂtation, les
Se aconseja, de todas formas, que se sustituyan los oÂrganos de validiteÂs sont indiqueÂes comme:
estanqueidad cada vez que se ejecute la revisioÂn o reparacioÂn de
los componentes. = jusqu'aÁ l'immatriculation
Al volver a montar, los segmentos de compresioÂn tienen que estar
lubricados en los bordes de estanqueidad. En el caso del par = aÁ partir de l'immatriculation et apreÁs
coÂnico, la sustitucioÂn de uno de sus engranajes comporta tambieÂn
la sustitucioÂn del otro. Al montar hay que tener en cuenta Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
escrupulosamente los juegos, las precargas y los pares descriptos.
deÂmontage et d'assemblage sont pareilles dans toutes les
VALIDEZ: El manual suministra la validez de los grupos en forma versions.
de matrõÂcula. Para poder tener una interpretacioÂn correcta, la
validez esta indicada: INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
Les dessins des installations speÂcifiques neÂcessaires pour
= hasta la matrõÂcula effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
= desde la matrõÂcula en adelante constructeur de la machine ou directement aux Centres de
Services, ou Distributeurs agreÂeÂs de la SocieÂte DANA ITALIA
S.p.A..

716 BOMAG
6 008 913 76
Axle DANA 193
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
9.5
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS

DEFINITION OF VIEWPOINTS - DEFINIZIONE VISTE - DEFINITION DER ANSICHTEN - DEFINICION VISTAS - DEÂFINITION VUES

LEFT SIDE RIGHT SIDE

LATO SINISTRO LATO DESTRO
LINKE SEITE RECHTE SEITE
LADO IZQUIERDO LADO DERECHO
COTE GAUCHE COTE DROITE

D1240138

DATA PLATE - TARGA MATRICOLA - KENNUMMERNSCHILD - MATRICULA - PLAQUE D'IMMATRICULATION

Type and model unit - modification index

1
Tipo e modello gruppo - indice di modifica
Typ und Modelleles Antriebes - AÈ nderungsverzeichnis
Tipo y modelo grupo - indice de modificacion
Type et modeÂle de ensemble - tableau des modifications

1 2 Serial number

2
Numero di serie
Seriennummer
3 NuÂmero de serie
Numero de serie
MFG. BY CLARK-HURTH COMPONENTS S.P.A. Lubricant

3
38062 Arco (Trento) Lubrificante
Schmieroel
MADE IN ITALY Lubricante
Lubrificant
D1240011

MAINTENANCE POINTS - PUNTI DI MANUTENZIONE - WARTUNGSSTELLEN - PUNTOS DE MANUTENCION - POINTS D'ENTRETIEN

3 1 1 1 3

2 2 2 2
2

1
Oil filling plug - Tappo di carico
EinfuÈllstopfen - Tapon de carga
Bouchon de ravitaillement

2
Oil draining plug - Tappo di scarico
1 3 Ablasstopfen - Tapon de descarga
Bouchon de vidange

2
3
Check level plug - Tappo controllo livello
È lpegelkontrolle -
Stopfen zur O
Tapon de contrl de nivel - Jauge de niveau
D1240139

008 913 76 BOMAG

7 717
9.5 Axle DANA 193

MAINTENANCE INTERVALS - INTERVALLI DI MANUTENZIONE - WARTUNGSINTERVALLE - INTERVALOS DE MANUTENCIOÁN - INTERVALLE DE SERVICE

OPERATION - OPERAZIONE - FREQUENCY - PERIODICITAÁ

LUBRICANTS - LUBRIFICANTI - SCHMIERSTOFFE -
ARBEITSVORGANG - - ZEITABSTAND -
LUBRICANTES - LUBRIFIANTS
OPERACION - OPERATION FRECUENCIA - PERIODICITE
Differential monthly
Differenziale mensile
Im differential monatlich . SAE85W90 (API GL4 - MIL L-2105)
. Check levels: Diferencial cada mes With additives for oil-bath brakes
. Controllo livelli: Differentiel mensuel Con additivi per freni a bagno d'olio
. È
Olstandkontrolle: Mit Zusatzmittel fuÈr Bremsen in OÈ lbad
. Control niveles: Planetary reduction every 200 hours
Con aditivos para frenos de banÄo de aceite
. ControÃle niveaux: Riduzione epicicloidale ogni 200 ore
Avec adjuvants pour freins en bain d'huile
Planetengetrieb alle 200 Std.
ReduccioÂn epicicloidal cada 200 horas . SAE85W90 (API GL5 - MIL 2105-B)
Reduction epicycloidale toutes les 200 heures With additives for oil-bath brakes, for units pre-
Differential every 800 hours ] senting hypoid crown wheel and pinion and /or
Differenziale ogni 800 ore self-locking differential gear
Im differential alle 800 Std. Per esecuzioni con coppia conica ipoide e/o con
Diferencial cada 800 horas differenziale autobloccante, con additivi per freni
Differentiel toutes les 800 heures a bagno d'olio
Bei AusfuÈhrungen mit Kegel- und Telleradpaar
. Oil change: Planetary reduction every 1000 hours ]
und/oder Selbstsperrdifferential, mit Zusatzmit-
. Cambio olio: Riduzione epicicloidale ogni 1000 ore È lbad
È lwechsel: teln fuÈr Bremsen in O
. O Planetengetrieb alle 1000 Std.
Para ejecuciones con par coÂnico hipoide y/o con
. Cambio aceite: ReduccioÂn epicicloidal cada 1000 horas
diferencial autobloqueante con aditivos para fre-
. Vidange huile: Reduction epicycloidale toutes les 1000 heures
nos de banÄo de aceite.
Self-locking differential gear every 700 hours ] r Pour exeÂcutions avec couple conique hypoõÈde et/
Differenziale autobloccante ogni 700 ore ou diffeÂrentiel autobloquant, avec adjuvants pour
Selbstsperrdifferential alle 700 Std. freins en bain d'huile
Diferencial autobloqueante cada 700 horas
Differentiel autobloquant toutes les 700 heures
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100 horas
de trabajo - Initialement apreÁs 100 heures de travail
r When it starts sounding noisy - Anche ai primi cenni di rumorositaÁ - Auch falls ungewoÈhnliche GeraÈusche zu bemerken sind - TambieÂn al primer
indicio de ruido - MeÃme aux premiers signaux de bruit
OPERATION - OPERAZIONE - MEMBER - ORGANO - CONDITIONS - CONDIZIONI - FREQUENCY - PERIODICITAÁ - LUBRICANTS - LUBRIFICANTI -
ARBEITSVORGANG - ELEMENT - BEDINGUNG - ZEITABSTAND - SCHMIERSTOFFE -
OPERACION - OPERATION ORGANO - ORGANE CONDICIONES - CONDITIONS FRECUENCIA - PERIODICITE LUBRICANTES - LUBRIFIANTS
Normal work monthly
Lavori normali mensile
Normale Arbeit monatlich
Greasing Articulations Trabajos normales cada mes
Ingrassaggio Snodi TaÃches ordinaires mensuel
Schmieren Gelenk MOLIKOTE
Engrase RoÂtula Awkward work Weekly
Graissage Articulations Lavori gravosi Settimanale
Schwere Arbeit WoÈchentlich
Trabajos pesados Semanal
TaÃches extraordinaires Hebdomadaire

ADJUSTMENT AND CHECKS - REGISTRAZIONE E CONTROLLI - EINSTELLUNGEN UND KONTROLLEN - AJUSTE Y CONTROLES - REGLAGES ET CONTROLES

UNIT - GRUPPO - OPERATION - OPERAZIONE FREQUENCY - PERIODICITAÁ - SERVICE BRAKE CIRCUIT - CIRCUITO COMANDO FRENI -
AGGREGAT - ARBEITSVORGANG - ZEITABSTAND - BREMSKREISLAUF - CIRCUITO MANDOS FRENOS -
GRUPO - GROUPE OPERACION - OPERATION FRECUENCIA - PERIODICITE CIRCUIT DE COMMANDE DES FREINS
Negative brake Adjustment every 1000 hours ]
Freno negativo Registrazione ogni 1000 ore Only for mineral oil use e.g. ATF Dexron II. Make sure
Federspeicherbremse Einstellen alle 1000 Std. that master cylinder seals are suitable for mineral oil.
Freno negativo Ajuste cada 1000 horas Usare esclusivamente olio minerale ATF Dexron II. Ac-
Frein neÂgatif ReÂglage toutes les 1000 hours certarsi che le guarnizioni del cilindro master siano
adatte a questo olio.
Service brake Adjustment every 500 hours È l verwenden, z.B.: ATF Dexron II.
Nur mineralisches O
Freni di servizio Registrazione ogni 500 ore
Achtung: Dichtringe des Hauptbremszylinders muÈs-
Hilfsbremse Einstellen alle 500 Std. È l geeignet sein.
sen fuÈr dieses O
Frenos de ejercicio Ajuste cada 500 horas
Usar exclusivamente aceite mineral ATF Dexron II.
Freins de service ReÂglage toutes les 500 hours
Asegurarse de que las juntas del cilindro principal
Wheel nuts Tightening every 200 hours son adecuadas para este aceite.
Dadi ruota Serraggio - ogni 200 ore Utiliser exclusivement huile mineÂrale ATF Dexron II.
Radmuttern Festziehen alle 200 Std. VeÂrifier que les joints du maõÃtre-cylindre, soien compa-
Tuercas rueda Apriete cada 200 horas tibles avec cette huile.
Ecrous de roue Serrage toutes les 200 hours
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100
horas de trabajo - Initialement apreÁs 100 heures de travail
718 BOMAG
8 008 913 76
Axle DANA 193 9.5

CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN

TABLAS DE CONVERSION - TABLEAUX DE CONVERSION

Units of pressure - UnitaÁ di pressione - Druckeinheiten

Unidad de presioÂn - UniteÂs de pression: 1 Atm%1 bar%105 PA%14.4 PSi

Units of weight - UnitaÁ di peso - Gewichtseinheiten Units of torque - UnitaÁ di coppia - Drehmomenteinheiten
Unidad de peso - UniteÂs de poids Unidad de par - UniteÂs de couple
N daN kN kg lbs Nm daNm kNm kgm lb-in
1N 1 0,1 0,001 0,102 0,225 1Nm 1 0,1 0,001 0,102 8,854
1daN 10 1 0,01 1,02 2,25 1daNm 10 1 0,01 1,02 88,54
1kN 1000 100 1 102 225 1kNm 1000 100 1 102 8854
1kg 9,81 0,981 0,00981 1 2,205 1kgm 9,81 0,981 0,00981 1 86,8
1lb-in 0,1129 0,01129 0,0001129 0,01152 1

TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE

PARES DE TORSION - COUPLES DE SERRAGE

Unit - UnitaÁ di misura - Meûeinheiten - Unidad de medida - UniteÂs de mesure: Nm

TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS
SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS 8.8 10.9 12.9
TAMAN Ä O TORNILLO
MESURE VIS Normali Normali Normali Normali Normali Normali
+ Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270
M6 x 1 9,5-10,5 10,5-11,5 14,3-15,7 15,2-16,8 16,2-17,8 18,1-20,0
COARSE PITCH - PASSO GROSSO - GROûER
SCHRITT - PASO GRUESO - GROS PAS

M8 x 1,25 23,8-26,2 25,6-28,4 34,2-37,8 36,7-40,5 39,0-43,0 43,7-48,3

M10 x 1,5 48-53 52-58 68-75 73-81 80-88 88-97
M12 x 1,75 82-91 90-100 116-128 126-139 139-153 152-168
M14 x 2 129-143 143-158 182-202 200-221 221-244 238-263
M16 x 2 200-221 219-242 283-312 309-341 337-373 371-410
M18 x 2,5 276-305 299-331 390-431 428-473 466-515 509-562
M20 x 2,5 390-431 428-473 553-611 603-667 660-730 722-798
M22 x 2,5 523-578 575-635 746-824 817-903 893-987 974-1076
M24 x 3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27 x 3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30 x 3,5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
FINE PITCH - PASSO FINE - KLEINER SCHRITT

M8 x 1 25,7-28,3 27,5-30,5 36,2-39,8 40,0-44,0 42,8-47,2 47,5-52,5

M10 x 1,25 49,4-54,6 55,2-61,0 71,5-78,5 78,0-86,0 86,0-94,0 93,0-103,0
M12 x 1,25 90-100 98-109 128-142 139-154 152-168 166-184
M12 x 1,5 86-95 94-104 120-132 133-147 143-158 159-175
PASO FINO - PAS FIN

M14 x 1,5 143-158 157-173 200-222 219-242 238-263 261-289

M16 x 1,5 214-236 233-257 302-334 333-368 361-399 394-436
M18 x 1,5 312-345 342-378 442-489 485-536 527-583 580-641
M20 x 1,5 437-483 475-525 613-677 674-745 736-814 808-893
M22 x 1,5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082

008 913 76 BOMAG

9 719
9.5 Axle DANA 193

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR
BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION -
MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITEÂ ET LUBRIFICATION

1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
I materiali per il bloccaggio, tenuta e lubrificazione specifica indicati nel manuale, sono quelli usati in fabbrica.
Die Materialien zur Blockierung von Schrauben, fuÈr Dichtungen und Schmiermittel, die im Handbuch aufgefuÈhrt sind, sind
dieselben die auch vom Hersteller verwendet werden.
Los materiales para el bloqueo, estanqueidad y lubricacioÂn especõÂfica indicados en el manual, son los que se usan en la faÂbrica
Les mateÂriaux de blocage, d'eÂtancheÂite et de lubrification speÂcifieÂs indiqueÂs dans ce manuel sont ceux employeÂs aÁ l'usine.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar
products marketed by different brand names with different trade marks.
Di questi materiali, vengono riportate le applicazioni tipiche che li distinguono, in modo da poterli sostituire con prodotti similari
commercializzati da altre marche e quindi con altre sigle.
Von diesen Materialien werden die typischen Anwendungen genannt, um sie mit aÈhnlichen Materialien zu ersetzen, die unter
anderen Namen und Kennzeichnungen im Handel erhaÈltlich sind.
De estos materiales damos las aplicaciones tõÂpicas que los distinguen, de manera que se puedan sustituir con productos similares
comercializados por otras marcas y por tanto con otras siglas.
De ces mateÂriaux ne sont reporteÂes que les applications typiques qui les distinguent de telle sorte qu'ils puissent eÃtre substitueÂs
par des produits semblables se trouvant dans le commerce sous d'autres marques et par conseÂquent sous d'autres sigles.

DENOMINATION
DENOMINAZIONE
BEZEICHNUNG APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength loc-
king. Before using it, completely remove any lubricant by using the specific activator.
. Prodotto anaerobico adatto a prevenire l'allentamento di viti, dadi e tappi. Usato per la frenatura a media re-
sistenza. Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
. Anaerobes Produkt, um das Lockern von Schrauben, Muttern und Stopfen zu verhindern. FuÈr mittlere Wi-
derstandskraÈfte geeignet. Darf erst aufgetragen werden, wenn die FlaÈchen von Schmiermittel richtig sauber
Loctite 242
sind. Dazu das entsprechende Produkt verwenden.
. Producto anaeroÂbico apto para prevenir el aflojamiento de tornillos, tuerca y tapones. Usado para el frenado
de media resistencia. Tiene que ser usado soÂlo despueÂs de haber quitado todo residuo de lubricante con el
activador especõÂfico.
. Produit anareÂobic servant aÁ preÂvenir le relaÃchement des vis, eÂcrous et bouchons. Utilise pour le freinage
demi reÂsistant. Il doit eÃtre utilise apreÁs avoir enleve toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
. Prodotto alternativo al 242 che, essendo oleocompatibile, non richiede l'attivazione di superfici lubrificate.
. Alternatives Produkt zu Loctite 242. Da es oÈlkompatibel ist muÈssen die geschmierten FlaÈchen nicht aktiviert
Loctite 243 werden.
. Producto alternativo al 242 que, siendo oleocompatible, no requiere la activacioÂn de superficies lubricadas.
. Produit en alternance avec le 242 lequel eÂtant oleÂocompatible ne requiert aucune activation des surfaces
lubrifieÂes.
. Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any
lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80ëC approx.
. Prodotto anaerobico adatto per la frenatura ad altissima resistenza di viti e dadi. Deve essere usato dopo aver
asportato ogni traccia di lubrificante con l'attivatore specifico.
La rimozione delle parti, puoÁ richiedere un riscaldamento a circa 80ëC.
. Anaerobes Produkt fuÈr hohe WiderstandskraÈfte fuÈr Schrauben und Muttern geeignet. Zuerst die FlaÈche sorg-
Loctite 270
faÈltig aktivieren. Um die FlaÈchen zu saÈubern, diese auf ca. 80ëC erwaÈrmen.
. Producto anaeroÂbico apto para el frenado de alta resistencia de tornillos y tuercas. tiene que ser usado de-
spueÂs de haber quitado todo residuo de lubricante con el activador especõÂfico.
La remocioÂn de las partes, puede requerir un calentamiento a unos 80ëC.
. Produit anareÂobic apte au freinage aÁ treÁs haute reÂsistance des vis et des eÂcrous. Il doit eÃtre utilise apreÁs avoir
enleve toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts,
for pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a max.
diametrical clearance of 0.25 mm.
. Prodotto anaerobico adatto per la frenatura e sigillatura ad alta resistenza di parti filettate, bulloni e prigionieri
di grandi dimensioni, protezione antimanomissione e sigillatura di tubazioni; puoÁ sigillare accoppiamenti con
gioco diametrale massimo di 0,25 mm.
. Anaerobes Produkt zum Bremsen und Siegeln von groûen Gewinden, Muttern und Stiftschrauben , sehr
Loctite 275 widerstandsfaÈhig, verschleierungsbestaÈndig, und zum Siegeln von Rohrleitungen geeignet; kann Kupplun-
gen mit einer maximalen Lagerluft von 0,25 mm siegeln.
. Producto anaerobico apto para el frenado y selladura a alta resistencia de tornillos, tuercas y prisioneros de
grandes dimensiones, protecion anti manomision y selladura de tubaciones ; puede sellar encolcados con
juego diametral.
. Produit anaeÂrobie adapte au freinage et au scellage aÁ haute reÂsistance des parties fileteÂes, boulons et pri-
sonniers de grandes dimensions, protection anti-alteÂration et scellage de tuyauteries; il peut sceller des ac-
couplements ayant un jeu diameÂtral maximal de 0,25 mm.

720 BOMAG
10 008 913 76
Axle DANA 193 9.5

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR
BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION -
MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITEÂ ET LUBRIFICATION

DENOMINATION
DENOMINAZIONE
BEZEICHNUNG APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can
seal clearances between flanges up to 0.2 mm.
. Prodotto anaerobico adatto alla tenuta ermetica di fluidi tra assiemi flangiati e di viti a foro comunicante con i
fluidi. PuoÁ sigillare giochi tra le flange fino a 0,2 mm.
. Anaerobes Produkt zur Abdichtung von FluÈssigkeiten an Flanschen und Schrauben mit LoÈcher, die mit FluÈs-
Loctite 510
sigkeiten in Kontakt stehen. Kann ein Spiel zwischen Flanschen bis 0,2 mm abdichten.
. Producto anaeroÂbico apto para le estanqueidad de fluidos entre grupos bridados y de tornillos de orificio co-
municante con los fluidos. Puede sellar juegos entre las bridas hasta 0,2 mm.
. Produit anareÂobic apte aÁ la tenue eÂtanche des fluides entre les pieÁces aÁ brides et des vis aÁ trou en contact
avec les fluides. Il peut sceller un jeu parmi les flasques jusqu'aÁ 0,2 mm.
. Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using
it, remove any lubricant with the specific activator. After polymerisation, disassembly may result rather dif-
ficult, so heating may be necessary for larger diameters.
. Prodotto anaerobico sigillante rapido per la tenuta di filettature di raccordi conici o cilindrici fino a M80.
Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
Dopo la polimerizzazione presenta una moderata difficoltaÁ di smontaggio per cui puoÁ richiedere, per i diametri
maggiori, un riscaldamento.
. Anaerobes Produkt zum schnellen Siegeln und Abdichten von Kegel- oder Zylinderkupplungen bis M80.
Darf erst aufgetragen werden, nachdem mit einem spezifischen Wirkstoff jede Spur von Schmiermittel ab-
getragen worden ist.
Loctite 577
Nach der Polymerisation koÈnnte das Abmontieren etwas schwierig sein weshalb groÈûere Durchmesser
zuerst erhitzt werden muÈssen.
. Producto anaerobico sellante rapido para el estanqueido de tornillos de empalme conico o cilindrico hasta
M80. Debe de ser utilisado despues de haber quitado cada mancha de lubrificante con activador especifico.
Despues de la polimeracion presenta una moderada dificultaÁde desmontaje por lo tanto puede necesitar, para
los diametros majores, un calientamiento.
. Produit anaeÂrobie collage rapide assurant l'eÂtancheÂite des filetages des raccords coniques ou cylindriques
jusqu'aÁ M80. Il doit eÃtre utilise apreÁs qu'on ait enleve toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
Une certaine difficulte de deÂmontage se preÂsente apreÁs la polymeÂrisation, on peut donc avoir la neÂcessite de
devoir chauffer preÂalablement pour de plus amples diameÁtres.
. Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue to-
gether parts with clearance ranging between 0.1 and 0.25 mm.
. Adesivo anaerobico per l'incollaggio rapido ad alta resistenza di giunti cilindrici in metallo (mozzo su albero).
PuoÁ incollare particolari con gioco tra 0,1 e 0, 25 mm.
. Anaerober Klebstoff fuÈr groûe WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 638
ben). Kann Einzelteil mit einem Radialspiel zwischen 0,1 mm und 0,25 mm zusammenkleben.
. Adhesivo anaeroÂbico para el encolado raÂpido de alta resistencia de juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego entre 0,1 mm y 0,25 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide et hautement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre). Il peut servir aÁ coller des pieÁces avec un jeu allant de 0,1 aÁ 0,25 mm.
. Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue
together parts with radial clearance below 0.1 mm.
. Adesivo anaerobico per l'incollaggio rapido a media resistenza di giunti cilindrici in metallo (mozzo su albero).
PuoÁ incollare particolari con gioco radiale inferiore a 0,1 mm.
. Anaerober Klebstoff fuÈr mittlere WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 648 ben). Kann Einzelteil mit einem Radialspiel von weniger als 0,1 mm zusammenkleben.
. Adhesivo anaeroÂbico para encolado raÂpido de media resistencia juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego radial inferior a 0,1 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide moyennement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre).
Il peut servir aÁ coller des pieÁces avec un jeu radial infeÂrieur aÁ 0,1 mm.
. Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer
diameter of sealing rings for rotating shafts with outer metal reinforcement.
(AREXONS) . Mastice sigillante per guarnizioni elastiche a base di solvente, essicante per evaporazione.
Repositionable jointing
compound for seals Viene utilizzato per la tenuta sul diamentro esterno di anelli di tenuta per alberi rotanti con armatura metallica
Mastice per guarnizioni esterna.
riposizionabile . Klebstoff fuÈr Gummidichtung auf LoÈsemittelbasis, trocknet durch Verdampfung.
Klebstoff fuÈr verstellbare Wird am aÈuûeren Durchmesser von Dichtungsringe bei rotierenden Wellen mit Metallmantel verwendet.
Dichtungen . Pasta para juntas de sellado para juntas elaÂsticas a base de disolvente, deshidratante por evaporacioÂn.
Pasta para juntas Se utiliza para la estanqueidad en el diaÂmetro externo de segmentos de compresioÂn, para ejes giratorios con
reposicionable
armadura metaÂlica exterior.
Mastic pour garnitures aÁ
remettre en place . Mastic adheÂsif aÁ base de solvants pour garnitures eÂlastiques, seÂchant par eÂvaporation.
Il sert garder eÂtanche le diameÁtre exteÂrieur des bagues d'eÂtancheÂite des arbres rotatifs ayant une arma-
ture meÂtallique externe.

008 913 76 BOMAG

11 721
9.5 Axle DANA 193

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR
BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION -
MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITEÂ ET LUBRIFICATION

DENOMINATION
DENOMINAZIONE
BEZEICHNUNG APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and
physical elements. Polymerises with non-corrosive dampness.
Silicone . Materiale adesivo semifluido usato per sigillatura, riempimenti e per la protezione di componenti dagli elementi
Silicone ambientali e fisici. Polimerizza con umiditaÁ non corrosiva.
. HalbfluÈssiger Klebstoff zum Befestigen, FuÈllen und zum Schutz von Bestandteilen vor aÈuûeren Einwirkun-
Silikon
gen. Polymerisiert durch nicht korrosive Feuchtigkeit
Silicona . Material adhesivo semifluido usado para el sellado, llenado y para la proteccioÂn de componentes de elemen-
Silicone tos ambientales y fõÂsicos. Polimeriza con humedad no corrosiva.
. Produit adheÂsif semi-fluide utilise pour le scellage, remplissage et protection des eÂleÂments ambiants et phy-
siques. PolymeÂrise aÁ une humidite non corrosive.
. Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
. Grasso sintetico con elevato grado di adesivitaÁ, additivato con composti siliconici.
(TECNO LUPE/101) Applicato su viti di registrazione a foro comunicante con fluidi di tipo oleoso.
Silicone-based grease Usato quando si richiedono frequenti interventi di registrazione.
Grasso al silicone . Synthetisches Fett mit hoher Haftfestigkeit, mit silikonhaltigen Stoffen legiert.
Wird auf Stellschrauben mit Loch, die mit oÈlhaltigen FluÈssigkeiten in Kontakt stehen, angebracht.
Silikonfett Wird verwendet, wenn die Schraub oÈfters eingestellt werden muû.
Grasa a la silicona . Grasa sinteÂtica con elevado grado de adhesioÂn, aditivada con componentes silicoÂnicos.
Graisse au silicone Aplicada en tornillos de ajuste de orificio comunicante con fluidos de tipo oleoso.
Se usa cuando se requieren frecuentes intervenciones de ajuste.
. Graisse syntheÂtique ayant un degre d'adheÂsivite eÂleveÂ, adjuve de composeÂs au silicone.
Applique sur les vis de reÂglage aÁ trou communiquant avec des fluides du type huileux.
Utilise quand il y a besoin de reÂglages freÂquents.
. Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent
sticking and oxidation of parts that are not lubricated on a regular basis.
. Composto lubrificante contenente bisolfuro di molibdeno, usato per la lubrificazione di perni snodo e per pre-
venire incollamenti ed ossidazioni di particolari non lubrificati in modo continuo.
Molikote . Schmierstoff mit MolybidaÈndisulfid; wird zum Schmieren von Gelenkstiften und gegen Ankleben und Oxy-
(DOW CORNING) dation von nicht dauergeschmierten Einzelteilen verwendet.
. Compuesto lubricante que contiene bisulfuro de molibdeno, usado para la lubricacioÂn de roÂtulas y para pre-
venir encoladuras y oxidaciones de piezas no lubricadas de manera continua.
. Compose lubrifiant contenant du bisulfure de molybdeÁne, utilise pour lubrifier les axes d'articulation et preÂ-
venir collages et oxydations des pieÁces qui ne sont pas continuellement lubrifieÂes.
. Applied to bearings, sliding parts and used to lubricate seals or parts during assembly
(Lithium-based) Grease . Applicato a cuscinetti, parti scorrevoli e per lubrificare guarnizioni o pezzi in fase di montaggio.
Grasso (al Litio) . Wird auf Lager, Gleitteilen aufgetragen und zum Schmieren von Dichtungen oder von Teilen bei der Mon-
(Lithium) Fett tage verwendet.
Grasa (al Litio) . Aplicada a cojinetes, partes deslizables o para lubricar juntas o piezas en fase de montaje.
Graisse (au Lithium) . Applique sur les paliers, parties coulissantes et pour lubrifier les garnitures ou pieÁces pendant la phase de
montage.

722 BOMAG
12 008 913 76
Axle DANA 193 9.5

NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR

SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
1 - During all operations described in this manual, the LoÈsemittel muÈssen als SondermuÈll und auf jeden Fall laut den
GB axle should be fastened onto a trestle, while the oÈrtlich geltenden Vorschriften entsorgt werden.
other parts mentioned should rest on supporting 9- Zur Reinigung ausschlieûlich schwache LoÈsemittel wie Petroleum,
benches. Terpentin oder wasserhaltige LoÈsemittel verwenden. Auf keinen
2 - When removing one of the arms, an anti-tilting safety trestle Fall TrichloraÈthylen, tuolol- oder xylolhlatige LoÈsemittel usw.
should be placed under the other arm. verwenden.
3 - When working on an arm that is fitted on the machine, make sure 10 - Um die ArbeitsvorgaÈnge verstaÈndlich abzubilden, werden in
that the supporting trestles are correctly positioned and that the einigen Fotos die Aggregate ohne Einzelteile gezeigt, die sonst
machine is locked lengthways. bei der Arbeit nicht abmontiert werden muÈssen.
4 - Do not admit any other person inside the work area; mark off the Nur die beschriebenen Teile abmontieren.
area, hang warning signs and remove the ignition key from the 11 - Unter RECHTS und LINKS versteht man in diesem Handbuch die
machine. Seite einer Person, die zur Achse schaut und zwar dem Antrieb
5 - Use only clean, quality tools; discard all worn, damaged, low- entgegengesetzt.
quality or improvised wrenches and tools. Ensure that all 12 - Nach beendeten Arbeiten und um Rostbildungen zu vermeiden,
dynamometric wrenches have been checked and calibrated. die Teile an denen der Lack ggf. beschaÈdigt worden ist,
6 - Always wear gloves and non-slip rubber shoes when performing anstreichen.
repair work. 1 - Las operaciones descritas se refieren al eje blo-
7 - Should you stain a surface with oil, remove marks straight away. ESP queado en un caballete y a algunas partes apoyadas
8 - Dispose of all lubricants, seals, rags and solvents once work has en el banco de trabajo.
been completed. Treat them as special waste and dispose of them 2- Cuando se saca un brazo del eje, colocar debajo del otro un
according to the relative law provisions obtaining in the country caballete de seguridad antivuelco.
where the axles are being overhauled. 3- Si se trabaja con un eje montado en la maÂquina, asegurarse de
9 - Make sure that only weak solvents are used for cleaning haber colocado caballetes soporte y de haber inmovilizado
purposes; avoid using turpentine, dilutants and toluol-, xylol- longitudinalmente la maÂquina.
based or similar solvents; use light solvents such as Kerosene, 4- No permitir que personas extranÄas entren en la zona de trabajo;
mineral spirits or water-based, environment friendly solvents. delimitar esta zona, colgar carteles de aviso de hombres
10 - For the sake of clarity, the parts that do not normally need to be trabajando y sacar las llaves de arranque de la maÂquina.
removed have not been reproduced in some of the diagrams. 5- Usar soÂlo y exclusivamente herramientas limpias y de buena
11 - The terms RIGHT and LEFT in this manual refer to the position of cualidad; descartar llaves o herramientas gastadas o danÄadas, de
the operator facing the axle from the side opposite the drive. calidad mediocre o improvisadas. Asegurarse de que las llaves
12 - After repair work has been completed, accurately touch up any dinamomeÂtricas han sido controladas y calibradas.
coated part that may have been damaged. 6- Durante las operaciones de reparacioÂn, llevar siempre guantes y
calzado antideslizamiento.
1 - Le operazioni descritte sono riferite all'assale bloc- 7- Limpiar inmediatamente las zonas que pudieran estar sucias de
ITA cato su cavalletto ed alcuni particolari appoggiati su aceite.
un banco di lavoro.
8- Los lubricantes, las juntas, los trapos para la limpieza y los
2 - Quando si asporta un braccio dell'assale, sistemare sotto l'altro disolventes usados hay que eliminarlos como desechos especia-
braccio un cavalletto di sicurezza antiribaltamento. les y, de todas formas, de acuerdo con las normativas vigentes en
3 - Se si opera su un'assale montato sulla macchina, assicurarsi di el paõÂs en el que se revisan los ejes.
aver sistemato dei cavalletti di sostentamento e di aver immobi- 9- Para limpiar, utilizar soÂlo disolventes deÂbiles excluyendo en
lizzato longitudinalmente la macchina. absoluto tricloroetileno, diluyentes y disolventes a base de toluol,
4 - Non permettere che persone estranee entrino nella zona di lavoro; silol, etc.; usar soÂlo disolventes ligeros como queroseno, aguarraÂs
delimitare questa zona, appendere dei cartelli di avviso di lavori in minerales o disolventes ecoloÂgicos a base de agua.
corso ed asportare le chiavi di avviamento della macchina. 10 - Para que resulte clara la exposicioÂn y la ilustracioÂn, en las figuras
5 - Usare solo ed esclusivamente attrezzi puliti e di buona qualitaÁ; de algunos grupos faltan algunas piezas que por lo general se
scartare chiavi od attrezzi usurati o danneggiati, di bassa qualitaÁ pueden dejar montadas. Sacar soÂlo las partes descritas.
od improvvisati. Assicurarsi che le chiavi dinamometriche siano 11 - Las palabras DERECHA E IZQUIERDA usadas en el manual se
state controllate e tarate. refieren a la persona que mira el eje del lado opuesto a la toma de
6 - Durante le operazioni di riparazione, indossare sempre guanti e movimiento.
scarpe antiscivolo. 12 - Al final de las reparaciones, para evitar oxidaciones, retocar
7 - Pulire immediatamente le zone eventualmente imbrattate d'olio. cuidadosamente las partes pintadas que estuvieran danÄadas.
8 - I lubrificanti, le guarnizioni, gli eventuali stracci di pulizia ed i
solventi usati devono essere smaltiti come rifiuti speciali e 1 - Les opeÂrations deÂcrites se rapportent aÁ l'essieu
comunque secondo le normative vigenti nel Paese ove vengono F bloque sur chevalet et de quelques pieÁces poseÂes
revisionati gli assali. sur un eÂtabli de travail.
9 - Per la pulizia, usare solo solventi deboli escludendo categorica- 2- Quand on enleÁve un essieu monte sur la machine, ajuster sous
mente trielina, diluenti e solventi a base di toluolo, xilolo, ecc.; l'autre bras un chevalet de seÂcurite contre tout basculement.
usare solo solventi leggeri quali cherosene, ragie minerali o 3- Si on oeuvre sur un essieu monte sur la machine, s'assurer
solventi ecologici a base d'acqua. d'avoir ameÂnage des chevalets de soutien et d'avoir bloque la
10 - Per chiarezza di illustrazione ed esposizione, sulle figure di alcuni machine en longueur.
gruppi mancano dei particolari che, normalmente, possono essere 4- Ne jamais permettre aÁ des eÂtrangers de peÂneÂtrer dans la zone de
lasciati montati. Rimuovere solo i particolari descritti. travail; deÂlimiter cette zone, mettre des pancartes de signalisation
11 - I termini DESTRA e SINISTRA usati nel manuale sono riferiti alla de travaux en cours et enlever les cleÂs de contact de la machine.
persona che guarda l'assale dal lato opposto alla presa di moto. 5- N'utiliser que des outils propres et de bonne qualiteÂ; eÂliminer cleÂ
12 - Al termine delle riparazioni, per evitare dannose ossidazioni, ou autres outils useÂs, abõÃmeÂs, de mauvaise qualite ou improviseÂs.
ritoccare con cura le parti verniciate eventualmente danneggiate. Veiller aÁ ce que les cleÂs dynamomeÂtriques aient eÂte controÃleÂes et
calibreÂes.
1 - Die beschriebenen VorgaÈnge werden an der Achse 6- Pendant les opeÂrations de reÂparation, endosser toujours gants et
D vorgenommen, wenn diese auf einem Bock blockiert chaussures antideÂrapantes.
ist. Zur Bearbeitung der Einzelteile, werden diese 7- Nettoyer tout de suite les eÂventuelles zones souilleÂes d'huile.
auf die Werkbank gelegt. 8- Les lubrifiants, les garnitures, les eÂventuels chiffons servant au
2- Wenn eine Achse abgenommen wird, einen Sicherheitsbock unter nettoyage et les solvants utiliseÂs devront eÃtre reÂcolteÂs et traiteÂs
den zweiten Arm legen. comme rebut speÂcial conformeÂment aux lois en vigueur dans le
3- Werden Arbeiten an der Achse vorgenommen, wenn diese noch pays ouÁ les essieux sont en reÂvision.
an der Maschine montiert ist, BoÈcke zur Halterung unter die 9- Pour le nettoyage, n'utiliser que des solvants aÁ base de toluol,
Achse stellen und die Maschine der LaÈnge nach blockieren. xylol, etc.; n'utiliser que des solvants leÂgers tels que keÂroseÁne,
4- Es duÈrfen sich keine fremde Personen in der NaÈhe der Maschine essences mineÂrales, ou solvants eÂcologiques aÁ base d'eau.
waÈhrend der Arbeiten aufhalten; diesen Bereich absperren und 10 - En ce qui concerne la clarte en matieÁre d'illustration et exposition,
mit Schilder kennzeichnen, die auf die laufenden Arbeiten sur les figures de certains groupes, il y a des pieÁces manquantes
hinweisen. ZuÈndschluÈssel von der Maschine abnehmen. qui normalement peuvent rester monteÂes.
5- Nur saubere Werkzeuge guter QualitaÈt verwenden; alte, beschaÈ- Enlever uniquement les pieÁces deÂcrites.
digte oder improvisierte Hilfsmittel nicht verwenden. Sicher- 11 - Les termes DROITE et GAUCHE utiliseÂs dans ce manuel se
stellen, daû die Dynamometer gepruÈft und geeicht worden sind. rapportent aÁ la personne regardant l'essieu du coÃte oppose aÁ celui
6- Bei Reparaturen, stets Handschuhe und rutschfeste Schuhe tragen. de la prise de mouvement.
7- Mit OÈ l beschmutzte Stellen, sofort reinigen. 12 - A la fin des opeÂrations, afin d'eÂviter un risque d'oxydation
8- Gebrauchte Schmiermittel, Dichtungen, Reinigungslappen und nuisible, retoucher soigneusement les parties vernies eÂventuelle-
ment abõÃmeÂes.
008 913 76 BOMAG
13 723
9.5 Axle
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHIDANA 193
FRENO - VERSCHLEISS
SIMBOLI KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS

Disassembly of assembly groups

Smontaggio di sottogruppi
Zerlegen von Baugruppen
Desmontaje de subgrupos
Demontage des sous-groupes
Reassemble to from assembly groups
Montaggio di sottogruppi 1
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts T1
Smontaggio di particolari ingombri
Abbauen-Ausbauen
Desmontaje de componentes abultados
Demontage des pieces encombrante
Reinstall-remount parts which had obstructed disassembly
Montaggio di particolari ingombri
Einbauen-Ausbauen
Montaje de componentes abultados
Montage des pieces encombrante
Attention ! Important notice S
Attenzione, indicazione importante
Achtung, wichtiger Hinweis F1241070 F1241071
¡ Cuidado ! IndicacioÂn importante
Attention, indication importante
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc.
GB a bar GB b
PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs.
Controlar y ajustar, por ej. pares, medidas, presiones, etc. CHECKING WEAR Introduce tool T1 between the disks and check shim "S".
Controler, regler p.e. couples, mesures, pressions ecc. CAUTION! Perform operations on both arms. Minimum size of "S": 4.5 mm.
T=Special tool P=page Remove the oil-level plug (1).
T=Attrezzature speciali P=Pagina
T=Spezialwerkzeug P=Seite
T=Herramientas especiales P=PaÂgina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccioÂn de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale P
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual
Controler, examiner, controle visuel 3
Possibly still serviceable, renew if necessary
Eventualmente riutilizzare (sostituire se necessario)
Bedingt weiderverwendbar
Puede volver a utilizarse (reemplazar, si es preciso)
Eventuellement a utiliser a noveau (remplacer si neÂcessaire)
Renew at each reassembly 2
Sostituire ad ogni montaggio
Beim Zusammenbau immer erneuern
Puede reemplazarse a cada ensamblaje
Remplacer avec chaque montage
Unlock - lock e.g. split pin, locking plate, etc.
Togliere-mettere la sicura F1241072 F1241073
Entsichern-Sichern
Quitar-colocar el seguro
Enlever-mettre la securite
Lock-adhere (liquid sealant)
bar GB c GB d
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung) ADJUSTING THE BRAKES Remove screw (2) and safety plate (3).
Colocar el seguro, pegar (mastique lõÂquido) Connect an external pump to the union piece "P" of the negative
Mettre la securite, coller (mastic liquide) brake and introduce a pressure of 15 ± 30 bar to eliminate the
Guard against material damage, damage to parts pressure of the Belleville washers (11).
Evitare danni materiali, danni a pezzi
Materialschaden verhuÈten
Evitar danÄar los materials o las piezas
Eviter dommages au materiaux, dommages au pieces
Mark before disassembly, observe marks when reassembly
Marchiare prima dello smontaggio (per il montaggio)
Vor dem Ausbau markieren (fuÈr den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje) 6
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
7
EinfuÈllen - AuffuÈllen - NachfuÈllen (OÈl-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
4
Drain off oil, lubricant
Scaricare olio, lubrificante
OÈl, bzw. Schmiermittel Ablassen
Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
Apply pressure into hydraulic circuit
8
Inserire pressione nel circuito idraulico F1241074 F1241075
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique GB e GB f
To clean
Pulire Turn the brake clearance adjustment pinion (4) clockwise and as REPLACING THE BRAKING DISKS
Reinigen
Limpiar far as the limit stop. Sling the arm (6) to be removed and connect it to a hoist.
Nettoyer Release pressure and disconnect the tubes. Loosen and remove screws (7) and nuts (8).
Lubricate - grease NOTE. Remove the lower plug (5) and drain the oil.
Lubrificare - ingrassare
Schmieren - einfetten
Lubrificar - Engrasar
724 Lubrifier - Graisser BOMAG 14 008 913 76
Axle DANA 193 9.5

CONTROLLO USURA Introdurre l'attrezzo T1 tra i dischi e controllare lo

ITA ATTENZIONE! Eseguire le operazioni per i due ITA spessore "S".
bracci. "S" minimo: 4,5 mm
Asportare il tappo (1) di livello olio.

VERSCHLEISS KONTROLLIEREN Werkzeug T1 zwischen den Scheiben einsetzen und

D D die StaÈrke "S" kontrollieren.
ACHTUNG! Die VorgaÈnge an beiden Armen vorneh-
men. "S" Minimum: 4,5 mm
È
OleinfuÈllstopfen (1) abnehmen.
a b
CONTROL DESGASTE Introducir la herramienta T1 entre los discos y
ESP ESP controlar el espesor "S".
ATENCION! Efectuar las operaciones por los dos
ejes. «S» minimo: 4,5 mm.
Sacar el tapon (1) de nivel aceite.

CONTROLE USURE Introduire l'outil T1 entre les disques et controÃler la

F F cale "S".
ATTENTION! Effectuer les opeÂrations aux deux bras.
Enlever le bouchon (1) du niveau d'huile. "S" minimum: 4,5 mm

REGISTRAZIONE FRENI Asportare la vite (2) e la piastrina di sicurezza (3).

ITA Collegare al raccordo "P" del freno negativo una pompa ITA
esterna ed immettere una pressione di 15v30 bar per
eliminare la pressione delle molle a tazza (11).

BREMSEN EINSTELLEN Schraube (2) und SicherheitsplaÈttchen (3) abnehmen.

D AnschluûstuÈck "P" der Federspeicherbremse an eine D
aÈuûere Pumpe anschlieûen und Druck bei 15v30 bar
einlassen, um Tellerfedern (11) zu entlasten.
c d
REGISTRACION FRENOS Sacar el tornillo (2) y la placa de securidad (3).
ESP Conectar al empalme «P» del freno negativo una ESP
pompa esterna y introducir una presion de 15v30 bar
para eliminar la presion de los muelles a taza (11).

REGLAGE DES FREINS Enlever les vis (2) et la plaquette de seÂcurite (3).
F Brancher au raccord "P" du frein neÂgatif une pompe F
externe et envoyer une pression de 15v30 bar pour
eÂliminer la pression des ressorts belleville (11).

Ruotare in senso orario il pignone (4) di regolazione SOSTITUZIONE DISCHI FRENO

ITA gioco freni fino a fondo corsa. ITA Imbragare il braccio (6) da asportare e collegarlo ad un
Rilasciare la pressione e scollegare i tubi. mezzo di sollevamento.
NOTA. Rimuovere il tappo inferiore (5) e scaricare l'olio. Allentare ed asportare le viti (7) ed i dadi (8).

Das Kegelrad (4) zur Einstellung des Bremsspiels bis BREMSSCHEIBEN AUSWECHSELN
D zum Endanschlag drehen. D Den abzunehmenden Arm (6) anschlagen und an eine
Druck ablassen und die Leitungen abtrennen. Hebezeug befestigen.
BEMERKUNG. Unteren Stopfen (5) abnehmen und das O È l. Schrauben (7) und Muttern (8) lockern und abschrauben.
e f
Girar en sentido horario el pinon (4) de regulacioÁn SUBSTITUCION DISCOS FRENOS.
ESP juego frenos hasta final carrera. ESP Atar el eje (6) de sacar y conectarlo a un medio de
Dejar la presion y desconectar los tubos. levantamiento.
NOTA. Remover el tapon inferior (5) y descargar el aceite. Aflojar y sacar los tornillos (7) y las tuercas (8).

Tourner le pignon de reÂglage du jeu des freins (4) dans Substitution des disques frein
F le sens des aiguilles d'une montre jusqu'en fin de F Elinguer le bras (6) aÁ enlever et brancher celui-ci aÁ un
course. moyen de relevage.
LibeÂrer la pression et deÂbrancher les tubes. Desserrer et enlever les vis (7), les eÂcrous (8).
REMARQUE: Enlever le bouchon infeÂrieur (5) et vidanger l'huile.

008 913 76 BOMAG

15 725
9.5 Axle
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO DANA
- VERSCHLEISS 193
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS

F1241076 F1241077

GB a GB b
Remove arm (6) together with brakes and axle shafts; lay down the Loosen screws (9) in an alternate manner and remove them.
arm vertically.

11
12

10 10

F1241078 F1241079

GB c GB d
Move the cylinder (10) outwards while supporting the Belleville Remove the cylinder (10) complete with piston (12).
washers (11).
Remove the Belleville washers (11) and note down direction of
assembly.

12
13
12

14

F1241080 F1241081

bar GB e GB f
Slowly introduce low-pressure compressed air through the con- Remove O-rings (13) and (14) from the piston (12).
nection member for the negative brake, in order to extract the NOTE. The O-rings (13) and (14) must be replaced each time the
piston (12). unit is disassembled.
CAUTION! Hold the piston (12) back, as it may be suddenly ejected
and damaged.

726 BOMAG
16 008 913 76
Axle DANA 193 9.5

Rimuovere il braccio (6) completo di freni e semiassi; Allentare in modo alternato le viti (9) ed asportarle.
ITA deporre il braccio in modo verticale. ITA

Den Arm (6) samt Bremsen und Halbachsen ab- Abwechselnd die Schrauben (9) lockern und ab-
D nehmen; den Arm senkrecht ablegen. D schrauben.

a b
Remover el eje (6) completo de frenos y semi-ejes; Aflojar de manera alternada los tornillos (9) y sacarlas.
ESP colocar el eje de manera vertical. ESP

Enlever le bras (6) complet de freins et demi-essieux; Desserrer les vis (9) en alternance, puis les enlever.
F deÂposer le bras en vertical. F

Spostare verso l'esterno il cilindro (10) sostenendo le Rimuovere il cilindro (10) completo di pistone (12).
ITA molle a tazza (11). ITA
Rimuovere le molle (11) ed annotare il senso di
montaggio.

Den Zylinder (10) nach auûen verstellen und dabei die Zylinder (10) samt Kolben (12) abnehmen.
D Tellerfedern (11) stuÈtzen. D
Federn (11) abnehmen und die Montagerichtung
notieren.
c d
Desplazar hacia el esterior el cilindro (10) sosteniendo Remover el cilindro (10) completo de piston (12).
ESP los muelles a taza (11). ESP
Remover los muelles (11) y anotar el sentido de
montaje.

DeÂplacer le cylindre (10) vers l'exteÂrieur en soutenant Enlever le cylindre (10) complet de piston (12).
F le ressort belleville (11). F
Enlever le ressort (11) et prendre note du sens de son
montage.

Immettere lentamente aria compressa a bassa pres- Rimuovere dal pistone (12) gli anelli OR (13) e (14).
ITA sione attraverso l'attacco per il freno negativo per ITA
NOTA. Gli anelli OR (13) e (14) devono essere
estrarre il pistone (12). sostituiti ad ogni smontaggio.
ATTENZIONE! Trattenere il pistone (12) che puoÁ essere espulso
velocemente ed essere danneggiato.

Langsam Druckluft bei Niederdruck durch den An- Kolben (12) und O-Ringe (14) und (14) abnehmen.
D schluû der Federspeicherbremse einlassen, um den D
BEMERKUNG. Die O-Ringe (13) und (14) muÈssen
Kolben (12) heraus zu druÈcken. jedesmal ausgewechselt werden, wenn das Teil zer-
ACHTUNG! Den Kolben (12) halten, da er ploÈtzlich heraus springen legt wird.
e und beschaÈdigt werden koÈnnte. f
Introducir lentamente aire comprimida a baja presioÁn Remover del piston (12) los anillos OR (13) y (14).
ESP atraves el empalme por el freno negativo para sacar el ESP
NOTA. Los anillos OR (13) y (14) deben de ser
piston (12). sobstituidos cada desmontaje.
ATENCION! Tener el piston (12) que puede ser expulso rapida-
mente y estropearse.

Envoyer lentement de l'air comprime aÁ basse pression Enlever le piston (12), les anneaux O'RING (13) et
F aÁ travers le raccord du frein neÂgatif pour extraire le F (14).
piston (12). REMARQUE. Les anneaux O'RING (13) et (14) sont aÁ
ATTENTION! Tenir le piston (12) qui pourrait eÃtre expulser substituer aÁ chaque deÂmontage.
rapidement et endommager.

008 913 76 BOMAG

17 727
9.5 Axle
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO DANA
- VERSCHLEISS 193
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS

16

15

A
16

F1241082 F1241083

GB a GB b
Remove checking and guiding screws (15) from the pressure plate Remove the pressure plate (16).
(16). CAUTION! Note down the direction of assembly; flow regulator wall
NOTE. Loosen screws (15) in sequence and proportionally. "A" and oil drain holes must face the oil drain plug.

19

17
18

F1241084 F1241085

GB c GB d
Remove springs (17). Remove braking discs (18) and (19), noting down direction of
NOTE. Accurately check the condition of springs. They should not assembly.
be warped. NOTE. If disks are not to be replaced, avoid changing their
Any deformation of the springs requires spring replacement. position.

4 21

20

F1241086 F1241087

GB e GB f
Remove pinion (4) complete with O-ring (20). Unscrew and extract the braking disk clearance adjustment crown
NOTE. The O-ring must be replaced each time the unit is wheel (21).
disassembled.

728 BOMAG
18 008 913 76
Axle DANA 193 9.5

Rimuovere le viti (15) di ritegno e guida dello Rimuovere lo spingidisco (16).

ITA spingidisco (16). ITA
ATTENZIONE! Annotare il senso di montaggio; la
NOTA. Allentare le viti (15) in modo sequenziale ed in parete frangiflusso "A" e gli scarichi olio, devono
uguale misura. essere rivolti verso il tappo di scarico olio.

Befestigungsschrauben (15) und die FuÈhrung der Druckplatte (16) abnehmen.

D Druckplatte (16) abnehmen. D
ACHTUNG! Montagerichtung notieren; der Strahlreg-
BEMERKUNG. Abwechselnd Schrauben (15) im È lablaûoÈffnungen muÈssen in Richtung
ler "A" und die O
gleichen Maû lockern. È
des Olablaûstopfens gerichtet sein.
a b
Remover los tornillos (15) de retencioÁn y guõÁa del Remover el empuja-disco (16).
ESP empuya-disco (16). ESP
ATENCION. Anotar el sentido de montaje; la pared
NOTA. Aflojar los tornillos (15) de manera secuencial rompe-flujo "A" y los descarge aceite, deben de ser
y en la misma mesura. dirijidos hacia el tapon de descarga aceite.

Enlever vis (15) de fixation et guide du plateau de Enlever le plateau de pression (16).
F pression (16). F
ATTENTION! Prendre noter du sens du montage; la
REMARQUE: Desserrer les vis (15) en seÂquence et en paroi brise-jet "A" et les eÂcoulements d'huile sont
eÂgale mesure. tourneÂs vers le bouchon de vidange d'huile.

Rimuovere le molle (17). Rimuovere i dischi di frenatura (18) e (19) annotando

ITA ITA l'ordine di montaggio.
NOTA. Controllare attentamente lo stato delle molle
che non devono essere deformate. NOTA. Se i dischi non devono essere sostituiti, evitare
Ogni deformazione deve portare alla sostituzione. lo scambio di posizione.

Federn (17) abnehmen. Bremsscheiben (18) und (19) abnehmen und Monta-
D D gerichtung notieren.
BEMERKUNG. Die Federn sorgfaÈltig kontrollieren; sie
duÈrfen nicht verformt sein. Sollte dies der Fall sein, BEMERKUNG. Falls die Scheiben ausgewechselt
Federn auswechseln. werden muÈssen, ihre Position nicht verwechseln.
c d
Remover los muelles (17). Remover los discos de frenadura (18) y (19) anotando
ESP ESP el orden de montaje.
NOTA. Controlar atentamente el estado de los
muelles que no deben de ser deformes. NOTA. Si los discos no deben de ser sobstituidos,
A cada deformacioÁn deben de ser cambiados. evitar el cambio de possicioÁn.

Enlever les ressorts (17). Enlever les disques de freinage (18) et (19) et prendre
F F note de l'ordre du montage.
REMARQUE. ControÃler attentivement l'eÂtat des res-
sorts, ils ne doivent pas eÃtre deÂformeÂs. REMARQUE. Si les disques doivent eÃtre substitueÂs,
Toute deÂformation veut dire substitution. eÂviter d'eÂchanger leur position.

Rimuovere il pignone (4) completo di anello OR (20). Svitare ed asportare la corona (21) di regolazione del
ITA ITA gioco dischi di frenatura.
NOTA. L'anello OR deve essere sostituito ad ogni
smontaggio.

Das Kegelrad (4) samt O-Ring (20) entfernen. Den Kranz (21) zur Einstellung des Bremsscheibens-
D D piels abnehmen.
BEMERKUNG. Den O-Ring bei jedem Zerlegen aus-
wechseln.
e f
Remover el pinon (4) completo de anillo OR (20). Destornillar y sacar la corona (21) de regulacioÁn del
ESP ESP juego discos de frenadura.
NOTA. El anillo OR debe de ser sobstituido a cada
desmontaje.

Enlever le pignon (4) complet de l'anneau O'RING DeÂvisser et enlever la couronne (21) de reÂglage du jeu
F (20). F des disques de freinage.
REMARQUE. L'anneau O-Ring est aÁ remplacer aÁ
chaque deÂmontage.

008 913 76 BOMAG

19 729
9.5 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOS
Axle DANA 193
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

22

11
13
12

10 14

9
18

18

18
15
21 17
23
16
6 19

19
7
19

4
20
1

3
5 2
24

26 8
25 D1240130

6
21 4

6 20

21
F1241133 F1241134

GB a GB b
Lubricate the threaded portion of the crown wheel (21) and screw it Replace the O-ring (20) of pinion (4).
down into the arm (6) as far as it will go. Lubricate and install the pinion in the slot provided on the arm (6),
inserting the toothing into crown wheel (21).

730 BOMAG
20 008 913 76
Axle DANA 193 9.5

GB

ESP

ITA

Lubrificare la filettatura della corona (21) ed avvitarla a Sostituire l'anello OR (20) del pignone (4).
ITA fondo nel braccio (6). ITA Lubrificare il pignone e montarlo nella sede del braccio
(6) innestando la dentatura nella corona (21).

Das Gewinde des Kranzes (21) schmieren und in den O-Ring (20) des Kegelrads (4) auswechseln. Kegelrad
D Arm (6) festschrauben. D schmieren und in den Sitz des Arms (6) montieren;
dabei die ZaÈhne des Kranzes (21) einrasten.

a b
Lubrificar la rosca de la corona (21) y atornillar a Sobstituir el anillo OR (20) del pinon (4).
ESP hondo en el eje (6). ESP Lubrificar el pinon y montarlo en la sed del eje (6)
introduciendo la dentadura en la corona (21).

Lubrifier le filetage de la couronne (21), puis visser Substituer l'anneau O'RING (20) du pignon (4).
F celle-ci aÁ fond dans le bras (6). F Lubrifier le pignon, puis monter celui-ci dans le
logement du bras (6) en introduisant en meÃme temps
la denture dans la couronne (21).

008 913 76 BOMAG

21 731
9.5 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOS
Axle DANA 193
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

19
18
B

F1241088 F1241089

GB a GB b
Lubricate the first friction disk (19) and install it on the axle shaft .
Lightly lubricate the first steel braking disk (18), then install it on the Complete the assembly, alternating steel disks and friction disks.
arm (6). CAUTION! Oval holes "B" of friction disks must be lined up.

16
17

6 A
F1241084 F1241083

GB c GB d
Position springs (17) in the appropriate slots of the arm (6). Fit the pressure plate (16).
CAUTION! Accurately check orientation: flow regulator "A" and oil
drains must be oriented towards the arm's oil drain plug.

16

15
15

F1241082 F1241090

GB e GB f
Lock the pressure plate into position (16) with screws (15). Lock screws (15) with a dynamometric wrench.
CAUTION! Tighten screws in sequence and a little at a time. Torque wrench setting: 20 ± 30 Nm.

732 BOMAG
22 008 913 76
Axle DANA 193 9.5

Lubrificare leggermente il primo disco di frenatura in Lubrificare il primo disco di attrito (19) e montarlo sul
ITA acciaio (18) e montarlo nel braccio (6). ITA semiasse.
Completare il montaggio alternando dischi di acciaio e
dischi di attrito.
ATTENZIONE! I dischi di attrito devono avere il foro ovale "B"
allineato.

Die erste Bremsscheibe aus Stahl (18) etwas schmie- Die erste Reibscheibe (19) schmieren und auf die
D ren und in den Arm (6) montieren. D Halbachse montieren.
Dann die Stahlscheiben abwechselnd mit den Reibs-
cheiben montieren.
a b ACHTUNG! Die LangloÈcher "B" der Reibscheiben muÈssen ge-
fluchtet sein.

Lubrificar ligermente el primer disco de frenadura en Lubrificar el primer disco de strito (19) y montarlo
ESP acero (18) y montarlo en el eje (6). ESP sobre el semi-eje.
Completar el montaje alternando discos de acero y
discos de atrito.
ATENCION! Los discos de atrito deben tener el agujero oval «B» en
linea.

Lubrifier leÂgeÁrement le premier disque de freinage en Lubrifier le premier disque de friction (19), puis monter
F acier (18), puis monter celui-ci dans le bras (6). F ce dernier sur le demi-essieu.
Achever le montage en alternant les disques en acier
et les disques de friction.
ATTENTION! Les disques de friction doivent avoir le trou ovale "B"
aligneÂ.

Posizionare nelle sedi del braccio (6) le molle (17). Montare lo spingidisco (16).
ITA ITA
ATTENZIONE! Controllare attentamente l'orientamen-
to; il frangiflusso "A" e gli scarichi olio, devono essere
orientati verso il tappo di scarico olio del braccio.

In den Sitz des Arms (6) die Federn (17) einsetzen. Die Druckplatte (16) montieren.
D D
ACHTUNG! SorgfaÈltig die Montagerichtung kontroll-
È lablaûoÈffnungen
ieren; den Stahlregler "A" und die O
muÈssen zum Ablaûstopfen des Arms gerichtet sein.
c d
Colocar en las sedes del eje (6) los muelles (17). Montar el empuja-disco (16).
ESP ESP
ATENCION! Controlar atentamente el orientamiento;
el rompe-flujo "A" y los descarga aceite, deben de ser
orientados hacia el tapon de descarga aceite del eje.

Mettre en place les ressorts (17) dans les logements Monter le plateau de pression (16).
F du bras (6). F
ATTENTION! ControÃler attentivement la direction; la
paroi brise-jet "A" et les eÂcoulements d'huile doivent
eÃtre dirigeÂs vers le bouchon de vidange d'huile du bras.

Fissare la posizione dello spingidisco (16) con le viti Bloccare le viti (15) con chiave dinamometrica.
ITA (15). ITA Coppia di serraggio: 20v30 Nm
ATTENZIONE! Serrare le viti in modo sequenziale ed
in piuÁ tempi.

Die Druckplatte (16) mit den Schrauben (15) be- Schrauben (15) mit dem Dynamometer blockieren.
D festigen. D Anzugsmoment: 20v30 Nm.
ACHTUNG! Die Schrauben der Reihe nach und
schrittweise festziehen.
e f
Fijar la posicioÁn del empuja-disco (16) con los tornillos Bloquear los tornillos (15) con llave dinamometrica.
ESP (15). ESP Par de serraje: 20v30 Nm.
ATENCION! Apretar los tornillos de manera secuen-
cial y en mas tiempos.

Fixer le plateau de pression (16) aÁ sa place avec les Bloquer les vis (15) aÁ l'aide de la cle dynamomeÂtrique.
F vis (15). F Couple de serrage: 20v30 Nm.
ATTENTION! Serrer les vis en plusieurs temps en
ordre seÂquentiel.

008 913 76 BOMAG

23 733
9.5 Axle DANA 193
ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOS
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

14 12
12

13 10

10
F1241091 F1241092

GB a GB b
Fit O-rings (13) and (14) onto the piston (12). Using a plastic hammer, ram the piston (12) into the cylinder (10).
Lubricate the piston and the O-rings and install the unit into the NOTE. Lightly hammer all around the edge in an alternate
cylinder (10). sequence.
NOTE. Piston relief «C» must face downwards.

22 11

10

F1241079 F1241078

GB c GB d
Check the condition and the position of the O-ring (22); lubricate Position the Belleville washers (11) and engage the cylinder (10).
the O-ring and position the cylinder on the studs without fastening. NOTE. Check the sense of direction of washers (11) and relative
centring.

10 23
6
9

F1241093 F1241094

GB e GB f
Lock the cylinder (10), tightening the screws (9) with a dynamo- Check integrity and position of the arm's O-ring (23); install the
metric wrench set to a torque of 86 ± 89 Nm. complete arm (6).
NOTE. To assist axle shaft centring, slightly move the wheel hub.

734 BOMAG
24 008 913 76
Axle DANA 193 9.5

Montare sul pistone (12) gli anelli OR (13) e (14). Utilizzando un mazzuolo in materiale plastico, inserire
ITA Lubrificare il pistone e gli anelli OR e montare il ITA a fondo il pistone (12) nel cilindro (10).
gruppo nel cilindro (10). NOTA. Battere leggeri colpi distribuiti in modo
NOTA. Lo scarico "C" del pistone deve essere rivolto verso il alternato su tutta la circonferenza.
basso.

Auf den Kolben (12) die O-Ringe (13) und (14) Mit einem Gummihammer den Kolben (12) in den
D montieren. D Zylinder (10) bis zum Anschlag einschlagen.
Den Kolben und die O-Ringe schmieren und das BEMERKUNG. Den Kolben abwechselnd rund um die
Aggregat in den Zylinder (10) montieren. gesamte Kreislinie leicht schlagen.
a BEMERKUNG. Die AblaûoÈffnung "C" des Kolbens muû nach unten b
gerichtet sein.

Montar sobre el piston (12) los anillos OR (13) y (14). Utilizando un martillo de materia plastica, introducir a
ESP Lubrificar el piston y los anillos OR y montar el grupo ESP fondo el piston (12) en el cilindro (10).
en los cilindros (10). NOTA. Pegar ligeros golpes distribuidos de manera
NOTA. El escargo "C" del piston debe de ser dirijido hacia el bajo. alternada sobre toda la circonferencia.

Monter sur le piston (12), les anneaux O'RING (13) et A l'aide d'un maillet en matieÁre plastique, introduire le
F (14). F piston (12) aÁ fond dans le cylindre (10).
Lubrifier le piston et les anneaux O'RING, puis monter REMARQUE. Donner de leÂgers coups reÂguliers tout
le groupe dans le cylindre (10). autour de la circonfeÂrence.
REMARQUE. L'eÂcoulement "C" du piston doit eÃtre tourne vers le
bas.

Controllare lo stato ed il posizionamento dell'anello Posizionare le molle a tazza (11) e mandare in battuta
ITA OR (22); lubrificare l'anello OR e posizionare il cilindro ITA il cilindro (10).
sui prigionieri senza mandarlo in battuta. NOTA. Controllare il senso di orientamento delle molle
a tazza (11) e la loro centratura.

Den Zustand und die Position des O-Ringes (22) Tellerfedern (11) positionieren und den Zylinder (10)
D kontrollieren; den O-Ring schmieren und den Zylinder D bis zum Anschlag einsetzen.
auf die Stiftschrauben positionieren, ohne ihn bis zum BEMERKUNG. Orientierung der Tellerfedern (11) und
Anschlag ganz einzusetzen. ihre Zentrierung kontrollieren.
c d
Controlar el estado y la colocacioÁn del anillo OR (22); Colocar los muelles a taza (11) y mandar a tope el
ESP lubrificar el anillo OR y colocar el cilindro sobre los ESP cilindro (10).
prigioneros sin llevarlo a tope. NOTA. Controlar el sentido de orientamiento de los
muelles a taza (11) y su centraje.

ControÃler l'eÂtat et la position de l'anneau O'RING (22); Positionner les ressorts belleville (11) et inseÂrer aÁ fond
F lubrifier l'anneau O'RING et positionner le cylindre sur F le cylindre (10).
les prisonniers sans l'envoyer en buteÂe. REMARQUE. ControÃler l'orientation des ressorts
belleville (11) et leur centrage.

Bloccare il cilindro (10) con le viti (9) serrate con chiave Verificare l'integritaÁ ed il posizionamento dell'anello
ITA dinamometrica ad un coppia di 86v89 Nm. ITA OR (23) del braccio; installare il braccio completo (6).
NOTA. Per agevolare la centratura del semiasse,
muovere lentamente il mozzo portaruota.

Den Zylinder (10) mit den Schrauben (9) mit einem Am Arm den Zustand und die Position des O-Ringes
D Dynamometer und einem Anzugsmoment von 86v89 Nm D (23) kontrollieren; den gesamten Arm (6) installieren.
blockieren. BEMERKUNG. Um die Halbachse leichter zentrieren
zu koÈnnen, die Radhalternabe etwas bewegen.
e f
Bloquear el cilindro (10) con los tornillos (9) apretados Averiguar la integridad y la colocacioÁn del anillo OR
ESP con llave dinamometrica a un par de 86v89 Nm. ESP (23) del eje; colocar el eje completo (6).
NOTA. Para facilitar el centraje del semi-eje, mover
lentamente el cubo porta-rueda.

Bloquer le cylindre (10) avec les vis (9), serrer aÁ l'aide VeÂrifier le bon eÂtat et le positionnement de l'anneau
F de la cle dynamomeÂtrique aÁ un couple de 86v89 Nm. F O'RING (23) du bras; installer le bras complet (6).
REMARQUE. Afin de rendre plus aise le centrage du
demi-essieu, bouger lentement le moyeu porte-roue.

008 913 76 BOMAG

25 735
9.5 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOS
Axle DANA 193
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

T2
6

8
F1241095 F1241096

GB a GB b
Temporarily lock the arm (6) with nuts (8) previously coated with Check the flatness of the arms, using tool T2; then lock the arms
Loctite 242; tighten lightly to make the unit touch the main body. into their final position, using screws (7) adequately coated with
Loctite 242.
Torque wrench setting: 182 ± 202 Nm.
NOTE. Tighten using the criss-cross method.

F1241097 F1241074

bar GB c GB d
Connect an external pump to the union piece "A" of the negative Rotate the adjustment pinion (4) anticlockwise (±) to eliminate all
brake and introduce pressure to 15 ± 30 bar. existing clearance between the braking disks.
Rotate up to a torque of 8 ± 10 Nm.

+ 3

4
-- 2

D1240132
F1241073

GB e GB f
Rotate pinion (4) clockwise (+) to determine the required clearance Install safety plate (3) and lock with screw (2).
of 1 mm. Torque wrench setting: 10 ± 11 Nm.
NOTE. A turn of the adjuster produces a clearance of 0.25 mm
(1mm = 4 turns).

736 BOMAG
26 008 913 76
Axle DANA 193 9.5

Fissare provvisoriamente il braccio (6) con i dadi (8) Controllare la planaritaÁ dei bracci con l'attrezzo T2 e
ITA spalmati con Loctite 242 e serrati leggermente per ITA fissarli definitivamente con le viti (7) spalmate con
frizionare il gruppo sul corpo centrale. Loctite 242.
Coppia di serraggio: 182v202 Nm
NOTA. Serrare con il metodo incrociato.

VoruÈbergehend den Arm (6) mit den mit Loctite 242 Die Ebenheit der Arme mit dem Werkzeug T2 kontroll-
D geschmierten Muttern (8) befestigen und Muttern D ieren und endguÈltig mit den mit Loctite 242 ge-
zuschrauben bis das Aggregat an dem ZentralkoÈrper schmierten Schrauben (7) befestigen.
anliegt. Anzugsmoment: 182v202 Nm
a b BEMERKUNG. Im Kreuz fest drehen.

Fijar provisoriamente el eje (6) con las tuercas (8) Controlar la planaridad de los ejes con la herramienta
ESP pasados con Loctite 242 y apretados ligermente para ESP T2 y fijarlos definitivamente con los tornillos (7) pasar
fricionar el grupo sobre el cuerpo central. con Loctite 242.
Par de serraje: 182v202 Nm
NOTA. Apretar de manera cruzada.

Fixer provisoirement le bras (6) avec les eÂcrous (8) ControÃler la planeÂite des bras aÁ l'aide de l'outil T2,
F enduits avec du Loctite 242, et serrer ceux-ci pour F puis fixer ceux-ci deÂfinitivement avec les vis (7)
frotter le groupe du corps central. enduites de Loctite 242.
Couple de serrage: 182v202 Nm.
REMARQUE. Serrer avec la meÂthode croiseÂe.

Collegare al raccordo "P" del freno negativo una pompa Ruotare in senso antiorario (±) il pignone di registro (4)
ITA esterna ed immettere una pressione di 15v30 bar. ITA per eliminare totalmente il gioco tra i dischi di frenatura.
Ruotare fino ad ottenere una coppia di 8v10 Nm.

An das AnschluûstuÈck "P" der Federspeicherbremse Gegen den Uhrzeigersinn (±) das Kegelrad (4),
D eine aÈuûere Pumpe schlieûen und Druck bei 15v30 bar D drehen, bis kein Spiel zwischen den Bremsscheiben
einlassen. mehr uÈbrig bleibt. Anzugsmoment: 8v10 Nm.

c d
Conectar al empalme "P" del freno negativo una Girar en sentido anti-horario (±) el pinon de registro (4)
ESP pompa externa y introducir presion de 15v30 bar. ESP para eliminar totalmente el juego entre discos de
frenadura.
Girar hasta obtener un par de 8v10 Nm.

Brancher au raccord "P" du frein neÂgatif une pompe Tourner le pignon de reÂglage (4) dans le sens contraire
F externe et envoyer une pression de 15v30 bar. F aux aiguilles d'une montre(-) le reÂgleur (4) pour faire
disparaõÃtre entieÁrement le jeu existant entre les
disques de freinage.
Tourner jusqu'aÁ obtenir un couple de 8v10 Nm.

Ruotare il pignone (4) in senso orario (+) per Montare la piastrina di sicurezza (3) e bloccarla con la
ITA determinare il gioco prescritto di 1 mm. ITA vite (2).
NOTA. Un giro del registro crea un gioco di 0,25 mm Coppia di serraggio: 10v11 Nm
(1 mm=4 giri).

Das Kegelrad (4) in den Uhrzeigersinn (+) drehen, bis Die Sicherheitsplatte (3) montieren und mit der
D das vorgeschriebene Spiel von 1 mm erreicht ist. D Schraube (2) blockieren.
BEMERKUNG. Eine Umdrehung gleicht einem Spiel Anzugsmoment: 10v11 Nm
von 0,25 mm (1 mm=4 Umdrehungen).
e f
Girar el pinon (4) en sentido horario (+) para Montar la plaqua de seguridad (3) y bloquearla con los
ESP determinar el juego prescrito de 1 mm. ESP tornillos 829.
NOTA. Un giro del registro crea un juego de 0,25 mm Par de serraje: 10v11 Nm
(1mm=4 giros).

Tourner le pignon (4) dans le sens des aiguilles d'une Monter la plaquette de seÂcurite (3), bloquer celle-ci aÁ
F montre (+) pour deÂfinir le jeu prescrit de 1 mm. F l'aide de la vis (2).
REMARQUE. Un tour de reÂgleur donne un jeu de 0,25 Couple de serrage: 10v11 Nm
mm (1mm=4 tours).

008 913 76 BOMAG

27 737
9.5 Axle-
MECHANICAL AND MANUAL RELEASE OF THE AXLE - SBLOCCAGGIO MECCANICO MANUALE DELL'ASSALE DANA 193
ACHSE MECHANISCH MANUELL ENTSICHERN - DESBLOQUEO MANUAL DE LOS AXAL -
DEBLOCAGE MECANIQUE MANUEL DE L'ESSIEU

11 16

24
25
25

26 24
D1240133
F1241098

GB a GB b
MANUAL EMERGENCY RELEASE Tighten screws (25) so as to fasten them onto the pressure plate
Loosen nuts (24) of screws (25) provided for the mechanical and (16).
manual release of the braking units, then move the nuts backwards
by approx. 8 mm.

25 26
24
25

F1241099 F1241100

GB c GB d
Using a wrench, tighten the screws (25) in an alternate sequence ADJUSTMENT AFTER MANUAL RELEASE
by 1/4 turn at a time so as to compress the Belleville washers (11) Remove screws (25) complete with nuts (24) and seals (26).
and disengage the braking disks. Replace seals (26), apply silicone-based Tecno Lupe /101 grease
IMPORTANT. Tighten max. by one turn. to the screws (25) and install all parts into the arm.

24

34 + 0,5
0

F1241101 F1241102

GB e GB f
+0.5
Adjust screws (25) to obtain a jut of 34 0 mm in relation to the arm. Lock into position with nuts (24).
CAUTION! Hold screws (25) into position while locking the nuts
(24); after locking, check the jut of screws (25) once more.

738 BOMAG
28 008 913 76
Axle DANA 193 9.5

SBLOCCAGGIO MANUALE D'EMERGENZA Avvitare le viti (25) fino a mandarle in battuta sullo
ITA Allentare i dadi (24) delle viti (25) per lo sblocco ITA spingidisco (16).
meccanico manuale dei gruppi di frenatura e far
arretrare i dadi di circa 8 mm.

MANUELLE NOT-ENTSICHERUNG Schrauben (25) bis zum Anschlag an die Druckplatte

D Die Muttern (24) der Schrauben (25) zur mechani- D (16) zudrehen.
schen manuellen Entsicherung der Bremsaggregate
lockern und die Muttern um 8 mm zuruÈck drehen.
a b
DESBLOQUEO MANUAL DE EMERGENCIA Atornillar los tornillos (25) hasta llegar al tope sobre el
ESP Aflojar las tuercas (24) de los tornillos (25) para el ESP empuja-disco (16).
desbloqueo mecanico manual de los grupos de
frenadura y hacer pasar las tuercas de 8 mm approx.

DEBLOCAGE MANUEL D'EMERGENCE Visser les vis (25) puis les envoyer en buteÂe sur le
F Desserrer les eÂcrous (24) des vis (25) pour le F plateau de pression (16).
deÂblocage meÂcanique manuel des groupes de frei-
nage en faisant reculer les eÂcrous d'environ 8 mm.

Utilizzando una chiave, avvitare le viti (25) in modo REGOLAZIONE DOPO LO SBLOCCAGGIO MANUALE
ITA alternato di 1/4 di giro alla volta, per comprimere le ITA Rimuovere le viti (25) complete dei dadi (24) e delle
molle a tazza (11) e liberare i dischi di frenatura. guarnizioni (26).
IMPORTANTE. Avvitare per max. un giro. Sostituire le guarnizioni (26), lubrificare le viti (25) con grasso al
silicone Tecno Lupe /101 e montare il tutto nel braccio.

Mit einem SchluÈssel, die Schrauben (25) abwechselnd EINSTELLUNG NACH DER MANUELLEN ENTSICHERUNG
D jeweils um 1/4 Umdrehung zudrehen, um die Tellerfe- D Die Schrauben (25) mit den Muttern (24) und den
dern (11) einzudruÈcken und die Bremsscheiben frei- Dichtungen (26) abnehmen.
zusetzen. Die Dichtungen (26) auswechseln, die Schrauben (25) mit Silikon-
c WICHTIG. Maximal um eine Umdrehung zuschrauben. d fett Tecno Lupe/101 schmieren und das ganze Teil in den Arm
montieren.

Utilizando una llave, atornillar los tornillos (25) de REGULACION DESPUES DEL DESBLOQUEO MANUAL
ESP manera alternada de 1/4 de giro a la vez, para ESP Remover los tornillos (25) completas de guarniciones
comprimir los muelles a taza (11) y librar los discos (26).
de frenadura. Sobstituir las guarniciones (26), lubrificar los tornillos (25) con
IMPORTANTE. Atornillar por max. un giro. grasa al silicone Tecno Lupe/101 y montar todo en el eje.

A l'aide d'une cleÂ, visser les vis (25) alternativement 1/ REGLAGE FAISANT SUITE AU DEBLOCAGE MANUEL
F 4 de tour aÁ la fois, pour contraindre le ressort belleville F Enlever les vis (25) compleÁtes d'eÂcrous (24) et de
(11) et deÂgager les disques de freinage. garnitures (26).
IMPORTANT. Visser pour max. un tour. Substituer les garnitures (26), lubrifier les vis (25) avec de la graisse
au silicone Tecno Lupe/101, monter le tout dans le bras.

Regolare le viti (25) fino ad avere una sporgenza Bloccare la posizione con i dadi (24).
ITA rispetto al braccio di 34+0,5
0 mm
ITA
ATTENZIONE! Mantenere la posizione delle viti (25)
quando si bloccano i dadi (24); dopo il bloccaggio,
ricontrollare la sporgenza delle viti (25).

È berstand zum Arm

Schrauben (25) einstellen, bis der U Die Position mit den Muttern (24) blockieren.
D 34+0.5
0 mm betraÈgt. D
ACHTUNG! Die Position der Schrauben (25) darf sich
beim Festziehen der Muttern (24) nicht aÈndern; nach
der Blockierung den U È berstand der Schrauben (25) nochmals
e f kontrollieren.

Regular los tornillos (25) hasta obtener una parte Bloquear la colocacioÁn con las tuercas (24).
ESP saliente respecto al eje de 34+0,5
0 mm
ESP
ATENCION! Mantener la posicion de los tornillos (25)
cuando se bloquean las tuercas (24); despues del
bloqueo, recontrolar la parte saliente de los tornillos (25).

ReÂgler les vis (25) jusqu'aÁ avoir une saillie de 34+0.5

0 mm Bloquer dans la position aÁ l'aide des eÂcrous (24).
F par rapport au bras. F
ATTENTION! Tenir les vis (25) en place quand on
bloque les eÂcrous (24); apreÁs avoir fixeÂ, controÃler la
saillie des vis (25).

008 913 76 BOMAG

29 739
9.5 Axle- PLANETENGE-
DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE DANA 193
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

4
12
9 11
10
3

8 13

14
7
16
15

2
1 D1240131

1
3

2
F1241103 F1241104

GB a GB b
Remove the locking screws (1) of planetary cover (2). Using two screwdrivers or two levers inserted in the slots provided,
pry the planetary cover (2) away from the wheel hub (3).

740 BOMAG
30 008 913 76
Axle DANA 193 9.5

SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE

NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR

GB The axle shafts can only be removed once the 2 - Achse zuerst von der Maschine abmontieren und auf eine
extraction of the planetary cover has been performed. Werkbank legen.
Different procedures need to be followed depending on
the kind of repair work required: Nachstehende Beschreibung bezieht sich auf das Zerlegen an der
Werkbank, doch ist die Vorgehensweise in beiden FaÈllen dieselbe.
1 - Disassembly with axle connected to the machine with machine
resting on safety stands.
2 - Disassembly with the axle disconnected from the machine and
supported by the appropriate equipment (at the bench).
The explanations given herein refer to the removal operation as is La remocioÁn de los semi-ejes puede ser efectuada solo
carried out on the bench, but the stages apply to all versions. ESP despues de la remocioÁn de las tapas lleva-satelites y de
manera deversificada, en funcion del tipo de repara-
cion de efectuar:
1 - Desmontaje con axal montado sobre la maquina colocada sobre
caballetes de seguridad;
2 - Desmontaje con axial desmontado desde la maquina y susten-
tado de apositas herramientas (al banco).
Las explicaciones reportadas se refieren a la remocioÁn efectuada al
La rimozione dei semiassi puoÁ essere eseguita solo banco, ma las fases son comunes.
ITA dopo la rimozione del coperchio portasatelliti ed in
modo diversificato, in funzione del tipo di riparazione
da eseguire:
1 - Smontaggio con assale montato sulla macchina appoggiata su
cavalletti di sicurezza.
2 - Smontaggio con assale smontato dalla macchina e sostenuto da
apposita attrezzatura (al banco).
Le spiegazioni riportate si riferiscono alla rimozione eseguita al Le deÂgagement des demi-essieux ne peut se faire
banco, ma le fasi sono comuni. F qu'apreÁs avoir enleve le couvercle porte-satellites
d'une facËon diversifieÂe, en fonction du type de
reÂparations aÁ effectuer:
1 - DeÂmontage essieu monte sur machine deÂposeÂe sur des baÃtis de
seÂcuriteÂ.
1 - DeÂmontage essieu deÂmonte de la machine et soutenu par un
outil speÂcial (sur banc).
Les explications reporteÂes se reÂfeÁrent au deÂgagement effectue au
Die Halbachse kann erst abmontiert werden, wenn der banc, mais les phases sont communes.
D Deckel des Planetenradhalters abgenommen worden
ist; auûerdem wird sie je nach Reparatur unterschied-
lich abmontiert:
1 - Mit Achse abmontieren, die an der Maschine montiert und durch
SicherheitsbloÈcke gestuÈtzt ist.

Rimuovere le viti (1) di fissaggio del coperchio Utilizzando due cacciaviti o due leve inserite nelle
ITA portasatelliti (2). ITA cave predisposte, staccare il coperchio portasatelliti
(2) dal mozzo portaruota (3).

Schrauben (1) abschrauben, die den Deckel des Zwei Schraubenzieher oder zwei Hebel in die vorge-
D Planetenradhalters (2) befestigen. D sehenen Nuten stecken und den Deckel (2) des
Planetenradhalters von den Radhalternaben (3) ab-
heben.
a b
Remover los tornillos (1) de fisaje de la tapa porta- Utilizando dos destornilladores o dos palancas inser-
ESP satelites (2). ESP tadas en las ranuras predispuestas, destacar la tapa
lleva-satelites (2) del cubo lleva-rueda (3).

Enlever les vis (1) de fixation du couvercle porte- A l'aide de deux tournevis ou de deux leviers dans les
F satellites (2). F creux preÂdisposeÂs, deÂgager le couvercle porte-satel-
lites (2) du moyeu porte-roue (3).

008 913 76 BOMAG

31 741
9.5 Axle- PLANETENGE-
DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE DANA 193
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

2 3
5

F1241105 F1241106

GB a GB b
Rotate the wheel hub (3) until one of the screw holes (1) appears at Only in case of replacement of component parts not requiring
the top. the disassembly of the crown wheel (5).
Apply a "U" piece to the screw hole; connect to a hoist and remove Countermark the position between one of the teeth of the axle shaft
the cover (2). (4) and the crown wheel (5).

F1241107 F1241108

GB c GB d
Remove the axle shaft (4). Loosen the screws (6) and remove them.
NOTE. The removal of the axle shaft allows for the substitution of
the snap ring as described in the following paragraphs.

3 5

7
F1241109 F1241110

GB e GB f
Remove the safety flange (7). Partially tighten five of the ten screws (6) in an alternate and
proportional manner.
Using an extractor and applying a counter pressure to the screws
(6), disengage the crown wheel (5) from the hub (3).

742 BOMAG
32 008 913 76
Axle DANA 193 9.5

Ruotare il mozzo portaruota (3) fino a portare un foro Solo se si devono sostituire dei componenti che
ITA per le viti (1) in posizione alta. ITA non richiedono lo smontaggio della corona (5).
Applicare un grillo ad "U" nel foro vite; collegare un Contrassegnare la posizione tra un dente del semias-
mezzo di sollevamento e rimuovere il coperchio (2). se (4) e la corona (5).

Nur wenn Bestandteile ausgewechselt werden

D Die Radhalternabe (3) drehen bis ein Loch fuÈr die D muÈssen, fuÈr die der Kranz (5) nicht abmontiert
Schrauben (1) in der oberen Position liegt. werden muû.
Einen U-foÈrmigen BuÈgel in das Schraubenloch stecken; ein Die Position zwischen einem Zahn der Halbachse (4) und dem
a Hebezeug anschlieûen und den Deckel (2) abnehmen. b Kranz (5) markieren.

Girar el cubo lleva-rueda (3) hasta hacer un agujero Solo si se deben de sobstituir algunos componentes
ESP para los tornillos (1) en posicioÁn alta. ESP que no comportan el desmontaje de la corona (5).
Aplicar un grillo a "U" en el agujero tornillos; conectar Senalar la colocacioÁn entre un diente del semi-eje (4) y
un medio de levantamiento y remover la tapa (2). la corona (5).

Tourner le moyeu porte-roue (3) jusqu'aÁ aÁ amener un Uniquement si on doit substituer des composants qui
F des trous pour les vis (1) en haut. F ne veulent pas le deÂmontage de la couronne (5).
Appliquer une manille en "U" dans le trou de vis; Marquer la position entre une dent du demi-essieu (4)
appliquer un moyen de relevage et enlever le couvercle (2). et la couronne (5).

Asportare il semiasse (4). Allentare le viti (6) ed asportarle.

ITA ITA
NOTA. L'asportazione del semiasse permette la
sostituzione dell'anello di tenuta come descritto di
seguito.

Die Halbachse (4) abnehmen. Schrauben (6) abschrauben.

D D
BEMERKUNG. Bei abgenommener Halbachse kann
der Dichtring, wie nachstehend beschrieben, ausge-
wechselt werden.
c d
Sacar el semi-eje (4). Aflojar los tornillos (6) y sacarlos.
ESP ESP
NOTA. Sacar el semi-eje permite la sobstitucioÁn del
anillo de tenida como descrito a seguir.

Enlever le demi-essieu (4). Desserrer les vis (6) puis les enlever.
F F
REMARQUE. Le deÂgagement du demi-essieu consent
la substitution de l'anneau d'eÂtancheÂite comme deÂcrit
par la suite.

Asportare la flangia di sicurezza (7). Avvitare parzialmente, in modo alternato ed in uguale

ITA ITA misura, cinque delle dieci viti (6).
Utilizzando un estrattore e facendo reazione sulle viti
(6) disimpegnare la corona (5) dal mozzo (3).

Sicherheitsflansch (7) abnehmen. Abwechselnd und im gleichen Maû fuÈnf von den zehn
D D Schrauben (6) zuschrauben.
Mit einem Abzieher den Kranz (5) aus der Nabe (3)
ziehen und dabei auf die Schrauben (6) wirken.
e f
Sacar la arandela de seguridad (7). Atornillar parcialmente, de manera alternada y en
ESP ESP igual mesera, cinco de las diez tornillos (6).
Utilizando un extractor y haciendo reacioÁn sobre los
tornillos (6) desempenar la corona (5) del cubo (3).

Enlever la flasque de seÂcurite (7). Visser partiellement, en alternance et de la meÃme

F F facËon cinq des dix vis (6).
A l'aide d'un extracteur, tout en faisant reÂagir les vis
(6), deÂgager la couronne (5) du moyeu (3).

008 913 76 BOMAG

33 743
9.5 Axle- PLANETENGE-
DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE DANA 193
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

3
F1241111 F1241112

GB a GB b
Remove screws (6) and crown wheel (5). Sling the hub (3) and connect it to a hoist; partially tighten a screw
(6) and with the help of a hammer, shift the hub (3) and the external
bearing (8).

3
9

8
10
3
F1241113 F1241114

GB c GB d
Remove the bearing (8) and the hub (3). Extract the hub (3) complete with snap ring (9) and internal bearing
(10).

14
13

11 12
F1241115 F1241116

GB e GB f
Using an extractor, remove at the same time the snap ring (11) and Remove the safety spring rings (13) of the planetary gears (14).
the centring ring (12).
NOTE. Note down the direction of assembly of snap and centring
rings.

744 BOMAG
34 008 913 76
Axle DANA 193 9.5

Rimuovere le viti (6) e la corona (5). Imbragare il mozzo (3) e collegarlo ad un mezzo di
ITA ITA sollevamento; avvitare parzialmente una vite (6) e, con
un mazzuolo, smuovere il mozzo (3) ed il cuscinetto
esterno (8).

Schrauben (6) und Kranz (5) abnehmen. Nabe (3) anschlagen und an ein Hebezeug befestigen;
D D Schrauben (6) etwas zudrehen und mit einem Ham-
mer die Naben (3) und das aÈuûere Lager (8) bewegen.

a b
Remover los tornillos (6) y la corona (5). Atar el cubo (3) y conectarlo a un medio de
ESP ESP levantamiento; atornillar parcialmente un tornillo (6)
y, con un martillo, mover el cubo (3) y el cojinete
externo (8).

Enlever les vis (6) et la couronne (5). Elinguer le moyeu (3) puis relier celui-ci aÁ un moyen de
F F relevage; visser partiellement une vis (6), puis aÁ l'aide
d'un maillet, bouger le moyeu (3) et le palier externe
(8).

Rimuovere il cuscinetto (8) ed il mozzo (3). Asportare il mozzo (3) completo di anello di tenuta (9) e
ITA ITA cuscinetto interno (10).

Lager (8) und Nabe (3) abnehmen. Nabe (3) samt Dichtring (9) und inneres Lager (10)
D D abnehmen.

c d
Remover el cojinete (8) y el cubo (3). Sacar el cubo (3) completo de anillo de retencioÁn (9) y
ESP ESP cojinete interno (10).

Enlever le palier (8) et le moyeu (3). Enlever le moyeu (3) complet de bague d'eÂtancheÂiteÂ
F F (9) et de palier interne (10).

Utilizzando un estrattore, rimuovere contemporanea- Rimuovere gli anelli elastici (13) di ritegno satelliti (14).
ITA mente l'anello di tenuta (11) e l'anello centratore (12). ITA
NOTA. Annotare il senso di montaggio degli anelli di
tenuta e di centratura.

Mit einem Abzieher gleichzeitig den Dichtring (11) und Kolbenringe (13) und Planetenhalter (14) abnehmen.
D den Zentrierring (12) abnehmen. D
BEMERKUNG. Montagerichtung der Dicht- und Zen-
trierringe notieren.
e f
Utilizando un extractor, remover contemporaneamen- Remover los anillos elasticos (13) de retencioÁn
ESP te el anillo de retencioÁn (11) y el anillo centrador (12). ESP satelites (14).
NOTA. Anotar el sentido de montaje de los anillos de
retencioÁn y de centraje.

A l'aide d'un extracteur enlever en meÃme temps Enlever les anneaux ressorts (13) de fixation des
F l'anneau d'eÂtancheÂite (11) et l'anneau centreur (12). F satellites (14).
REMARQUE. Prendre note du sens de montage des
anneaux d'eÂtancheÂite et de centrage.

008 913 76 BOMAG

35 745
9.5 Axle- PLANETENGE-
DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE DANA 193
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

14

15

F1241117 F1241118

GB a GB b
Remove the planetary gears (14). Only if necessary.
NOTE. Note down direction of assembly of planetary gears. Using an extractor, remove the shim washer (15) from the planet
carrier.

9 9

3 10

F1241119 F1241120

GB c GB d
Remove the snap ring (9) from the hub (3). Remove the internal bearing (10).
NOTE. Note down direction of assembly.
CAUTION! The snap ring may not be reused.

10
8

F1241121

GB e GB f
Remove the external thrust blocks of bearings (8) and (10), using a
pin-driver.
NOTE. Hammer in an alternate sequence to prevent crawling and
deformation of the thrust blocks.

746 BOMAG
36 008 913 76
Axle DANA 193 9.5

Asportare gli ingranaggi satelliti (14). Solo se necessario.

ITA ITA Utilizzando un estrattore, rimuovere dal portasatelliti la
NOTA. Annotare il senso di montaggio dei satelliti.
rondella di rasamento (15).

Planetengetriebe (14) abnehmen. Nur wenn notwendig.

D D Mit einem Abzieher vom Planetenradhalter die Zwi-
BEMERKUNG. Montagerichtung notieren.
schenlegscheibe (15) abnehmen.

a b
Sacar los engranajes satelites (14). Solo si necesario.
ESP ESP Utilizando un extractor, remover del lleva-satelites la
NOTA. Anotar el sentido de desmontaje de los
satelites. arandela de rasamiento (15).

Enlever les engrenages satellites (14). Uniquement si besoin.

F F A l'aide d'un extracteur, enlever du porte-satellite la
REMARQUE. Prendre note du sens de montage.
rondelle de rasage (15).

Rimuovere dal mozzo (3) l'anello di tenuta (9). Rimuovere il cuscinetto interno (10).
ITA ITA
NOTA. Annotare il senso di montaggio.
ATTENZIONE! L'anello di tenuta non puoÁ essere
riutilizzato.

Von der Nabe (3) den Dichtring (9) abnehmen. Das innere Lager (10) abnehmen.
D D
BEMERKUNG. Montagerichtung notieren.
ACHTUNG! Der Dichtring darf nicht wieder verwendet
werden.
c d
Remover del cubo (3) los anillos de retencioÁn (9). Remover el cojinete interior (10).
ESP ESP
NOTA. Anotar el sentido de montaje.
ATENCION! El anillo de retencioÁn no puede ser
reutilizado.

Oter du moyeu (3) l'anneau d'eÂtancheÂite (9). Enlever le palier interne (10).
F F
REMARQUE. Prendre note du sens de montage.
ATTENTION! L'anneau d'eÂtancheÂite ne peut pas eÃtre
reÂutiliseÂ.

Rimuovere le ralle esterne dei cuscinetti (8) e (10)

ITA utilizzando un cacciaspine. ITA
NOTA. Battere in modo alternato per evitare impunta-
menti e deformazioni delle ralle.

Die aÈuûeren Scheiben (8) und (10) mit einem DuÈbel

D abnehmen. D
BEMERKUNG. Abwechselnd schlagen, um ein Durch-
schlagen und Verformungen der Scheiben zu vermeiden.
e f
Remover las ranguas externas de los cojinetes (8) y
ESP (10) utilizando un extractor de clavijas. ESP
NOTA. Pegar de manera alternada para evitar
empuntamientos y deformacioÁnes de las ranguas.

Enlever les crapaudines externes des paliers (8) et

F (10) aÁ l'aide d'un chasse-clou. F
REMARQUE. Donner des coups alterneÂs pour eÂviter
talonnages et deÂformations des crapaudines.

008 913 76 BOMAG

37 747
9.5 Axle
ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE DANA 193
- PLANETENGE-
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

T3 10 9

3
10

F1241122 F1241123

GB a GB b
Position the wheel hub (3) under a press; lubricate the seat of the Install the bearing (10).
external bearing and, using tool T3, install the thrust block of the Apply an appropriate sealant to the outer surface of the snap ring
bearing (10). (9).
Position the snap ring (9) into the hub (3).
NOTE. Check orientation of the ring.

T4 T3
9 3

8
F1241124 F1241125

GB c GB d
Position tool T4 and press the snap ring (9) down into its seat. Turn the hub (3) upside down, lubricate the seat of the bearing and,
using tool T3, install the thrust block of the bearing (8).

15
2 14

F1241126 F1241117

GB e GB f
Only if shim washer has previously been removed. Fit the planetary gear (14) onto the planetary gear cover (2).
Apply a sealant for removable seals to the outer surface of the shim CAUTION! The jointed portion of the internal ring of the bearings
washer (15) and, using a driver, fit it into the planetary gear cover must face the bottom of the pin.
(2).

748 BOMAG
38 008 913 76
Axle DANA 193 9.5

Posizionare il mozzo ruota (3) sotto una pressa; Installare il cuscinetto (10).
ITA lubrificare la sede del cuscinetto esterno e, utilizzando ITA Spalmare la superficie esterna dell'anello di tenuta (9)
l'attrezzo T3, montare la ralla del cuscinetto (10). con sigillante per guarnizioni.
Posizionare l'anello di tenuta (9) nel mozzo (3).
NOTA. Controllare l'orientamento dell'anello.

Die Radnabe (3) unter eine Presse positionieren; den Lager (10) installieren.
D Sitz des aÈuûeren Lagers schmieren und mit dem D AÈuûere FlaÈche des Dichtringes (9) mit etwas Dicht-
Werkzeug T3 die Scheibe des Lagers (10) montieren. masse schmieren.
Dichtring (9) in die Nabe (3) positionieren.
a b BEMERKUNG. Richtung des Ringes kontrollieren.

Colocar el cubo rueda (3) bajo una prensa; lubrificar la Colocar el cojinete (10).
ESP sed del cojinete externo y, utilizando la herramienta ESP Pasar la superficie externa del anillo de retencioÁn (9)
T3, montar la rangua del cojinete (10). con sigilante para guarniciones.
Colocar el anillo de retencioÁn (9) en el cubo (3).
NOTA. Controlar el orientamiento del anillo.

Positionner le moyeu roue (3) sous la presse; lubrifier Installer le palier (10).
F le logement du palier externe, puis aÁ l'aide de l'outil F Enduire la superficie externe de l'anneau d'eÂtancheÂiteÂ
T3, monter la crapaudine du palier (10). (9) avec de la colle aÁ garnitures.
Positionner l'anneau d'eÂtancheÂite (9) dans le moyeu (3).
REMARQUE. ControÃler la bonne direction de l'anneau.

Posizionare l'attrezzo T4 e pressare in sede l'anello di Capovolgere il mozzo (3), lubrificare la sede cuscinetto
ITA tenuta (9). ITA e, utilizzando l'attrezzo T3, montare la ralla del
cuscinetto (8).

Das Werkzeug T4 positionieren und den Dichtring (9) Die Nabe (3) wenden, den Lagersitz schmieren und
D in seinen Sitz druÈcken. D mit dem Werkzeug T3 die Nabe des Lagers (8)
montieren.

c d
Colocar la herramienta y apretar en sed el anillo de Volcar el cubo (3), lubrificar la sed cojinete y,
ESP retencioÁn (9). ESP utilizando la herramienta T3, montar la rangua del
cojinete (8).

Placer l'outil T4 et presser dans son logement Faire basculer le moyeu (3), lubrifier le logement du
F l'anneau d'eÂtancheÂite (9). F palier, puis aÁ l'aide de l'outil T3, monter la crapaudine
dans le palier (8).

Solo se eÁ stata rimossa. Montare sui perni del coperchio portasatelliti (2) gli
ITA Spalmare la superficie esterna della rondella di ITA ingranaggi planetari (14).
rasamento (15) con sigillante per guarnizioni removibili ATTENZIONE! La parte raccordata dell'anello interno
e, utilizzando uno spintore, montarla nel coperchio portasatelliti (2). dei cuscinetti deve essere rivolta verso il fondo del perno.

Nur wenn zuvor abgenommen. Auf die Stifte des Deckels des Planetenradhalters (2)
D AÈuûere FlaÈche der Zwischenlegscheibe (15) mit D die Planetengetriebe (14) montieren.
Dichtmasse fuÈr abnehmbare Dichtungen schmieren ACHTUNG! Das AnschluûstuÈck des inneren Lagerrin-
und mit einem StoÈûel diese Zwischenlegscheibe in den Deckel des ges muû zur unteren Seite des Stiftes gerichtet sein.
e Planetenradhalters (2) montieren. f
Solo si ha sido desplazada. Montar sobre los pernos de la tapa lleva-satelites (2)
ESP Pasar la superficie externa de la arandela de ESP los engranajes planetares (14).
rasamiento (15) con sigilante para guarnicioÁnes ATENCION! La parte empalmada del anillo interno de
removibles y, utilizando un empuje, montarla en la tapa lleva- los cojinetes debe de ser dirijida hacia el fondo de la rotula.
satelites (2).

Uniquement si elle a eÂte enleveÂe. Monter sur les pivots du couvercle porte-satellites (2)
F Enduire la superficie externe de la rondelle de rasage F les engrenages planeÂtaires (14).
(15) avec de la colle pour garnitures amovibles, aÁ ATTENTION! La partie raccordeÂe de l'anneau aÁ
l'aide d'un poussoir monter celle-ci dans le couvercle porte- l'inteÂrieur du palier doit eÃtre tourneÂe vers la partie basse du pivot.
satellites (2).

008 913 76 BOMAG

39 749
9.5 Axle
ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE DANA 193
- PLANETENGE-
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

T5
13

14

11 12
F1241127 F1241128

GB a GB b
Lock into position the planetary gears (14) with the snap rings (13). Lubricate and fit the centring ring (12) and snap ring (11) onto tool
T5; install the rings into the arm.
CAUTION! Pay particular attention to the direction of assembly of
the rings.

3
9

3
F1241114 F1241113

GB c GB d
Grease the snap ring (9) and the hub of the arm. Install the external bearing (8).
Install the wheel hub (3). NOTE. Move the bearing to the limit stop by hammering lightly all
around the edge.

7
F1241129 F1241109

GB e GB f
Install the crown wheel (5) and, using a driver with adequate Using Tecno Lupe /101, grease the surface of the safety flange (7)
diameter, fasten it onto the hub of the arm. that touches the crown wheel.

750 BOMAG
40 008 913 76
Axle DANA 193 9.5

Fissare la posizione degli ingranaggi satelliti (14) con Lubrificare e montare sull'attrezzo T5 l'anello centra-
ITA gli anelli elastici (13). ITA tore (12) e l'anello di tenuta (11); montare gli anelli nel
braccio.
ATTENZIONE! Controllare attentamente il senso di montaggio
degli anelli.

Die Position der Planetengetriebe (14) mit den Das Werkzeug T5 schmieren und darauf den Zen-
D Kolbenringen (13) festigen. D trierring (12) und den Dichtring (11) montieren; die
Ringe in den Arm montieren.
ACHTUNG! Montagerichtung der Ringe sorgfaÈltig kontrollieren.
a b
Fijar la posicioÁn de los engranajes satelites (14) con Lubrificar y montar sobre la herramienta T5 el anillo
ESP los anillos elasticos (13). ESP central (12) y el anillo de retencioÁn (11); montar los
anillos en el eje.
ATENCION! Controlar atentamente el sentido de montaje de los
anillos.

Fixer les engrenages porte-satellites (14) aÁ leur place Lubrifier et monter sur l'outil T5 l'anneau centreur (12)
F avec les anneaux ressorts (13). F et l'anneau d'eÂtancheÂite (11); monter les anneaux
dans le bras.
ATTENTION! ControÃler attentivement le sens du montage des
anneaux.

Lubrificare con grasso l'anello di tenuta (9) ed il mozzo Montare il cuscinetto esterno (8).
ITA del braccio. ITA
NOTA. Mandare a fondo corsa il cuscinetto con
Montare il mozzo portaruota (3). leggeri colpi di mazzuolo distribuiti su tutta la
circonferenza.

Mit Fett den Dichtring (9) und die Armnabe schmieren. AÈuûeres Lager (8) montieren.
D Radhalternabe (3) montieren. D
BEMERKUNG. Das Lager bis zum Anschlag mit
leichten HammerschlaÈgen an der gesamten Kreislinie
einsetzen.
c d
Lubrificar con grasa el anillo de retencioÁn (9) y el cubo Montar el cojinete esterno (8).
ESP del eje. ESP
NOTA. Mandar a tope el cojinete con ligeros colpes de
Montar el cubo lleva-rueda (3). martillo repartidos sobre toda la circonferencia.

Lubrifier avec de la graisse l'anneau d'eÂtancheÂite (9), Monter le palier externe (8).
F le moyeu du bras. F
REMARQUE. Envoyer en buteÂe le palier avec de
Monter le moyeu porte-roue (3). leÂgers coups de maillet distribueÂs tout autour de la
circonfeÂrence.

Montare la corona (5) e, utilizzando uno spintore di Lubrificare con grasso Tecno Lupe /101 la superficie
ITA diametro adatto, mandarla in battuta sul mozzo del ITA della flangia di sicurezza (7) a contatto con la corona.
braccio.

Den Kranz (5) montieren und mit einem geeigneten Mit Fett Typ Tecno Lupe/ 101 die FlaÈche des Sicher-
D StoÈûel den Kranz bis zum Anschlag an der Armnabe D heitsflanschs (7), der am Kranz anliegt, schmieren.
einsetzen.

e f
Montar la corona (5) y, utilizando un empuje de Lubrificar con grasa Tecno Lupe/101 la superficie de
ESP diametro apto, mandarla a tope sobre el cubo del eje. ESP la brida de seguridad (7) a contacto con la corona.

Monter la couronne (5), puis aÁ l'aide d'un poussoir Lubrifier avec de la graisse Tecno Lupe/ 101 la
F d'un diameÁtre adapteÂ, envoyer celle-ci en buteÂe sur le F superficie de la flasque de seÂcurite (7) au contact de
moyeu du bras. la couronne.

008 913 76 BOMAG

41 751
9.5 Axle
ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE DANA 193
- PLANETENGE-
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

11

4
F1241130 F1241107

GB a GB b
Coat the screws (6) with Loctite 270 and screw them. Lubricate the snap ring (11), the toothed portions and the sealing
Tighten screws (6) in two stages, using the criss-cross method. surface of the axle shaft.
Initial torque wrench setting: 120 Nm Install the axle shaft (4), making sure that it is properly inserted into
Final torque wrench setting: 219 ± 242 Nm braking disks and differential unit.

3 1
2
2

16
F1241131 F1241132

GB c GB d
Fit the planetary gear cover (2) onto the wheel hub (3). Lock the planetary gear cover (2) onto the wheel hub (3) with
CAUTION! 1 - Check the condition and position of the O-ring (16). screws (1).
2 - Line up the locating release points. Screws torque wrench setting: 40 ± 0 Nm.

GB e GB f

752 BOMAG
42 008 913 76
Axle DANA 193 9.5

Spalmare le viti (6) con Loctite 270 ed avvitarle. Lubrificare l'anello di tenuta (11), le dentature e la
ITA Serrare le viti (6) in due tempi e con il metodo del ITA superficie di tenuta del semiasse.
serraggio incrociato. Montare il semiasse (4) assicurandosi che si innesti
Coppia di serraggio iniziale: 120 Nm nei dischi freni e nel differenziale.
Coppia di serraggio finale: 219v242 Nm

Die Schrauben (6) mit Loctite 270 schmieren und Dichtring (11), ZaÈhne und DichtflaÈche der Halbachse
D festschrauben. D schmieren.
Schrauben (6) im Kreuz schrittweise festziehen. Halbachse (4) montieren und darauf achten, daû sie in
Anzugsmoment zuerst: 120Nm die Bremsscheiben und in das Differential einrastet.
a Anzugsmoment am Ende: 219v242 Nm b
Pasar los tornillos (6) con Loctite 270 y atornillarlos. Lubrificar el anillo de retencioÁn (11), las dentaduras y
ESP Apretar los tornillos (6) en doss tiempos con el metodo ESP la superficie del semieje.
de torsion cruzada. Montar el semieje (4) asegurandose que se encaje en
Par de torsion inicial: 120 Nm. los discos y en el diferencial.
Par de torsion final: 219v242 Nm.

Enduire les vis (6) avec du Loctite 270 puis visser. Lubrifier l'anneau d'eÂtancheÂite (11), les dents, la
F Serrer les vis (6) en deux temps avec la meÂthode du F superficie eÂtanche des demi-essieux.
serrage croiseÂ. Monter le demi-essieu (4) en veillant aÁ ce qu'il
Couple de serrage initial: 120Nm s'enclenche bien dans les disques freins et dans le diffeÂrentiel.
Couple de serrage final: 219v242 Nm.

Montare il coperchio portasatelliti (2) sul mozzo Bloccare il coperchio portasatelliti (2) sul mozzo
ITA portaruota (3). ITA portaruota (3) con le viti (1).
ATTENZIONE! 1 - Controllare lo stato e la posizione Coppia di serraggio viti: 40v50 Nm
della guarnizione OR (16).
2 - Allineare gli scarichi di riferimento.

Den Deckel des Planetenradhalters (2) auf die Nabe Den Deckel des Planetenradhalters (2) an der Rad-
D des Radhalters (3) montieren. D halternabe (3) mit den Schrauben (1) blockieren.
ACHTUNG! 1 - Zustand und Position der O-Ringe (16) Anzugsmoment der Schrauben: 40v50 Nm
kontrollieren.
c 2 - Die Bezugsstellen bzw. AblaûoÈffnung fluchten. d
Montar la tapa lleva-satelites (2) sobre el cubo lleva- Bloquear la tapa lleva-satelietes (2) sobre el cubo
ESP rueda (3). ESP lleva-rueda (3) con los tornillos (1).
ATENCION! 1 - Controlar el estado y la posicioÁn de la Par de torsion tornillos: 40v50 Nm
guarnicioÁn OR (16).
2 - Alinear los descarges de referencia.

Monter le couvercle porte-satellite (2) sur le moyeu Bloquer le couvercle porte-satellite (2) sur le moyeu
F porte-roue (3). F porte-roue (3) aÁ l'aide des vis (1).
ATTENTION! 1 - ControÃler l'eÂtat et la position des Couple de serrage des vis: 40v50 Nm.
garnitures O'Ring (16).
2 - Aligner les points de deÂcharge de reÂfeÂrence.

ITA ITA

D D

e f

ESP ESP

F F

008 913 76 BOMAG

43 753
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

T6

T7A

F1241141 F1241142

GB a GB b
REMOVAL OF THE DIFFERENTIAL UNIT Apply tool T6 - for crown wheel side centring - with relative distance
Remove the whole arms, the cylinders, and the whole reduction pieces and lock it with two nuts.
unit. Apply centring tool T7A as well.
For details, see «CHECKING WEAR AND REPLACING THE
BRAKING DISKS» and «REMOVAL OF REDUCTION GEAR».

1 T7B

F1241143 F1241144

GB c GB d
Remove the stud screws and remove the intermediate cover (1) on Install centring tool T7B on the opposite side of the crown wheel.
the crown wheel opposite side.

2 T7B
A

4
3
5 6

F1241145 F1241146

GB e GB f
Remove centring tools T6 and T7A from crown wheel side; remove Position a stop block «A» made from tender material (aluminium,
the studs and the intermediate cover (2) on the crown wheel side. etc.) between the main body (3) and the toothed portion of the
crown wheel (4).
With the crown (4) resting on block "A", remove and extract the
screws (5) and the spring washers (6).

754 BOMAG
44 008 913 76
Axle DANA 193 9.5

RIMOZIONE DIFFERENZIALE Applicare l'attrezzo T6 di centraggio dal lato corona

ITA Rimuovere i bracci completi, i cilindri freni ed il ITA con i relativi distanziali e fissarlo con due dadi.
riduttore completo. Applicare anche l'attrezzo T7A di centratura.
Per i dettagli, vedere «CONTROLLO USURA E SOSTITUZIONE
DISCHI FRENO» e «RIMOZIONE RIDUTTORE».

DIFFERENTIAL ABNEHMEN Das Werkzeug T6 zur Zentrierung an der Kranzseite

D Die kompletten Arme, die Bremszylinder und den D mit den entsprechenden DistanzstuÈcken anbringen
kompletten Reduzierer abnehmen. und das Werkzeug mit zwei Muttern befestigen.
Siehe «VERSCHLEISS KONTROLLIEREN UND BREMSSCHEI- Das Werkzeug T7A zur Zentrierung anbringen.
a BEN AUSWECHSELN» und «REDUZIERER ABNEHMEN». b
REMOCION DIFERENCIAL Aplicar la herramienta T6 de centraje del lado corona
ESP Remover los ejes completos, los cilindros frenos y el ESP con los relativos distanciales y fijarla con dos tuercas.
reductor completo. Aplicar tambien la herramienta T7A de centradura.
Para los detalles, vease «CONTROL DESGASTE Y SOBSTITU-
CION DISCOS FRENOS» y «REMOCION REDUCTOR».

DEGAGEMENT DU DIFFERENTIEL Appliquer l'outil T6 de centrage du coÃte couronne

F Enlever les bras entieÁrement, les cylindres freins et le F avec les entretoises correspondantes et fixer l'outil
reÂducteur tout entier. avec deux eÂcrous.
Pour de plus amples deÂtails, voir "CONTROLE DE L'USURE ET Appliquer eÂgalement l'outil de centrage T7A.
SUBSTITUTION DU DISQUE FREIN" et "DEGAGEMENT DU
REDUCTEUR".

Rimuovere le viti prigioniere e rimuovere il coperchio Montare l'attrezzo T7B di centraggio sul lato opposto
ITA intermedio (1) dal lato opposto corona. ITA corona.

Die Stiftschrauben und den Zwischendeckel (1) von Das Werkzeug T7B zur Zentrierung an der dem Kranz
D der dem Kranz entgegengesetzte Seite abnehmen. D entgegengesetzte Seite montieren.

c d
Remover los tornillos prigioneros y remover la tapa Montar la herramienta T7B de centraje sobre el lado
ESP intermedia (1) del lado opuesto corona. ESP opuesto corona.

Enlever les vis prisonnieÁres et enlever le couvercle Monter l'outil de centrage T7B du coÃte oppose aÁ la
F intermeÂdiaire (1) du coÃte oppose aÁ la couronne. F couronne.

Rimuovere gli attrezzi T6 e T7A di centraggio del lato Posizionare tra il corpo centrale (3) e la dentatura della
ITA corona; asportare i prigionieri e rimuovere il coperchio ITA corona (4) un blocchetto "A" di contrasto in materiale
intermedio (2) lato corona. tenero (alluminio ecc.).
Mantenendo in appoggio la corona (4) sul blocchetto "A",
rimuovere ed asportare le viti (5) e le rondelle elastiche (6).

Die Werkzeuge T6 und T7A zur Zentrierung an der Zwischen dem ZentralkoÈrper (3) und den ZaÈhnen des
D Kranzseite entfernen; die Stiftschrauben und den D Kranzes (4) den Block "A" aus weichem Material
Zwischendeckel (2) an der Kranzseite abnehmen. (Aluminium usw.) legen.
Den Kranz (4) am Block "A" anliegen lassen und die Schrauben (5)
e f und die Federscheiben (6) abnehmen.

Remover las herramientas T6 y T7A de centraje del Colocar entre el cuerpo central 83) y la dentadura de
ESP lado corona; sacar los prigioneros y remover la tapa ESP la corona (4) un bloque "A" de contraste de material
intermedia (2) lado corona. tierno (aluminio ect.).
Manteniendo en apoyo la corona (4) sobre el bloque "A", remover y
sacar los tornillos (5) y las arandelas elasticas (6).

Enlever les outils T6 et T7A de centrage du coÃte Placer entre le corps central (3) et la denture de la
F couronne; enlever les prisonniers et deÂplacer le F couronne (4) un petit bloc "A" en mateÂriel leÂger
couvercle intermeÂdiaire (2) du coÃte couronne. (aluminium etc.) de contraste.
En maintenant la couronne (4) sur le petit bloc "A", deÂvisser et
enlever les vis (5), et ensuite les rondelles eÂlastiques (6).

008 913 76 BOMAG

45 755
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

7
7

F1241147 F1241148

GB a GB b
Using a driver, push the differential unit (7) or (8) towards the Extract the whole differential unit (7) or (8).
opposite side of the crown so as to disengage it from the crown (4).

T7B 3 3

4
4

F1241223 F1241174

GB c GB d
Remove tool T7B from the crown opposite side. Extract the crown (4).

B
9
9

F1241149 F1241150

GB e GB f
DISASSEMBLY OF THE DIFFERENTIAL UNIT DISASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT
Using an extractor, remove bearings (9) from the differential unit. Insert stay "B" provided for holding into position the no-spin unit
(14) and screw tight the wing nut.

756 BOMAG
46 008 913 76
Axle DANA 193 9.5

Utilizzando uno spintore, spingere il differenziale (7) o Estrarre il gruppo differenziale (7) o (8) completo.
ITA (8) verso il lato opposto corona fino a disimpegnarlo ITA
dalla corona (4).

Mit einem StoÈûel das Differential (7) oder (8) in die dem Das komplette Differentialaggregat (7) oder (8) ab-
D Kranz entgegengesetzte Seite druÈcken und aus dem D ziehen.
Kranz (4) freisetzen.

a b
Utilizando un empuje, empujar el diferencial (7) o (8) Sacar el grupo diferencial (7) o (8) completo.
ESP hacia el lado opuesto corona hasta desempenarlo de ESP
la corona (4).

A l'aide d'un poussoir, pousser le diffeÂrentiel (7) ou (8) Extraire le groupe diffeÂrentiel (7) ou (8) tout entier.
F du coÃte oppose aÁ la couronne jusqu'aÁ le deÂgager de la F
couronne (4).

Rimuovere l'attrezzo T7B montato sul lato opposto Estrarre la corona (4).
ITA corona. ITA

Das Werkzeug T7B abnehmen, das an der dem Kranz Kranz (4) abziehen.
D entgegengesetzte Seite montiert ist. D

c d
Remover la herramienta T7B montado sobre el lado Extraer la corona (4).
ESP opuesto corona. ESP

DeÂplacer l'outil T7B monte du coÃte oppose aÁ la Extraire la couronne (4).

F couronne. F

SMONTAGGIO DIFFERENZIALE SMONTAGGIO DIFFERENZIALE NO-SPIN

ITA Utilizzando un estrattore, asportare i cuscinetti (9) dal ITA Inserire il tirante "B" di trattenimento del gruppo no-
gruppo differenziale. spin (14) ed avvitare a fondo il dado ad alette.

DIFFERENTIAL ABMONTIEREN DAS NO-SPIN DIFFERENTIAL ABMONTIEREN

D Mit einem Abzieher die Lager (9) vom Differentialag- D Sie Spannstange "B" einsetzen, um das No-Spin
gregat abnehmen. Aggregat (14) festzuhalten und die FluÈgelmutter fest-
ziehen.
e f
DESMONTAJE DIFERENCIAL DESMONTAJE DIFERENCIAL NO-SPIN
ESP Utilizando un extractor, sacar los cojinetes (9) del ESP Introducir el tirante "B" de detencion del grupo no-spin
grupo diferencial. (14) y atornillar hasta el fondo la tuerca a aletas.

DEMONTAGE DU DIFFERENTIEL DEMONTAGE DU DIFFERENTIEL NO-SPIN

F A l'aide d'un extracteur, enlever les paliers (9) du F Introduire la tringle "B" de retenue du groupe no-spin
groupe diffeÂrentiel. (14), puis visser l'eÂcrou aÁ ailettes aÁ fond.

008 913 76 BOMAG

47 757
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

12

10 11

12

F1241151 F1241152

GB a GB b
Remove the screws (10) and the spring washers (11) jointing the Using a plastic hammer, take the half box (12) to pieces.
differential unit half box (12). NOTE. Note down the coupling marks.

13

14
F1241153 F1241154

GB c GB d
Extract the no-spin unit (13). Unscrew the wing nut of stay "B" and take the no-spin unit to
pieces in order to remove the distance piece (14) that prevents the
axial sliding of the axle shafts.

19
16
17
18

20 21

F1241155 F1241156

GB e GB f
DISASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Remove the differential cover (18), any shims (19) and the friction
Remove the screws (16) and the spring washers (17) jointing the (20) complete with ring (21).
differential unit. CAUTION! 1 - Do not change the position of the disks forming the
friction.
2 - Check that the overall thickness of friction exceeds 17.3 mm; if
lower, substitute both friction units.
758 BOMAG
48 008 913 76
Axle DANA 193 9.5

Rimuovere le viti (10) e le rondelle elastiche (11) di Utilizzando un mazzuolo in materiale plastico scom-
ITA unione della semiscatola differenziale (12). ITA porre la semiscatola differenziale (12).
NOTA. Annotare la marcatura di accoppiamento.

Schrauben (10) und Federscheiben (11) abnehmen, Mit einem Gummihammer das halbe Differentialge-
D die das halbe DifferentialgehaÈuse (12) zusammen D haÈuse (12) zerlegen.
halten. BEMERKUNG. Die Kupplungsmarkierung notieren.
a b
Remover los tornillos (10) y las arandelas elasticas Utilizando un martillo en material plastico decomponer
ESP (11) de union de la semi-caja diferencial (12). ESP la semicaja diferencial (12).
NOTA. Anotar la marcatura de acoplamiento.

Enlever les vis (10) et les rondelles eÂlastiques (11) A l'aide d'un maillet en matieÁre plastique deÂcomposer
F d'union de la moitie du boõÃtier diffeÂrentiel (12). F la moitie du boõÃtier diffeÂrentiel (12).
REMARQUE. Prendre note de la marque d'accou-
plement.

Estrarre il gruppo no-spin (13). Svitare il dado ad alette del tirante "B" e scomporre il
ITA ITA gruppo no-spin per rimuovere il distanziale (14) contro
lo scorrimento assiale dei semiassi.

Das No-Spin Aggregat (13) abziehen. Die FluÈgelmutter der Spannstange "B" abschrauben
D D und das No-Spin Aggregat zerlegen, um das Differen-
tial (14) an der Achsengleitung der Halbachsen
abnehmen zu koÈnnen.
c d
Sacar el grupo no-spin (13). Destornillar la tuerca a aletas del tirante "B" y
ESP ESP decomponer el grupo no-spin para remover el distan-
cial (14) contra el deslizamiento axial de los semi-ejes.

Extraire le groupe no-spin (13). DeÂvisser l'eÂcrou aÁ ailettes de la tringle "B" et

F F deÂcomposer le groupe no-spin pour enlever le
diffeÂrentiel (14) contre le coulisseau axial des demi-
essieux.

SMONTAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Rimuovere il coperchio differenziale (18), gli eventuali
ITA Rimuovere le viti (16) e le rondelle elastiche (17) di ITA spessori (19) e la frizione (20) completa dell'anello (21).
unione del corpo differenziale. ATTENZIONE! 1 - Non scambiare di posizione i dischi
componenti la frizione.
2 - Controllare che lo spessore totale della frizione sia superiore a
17,3 mm; se eÁ inferiore sostituire ambedue le frizioni.

DAS ZU 45% SELBSTHEMMENDE DIFFERENTIAL ABMONTIEREN Differentialdeckel (18) und evtl. Unterlegscheiben (19)
D Schrauben (16) und Federscheiben (17), die den D und die Kupplung (20) mit dem Ring (21) abnehmen.
DifferentialkoÈrper verbinden, abnehmen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
e f 2 - Die GesamtstaÈrke der Kupplung muû mehr als 17,3 mm betragen;
sollte dies nicht der Fall sein, beide Kupplungen auswechseln.

DESMONTAJE DIFERENCIAL AUTOBLOQUEO AL 45% Remover la tapa diferencial (18), los eventuales
ESP Remover los tornillos (16) y las arandelas elasticas ESP espesores (19) y la fricion (20) completa del anillo (21).
(17) de union del cuerpo diferencial. ATENCION! 1 - No cambiar de posicion los discos
componentes la fricion.
2 - Controlar que el espesor total de la fricion sea superior a 17,3
mm; si es inferior sobstituir las dos friciones.

DEMONTAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Enlever le couvercle diffeÂrentiel (18), les eÂventuelles
F Enlever les vis (16), les rondelles eÂlastiques (17) F cales (19) et la friction (20) compleÁte d'anneau (21).
d'union du corps diffeÂrentiel. ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ
17,3 mm; s'il est infeÂrieur substituer les deux frictions.

008 913 76 BOMAG

49 759
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

22
25 23

24

26 24
26

F1241157 F1241158

GB a GB b
Remove the planetary gear (22). Remove the long planetary carrier journal (23) and the two short
Mark the 37 mm value on a pin-driver; using the same pin-driver, journals (24).
insert the spring pins (25) into the journals (23) and (24).
NOTE. The spring pins are centred in journals (23) and (24) when
the countermark is lined up with the edge of the body of the
differential unit (26).

29
28
33
32

F1241159 F1241160

GB c GB d
Extract the cross journal (27), the planet wheels (28) complete with Remove the 2nd friction (20) complete with ring (21). Also remove
shim washers (29) and the second planetary gear (22). any shims (19).
CAUTION! 1 - Do not change the position of the disks forming the
friction.
2 - Check that the overall thickness of friction exceeds 17.3 mm; if
lower, substitute both friction units.

25
23 24
1
9
F1241161 F1241162

GB e GB f
Extract the spring pins (25) from journals (23) and (24). Only if bearings are replaced.
Remove the thrust blocks of bearings (9) from the intermediate
covers (1) and (2).

760 BOMAG
50 008 913 76
Axle DANA 193 9.5

Rimuovere l'ingranaggio planetario (22). Rimuovere il perno porta satelliti lungo (23) ed i due
ITA Segnare su un cacciaspine un contrassegno a 37 mm; ITA perni corti (24).
utilizzando lo stesso cacciaspine, inserire nei perni
(23) e (24) le spine elastiche (25).
NOTA. Le spine elastiche sono centrate nei perni (23) e (24)
quando il contrassegno arriva a filo del corpo differenziale (26).

Das Planetengetriebe (20) abnehmen. An einem DuÈ- Den langen Planetenradhalterstift (23) und die beiden
D bel das Maû von 37 mm markieren; mit diesem DuÈbel D kurzen Planetenradhalterstifte (24) entfernen.
die Federstifte (25) in die Stifte (23) und (24) einsetzen.
BEMERKUNG. Die Federstifte sind in den Stiften (23) und (24)
a zentriert, wenn das markierte Maû auf der HoÈhe des Differential- b
koÈrpers (26) liegt.

Remover el engranaje planetario (22). Senalizar sobre Remover la rotula porta satelites largo (23) y las dos
ESP un extractor de clavijas un contra-segno a 37 mm; ESP rotulas cortas (24).
utilizando el mismo extractor de clavijas, introducir en
los pernos (23) y (24) las clavijas elasticas (25).
NOTA. Las clavijas elasticas son centradas en los pernos (23) y
(24) cuando el contrasegno llega al hilo del cuerpo diferencial (26).

Enlever l'engrenage planeÂtaire (22). Marquer d'une Enlever le pivot porte-satellite long (23) et les deux
F estampille le chasse-clou aÁ 37 mm; a l'aide de ce meÃme F pivots courts (24).
chasse-clou, introduire dans les pivots (23) et (24) les
goupilles eÂlastiques (25).
REMARQUE. Les goupilles eÂlastiques sont centreÂes dans les pivots
(23) et (24) quand l'estampille atteint le bord du corps diffeÂrentiel (26).

Estrarre la crociera (27), i satelliti (28) completi delle Rimuovere la 2ã frizione (20) completa dell'anello (21).
ITA rondelle di rasamento (29) ed il 2ë ingranaggio ITA Rimuovere anche gli eventuali spessori (19).
planetario (22). ATTENZIONE! 1 - Non scambiare di posizione i dischi
componenti la frizione.
2 - Controllare che lo spessore totale della frizione sia superiore a
17,3 mm; se eÁ inferiore sostituire ambedue le frizioni.

Das Kreuz (27), die Planetengetriebe (28) samt Die 2. Kupplung (20) mit Ring (21) abnehmen.
D Zwischenlegscheiben (29) und das 2. Planetengetrie- D Eventuelle Unterlegscheiben (19) auch entfernen.
be (30) abziehen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
c d 2 - Kontrollieren, ob die GesamtstaÈrke der Kupplung mehr als 17,3 mm
betraÈgt; anderenfalls beide Kupplungen auswechseln.

Sacar la cruceta (27), los satelites (28) completos de Remover la 2ë fricion (30) completa del anillo (21).
ESP las arandelas de rasamiento (29) y el 2ë engranaje ESP Remover tambien los eventuales espesores (19).
planetario (22). ATENCION! 1 - No cambiar de posicion los discos
componentes la fricion.
2 - Controlar que el espesor total de la fricion sea superior a 17,3 mm;
si es inferior sobstituir las dos friciones.

Extraire le croisillon (27), les satellites (28) complet de Enlever la 2ë friction (20) compleÁte d'anneau (21).
F rondelles de rasage (29), puis le 2ë engrenage F Enlever eÂgalement les eÂventuelles cales (19).
planeÂtaire (22). ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ
17,3 mm; s'il est infeÂrieur substituer les deux frictions.

Estrarre le spine elastiche (25) dai perni (23) e (24). Solo se si sostituiscono i cuscinetti
ITA ITA Rimuovere le ralle dei cuscinetti (9) dai coperchi
intermedi (1) e (2).

Die Federstifte (25) von den Stiften (23) und (24) Nur falls die Lager ausgewechselt werden.
D abziehen. D Die Scheiben von den Lagern (9) der Zwischendeckel
(1) und (2) abnehmen.

e f
Sacar las clavijas elasticas (25) de las rotulas (23) y Solo si se sobstituiyen los cojinetes
ESP (24). ESP Remover las ranguas de los cojinetes (9) de las tapas
intermedias (1) y (2).

Extraire les goupilles eÂlastiques (25) des pivots (23) et Uniquement en cas de substitution des paliers.
F (24). F Enlever les crapaudines des paliers (9) des couvercles
intermeÂdiaires (1) et (2).

008 913 76 BOMAG

51 761
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

30
4 33
35 36 3 34
32
7
45 31
1
8

38
44 40
GB a GB b
6 41

39
37

46

43 47
32
42

30

GB
33 34
c GB d
31

D1240134

GB e GB f

762 BOMAG
52 008 913 76
Axle DANA 193 9.5

ITA ITA
18

20 9
29
D 25 22 D
28
a b
24 19 16

ESP 29 ESP 21 17
27
20 29
25

19 24
28
F F
22 29
21 25

23 10
11
ITA 7ITA

26 12
14
9
D D

15
c d 9
9
ESP ESP

13

F F 8

D1240135

ITA ITA

D D

e f

ESP ESP

F F

008 913 76 BOMAG

53 763
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

12
13

15

14
F1241154 F1241163

GB a GB b
ASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT Fit the no-spin unit into the differential unit half box (15).
Assemble the no-spin unit (13), inserting the distance piece (14) Centre the half box (12) and fasten.
and using stay "B". CAUTION! Make sure the connection marks coincide.

10

F1241164 F1241150

GB c GB d
Fit the spring washers (11) onto the screws (10). Remove stay "B".
Coat the screws (10) with Loctite 270 and screw tight to form the
differential box. Tighten screws using the criss-cross method and a
torque of 86 ± 89 Nm.

21
20
21
20 26

17,6

19
F1241224 F1241160

GB e GB f
ASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Insert in the body of the differential unit (26) any required shims
Using a depth gauge, check the shim of friction units complete with (19) and the friction (20) complete with ring (21).
rings (21). If thickness is lower than 17.6 mm, add more shims (19). CAUTION! Ring (21) must touch the planetary gear (22).
CAUTION! Shims must be placed right behind the body of the
differential unit (26).

764 BOMAG
54 008 913 76
Axle DANA 193 9.5

ASSEMBLAGGIO DIFFERENZIALE NO-SPIN Montare il gruppo no-spin nella semiscatola differen-

ITA Assemblare il gruppo no-spin (13) inserendo il distan- ITA ziale (15).
ziale (14) ed utilizzando il tirante "B". Centrare la semiscatola (12) e mandarla in battuta.
ATTENZIONE! Controllare che le marcature di accoppiamento
coincidano.

NO-SPIN DIFFERENTIAL ZUSAMMENBAUEN Das No-Spin Aggregat in das halbe Differentialge-

D Das No-Spin (13) Aggregat zusammenbauen; dazu D haÈuse (15) montieren.
das DistanzstuÈck (14) mit der Spannstange "B" Das halbe GehaÈuse (12) zentrieren und bis zum
einsetzen. Anschlag einsetzen.
a b ACHTUNG! Kontrollieren, ob die Kupplungsmarkierungen uÈberein-
stimmen.

MONTAJE DIFERENCIAL NO-SPIN Montar el grupo no-spin en la semi-caja diferencial

ESP Asemblaje el grupo no-spin (13) introduciendo el ESP (15).
diferencial (14) y utilizando el tirante "B". Centrar la semi-caja (12) y mandarla a tope.
ATENCION! Controlar que las marcaduras de acoplamiento
coincidan.

ASSEMBLAGE DU DIFFERENTIEL NO-SPIN Monter le groupe no-spin dans la moitie du boõÃtier

F Assembler le groupe no-spin (13) en introduisant F diffeÂrentiel (15).
l'entretoise (14), puis aÁ l'aide de la tringle "B". Centrer la moitie du boõÃtier (12) et l'envoyer en buteÂe.
ATTENTION! ControÃler que les estampilles d'accouplement
correspondent.

Infilare sulle viti (10) le rondelle elastiche (11). Rimuovere il tirante "B".
ITA Spalmare le viti (10) con Loctite 270 ed avvitarle a ITA
fondo per comporre la scatola differenziale.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
86v89 Nm.

Federscheiben (11) in die Schrauben (10) einsetzen. Spannstange "B" abnehmen.

D Die Schrauben (10) mit Loctite 270 schmieren und D
festziehen, um das DifferentialgehaÈuse zusammenzu-
bauen.
c Die Schrauben im Kreuz und mit einem Anzugsmoment von 86v89
Nm festziehen.
d
Insertar sobre tornillos (10) las arandelas elasticas Remover el tirante "B".
ESP (11). ESP
Pasar los tornillos (10) con Loctite 270 y atornillar
hasta el fondo para componer la caja diferencial.
Apretar los tornillos con el metodo cruzado y un par de serraje de
86v89 Nm.

Passer sur les vis (10) les rondelles eÂlastiques (11). Enlever la tringle "B".
F Enduire les vis (10) avec du Loctite 270, puis visser F
celles-ci aÁ fond pour recomposer le boõÃtier diffeÂrentiel.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
86v89 Nm.

ASSEMBLAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Inserire nella corpo differenziale (26) gli eventuali
ITA Controllare con un calibro di profonditaÁ lo spessore ITA spessori (19) e la frizione (20) completa dell'anello
delle frizioni complete degli anelli (21). Se lo spessore (21).
eÁ inferiore a 17,6 mm, aggiungere degli spessori (19). ATTENZIONE! L'anello (21) deve rimanere a contatto dell'ingra-
ATTENZIONE! Gli spessori devono essere posizionati a ridosso del naggio planetario (22).
corpo differenziale (26).

ZU 45% SELBSTHEMMENDE DIFFERENTIAL ZUSAMMENBAUEN In den DifferentialkoÈrper (26) eventuelle Unterleg-

D Mit Hilfe einer Tiefenlehre die StaÈrke der Kupplungen D scheiben (19) und die Kupplung (20) samt Ring (21)
mit den Ringen (21) messen. Sollte das Maû weniger einsetzen.
als 17,6 mm betragen, noch Unterlegscheiben (19) hinzufuÈgen. ACHTUNG! Der Ring (21) muû am Planetengetriebe (22) anliegen.
e ACHTUNG! Die Unterlegscheiben muÈssen am DifferentialkoÈrper f
(26) anliegen.

MONTAJE DIFERENCIAL AUTO-BLOQUEO AL 45% Introducir en el cuerpo diferencial (26) los eventuales
ESP Controlar con un calibro de profundidad el espesor de ESP espesores (19) y la fricion (20) completa del anillo (21).
las friciones completas de los anillos (21). Si el ATENCION! El anillo (33) debe quedar a contacto del
espesor es inferior a 17,6 mm, sumar de los espesorees (19). engranaje planetario (22).
ATENCION! Los espesores deben de ser colocados detraÁs del
cuerpo diferencial (26).

ASSEMBLAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Introduire le corps diffeÂrentiel (26), les eÂventuelles
F ControÃler aÁ l'aide d'un calibre de profondeur l'eÂpais- F cales (19) et la friction (20) compleÁte d'anneau (21.
seur des frictions compleÁtes d'anneaux (21). Si le ATTENTION! L'anneau (21) doit rester au contact de
calage est infeÂrieur aÁ 17,6 mm, ajouter des cales (19). l'engrenage planeÂtaire (22).
ATTENTION! Les cales doivent eÃtre placeÂes aÁ l'abri du corps
diffeÂrentiel (226).

008 913 76 BOMAG

55 765
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

27
22 28

26
23

24

F1241165 F1241166

GB a GB b
Install the planetary gear (22) and three of the planet wheels (28), Install the cross journal (27), holding it into position with the long
complete with shim washers (29). journal (23).
Hold the planet wheels (28) and relative washers (29) into position Before inserting journal (23) completely, install the last planet
with pins (24). wheel (28) and the relative washer (29).

19
22
25

20
26 21
26
25,5

F1241167 F1241168

GB c GB d
Countermark a point at 25.5 mm on a pin-driver; using the same Install the second planetary gear (22) and the friction (20) complete
pin-driver, engage the journals (23) and (24) with the spring pins with ring (21) and any shims required (19).
(25). CAUTION! Ring (21) must be installed right behind the planetary
NOTE. When the countermark is lined up with the edge of the body gear (22) and the shims (19) right behind the differential cover (18).
of the differential unit (26), the journals are engaged by half.

16 17

18

26

F1241169 F1241170

GB e GB f
Position the differential cover (18). Fit the spring washers (17) onto the screws (16).
NOTE. Make sure that the assembly marks coincide. Coat the screws (16) with Loctite 270 and screws tight.
Tighten screws using the criss-cross method and a torque of
135 ± 138 Nm.

766 BOMAG
56 008 913 76
Axle DANA 193 9.5

Montare l'ingranaggio planetario (22) e tre degli Montare la crociera (27) e mantenerla in posizione con
ITA ingranaggi satelliti (28) completi di rondelle di rasa- ITA il perno lungo (23).
mento (29). Prima di inserire completamente il perno (23), montare
Mantenere in posizione gli ingranaggi satelliti (28) e le relative l'ultimo satellite (28) e la relativa rondella (29).
rondelle (29) con i perni (24).

Das Planetengetriebe (22) und drei der Planetenge- Das Kreuz (27) montieren und in der Position mit
D triebe (28) samt Zwischenlegscheiben (29) montieren. D einem langen Stift (23) festhalten.
Die Planetengetriebe (28) und die Zwischenlegschei- Bevor der Stift (23) ganz eingesetzt wird, das letzte
ben (29) mit den Stiften (24) in der Position festhalten. Planetengetriebe (28) und die Unterlegscheibe (29) montieren.
a b
Montar el engranaje planetario (22) y tres de los Montar la cruceta (27) y mantenerla en posicion con la
ESP engranajes satelites (28) completos de las arandelas ESP rotula larga (28).
de rasadura (29). Antes de insertar completamente la rotula (23), montar
Mantener en posicion los engranajes satelites (28) y las relativas el ultimo satelite (28) y la relativa arandela (29).
arandelas (29) con las rotulas (24).

Monter l'engrenage planeÂtaire (22) et trois des Monter le croisillon (27) et maintenir celui-ci aÁ sa place
F engrenages satellites (28) complets de rondelles de F aÁ l'aide du pivot long (23).
rasage (29). Avant d'introduire entieÁrement le pivot (23), monter le
Maintenir les engrenages satellites (28) et relatives rondelles (29) aÁ dernier satellite (28) et sa rondelle (29).
leur place avec les pivots (24).

Segnare sul cacciaspine un contrassegno a 25,5 mm; Montare il secondo ingranaggio planetario (22) e la
ITA utilizzando lo stesso cacciaspine impegnare i perni ITA frizione (20) completa dell'anello (21) e degli eventuali
(23) e (24) con le spine elastiche (25). spessori (19).
NOTA. Le spine impegnano metaÁ dei perni quando il contrassegno ATTENZIONE! L'anello (21) deve essere montato a ridosso
arriva a filo del corpo differenziale (26). dell'ingranaggio planetario (22) e gli eventuali spessori (19) a
ridosso del coperchio differenziale (18).

An dem DuÈbel das Maû von 25,5 mm markieren; mit Das zweite Planetengetriebe (22) und die Kupplung
D demselben DuÈbel die Stifte (23) und (24) mit den D (20) mit dem Ring (21) und eventuelle Unterlegschei-
Federstiften (25) einsetzen. ben (19) montieren.
BEMERKUNG. Die Stifte sind durch die Federstifte zur HaÈlfte ACHTUNG! Der Ring (21) muû nach der Montage am Planetenge-
c eingesetzt, wenn die Markierung auf halber HoÈhe des Differential- d triebe (22) und die eventuellen Unterlegscheiben (19) muÈssen am
koÈrpers (26) liegt. Differentialdeckel (18) anliegen.

Senalar sobre el extractor de clavijas un contra-segno Montar el segundo engranaje planetario (22) y la
ESP a 25,5 mm; utilizando el mismo extractor de clavijas ESP fricion (20) completa del anillo (21) y de los eventuales
empegnar las rotulas (23) y (24) con las clavijas espesores (19).
elasticas (25). ATENCION! El anillo (21) debe deser montado detras del
NOTA! Las clavijas empegnan midad de las rotulas cuando el engranaje planetario (22) y los eventuales espesores (19) detras
contra-segno llega al borde del cuerpo diferencial (26). de la tapa diferencial (18).

Marquer d'une estampille le chasse-clou aÁ 25,5 mm; Monter le second engrenage planeÂtaire (22), la friction
F a l'aide de ce meÃme chasse-clou, engager les pivots F (20) compleÁte d'anneau (21) et des eÂventuelles cales
(23) et (24) et les goupilles eÂlastiques (25). (19).
REMARQUE. Les goupilles arrivent aÁ la moitie des pivots quand ATTENTION! L'anneau (21) est aÁ monter aÁ l'abri de l'engrenage
l'estampille atteint le bord du corps diffeÂrentiel (26). planeÂtaire (22) et les eÂventuelles cales (19) aÁ l'abri du couvercle
diffeÂrentiel (18).

Posizionare il coperchio differenziale (18). Infilare sulle viti (16) le rondelle elastiche (17).
ITA ITA Spalmare le viti (16) con Loctite 270 ed avvitarle a
NOTA. Controllare che le marcature di montaggio
coincidano. fondo.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
135v138 Nm.

Den Differentialdeckel (18) positionieren. Auf die Schrauben (16) die Federscheiben (17)
D D montieren.
BEMERKUNG. Kontrollieren, ob die Montagemarkie-
rungen uÈbereinstimmen. Die Schrauben (16) mit Loctite 270 schmieren und
festziehen. Die Schrauben im Kreuz mit einem Anzugsmoment von
e f 135v138 Nm festziehen.

Colocar la tapa diferencial (18). Introducir sobre los tornillos (16) las arandelas
ESP ESP elasticas (17).
NOTA. Colocar que las marcaduras de montaje
coincidan. Pasar los tornillos (16) con Loctite 270 y atornillarlos a
fondo.
Apretar los tornillos con el metodo cruzado a un par de serraje de
135v138 Nm.

Mettre le couvercle diffeÂrentiel (18) en place. Passer sur les vis (16) les rondelles eÂlastiques (17).
F F Enduire les vis (16) avec du Loctite 270 et visser
REMARQUE. ControÃler que les estampilles de mon-
tage coõÈncident. celles-ci aÁ fond.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
135v138 Nm.

008 913 76 BOMAG

57 767
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

9 9 9 9

7
8
8 7

F1241171 F1241172

GB a GB b
INSTALLATION OF THE DIFFERENTIAL UNIT Turn the unit upside down and install the second bearing (9).
Position the differential unit (7) or (8) under a press and, using a CAUTION! Pay particular attention; position a shim with adequate
driver with an adequate diameter, install the first bearing (9). diameter in order to engage the internal ring of bearing (9) without
engaging the cage.

T8
9

F1241173 F1241174

GB c GB d
Only if bearings are replaced Position the crown wheel (4) in the main body (3).
Using tool T8, insert the thrust blocks of the bearings (9) into the
intermediate covers (1) and (2).

T7B 7 8

F1241175 F1241176

GB e GB f
Fit tool T7B on the crown wheel opposite side, holding it in position Install the differential unit (7) or (8), by fitting it into the hole of tool
with two studs and two nuts. T7B.
NOTE. Engage the crown (4) onto tool T7B. Install the crown (4) onto the differential unit (7) or (8), and fasten it
to the flange.
NOTE. Make sure the holes of the flange match those of the crown.

768 BOMAG
58 008 913 76
Axle DANA 193 9.5

INSTALLAZIONE DIFFERENZIALE Capovolgere il gruppo e montare il secondo cuscinetto

ITA Posizionare il differenziale (7) o (8) sotto una pressa ed ITA (9).
utilizzando uno spintore di diametro adatto montare il ATTENZIONE! Prestare molta attenzione e posiziona-
primo cuscinetto (9). re uno spessore di diametro adatto al fine di impegnare l'anello
interno del cuscinetto (9) senza impegnare la gabbia.

DIFFERENTIAL ZUSAMMENBAUEN Das Aggregat wenden und das zweite Lager montie-
D Das Differential (7) oder (8) unter eine Presse legen D ren (9).
und mit einem geeigneten Dynamometer-StoÈûel das ACHTUNG! Den Vorgang mit groûer Sorgfalt durch-
erste Lager (9) montieren. fuÈhren und einen fuÈr die StaÈrke geeigneten Dynamometer
a b verwenden, um den Ring des inneren Lagers (9) einzusetzen,
ohne den KaÈfig einzuklemmen.

INSTALACION DIFERENCIAL Volcar el grupo y montar el segundo cojinete (9).

ESP Colocar el diferencial (7) y (8) bajo una prensa y ESP
ATENCION! Tener mucho cuidado y colocar un
utilizando un empuje de diametro adapto montar el espesor de diametro apto al fin de empegnar el anillo
primer cojinete (9). interno del cojinete (9) si empegnar la jaula.

INSTALLATION DU DIFFERENTIEL Faire basculer le groupe et monter le second palier (9).

F Mettre le diffeÂrentiel (7) ou (8) en place sous la presse, F
ATTENTION! Faire treÁs attention, mettre une cale au
aÁ l'aide d'un poussoir au diameÁtre adeÂquat, monter le diameÁtre adeÂquat afin d'engager l'anneau interne du
premier palier (9). palier (9) sans y engager la cage.

Solo se si sostituiscono i cuscinetti Posizionare la corona (4) dentro il corpo centrale (3).
ITA Utilizzando l'attrezzo T8 inserire le ralle dei cuscinetti ITA
(9) nei coperchi intermedi (1) e (2).

Nur wenn die Lager ausgewechselt werden. Den Kranz (4) in den zentralen KoÈrper (3) einsetzen.
D Mit dem Werkzeug T8 die Scheiben der Lager (9) in D
die Zwischendeckel (1) und (2) einsetzen.

c d
Solo si se sobstituyen los cojinetes Colocar la corona (4) dentro del cuerpo central (3).
ESP Utilizando la herramienta T8 Introducir las ranguas de ESP
los cojinetes (9) en las tapa intermedias (1) y (2).

Uniquement en cas de substitution des paliers Mettre la couronne (4) en place dans le corps central
F A l'aide de l'outil T8, introduire la crapaudine des F (3).
paliers (9) dans les couvercles intermeÂdiaires (1) et (2).

Montare l'attrezzo T7B sul lato opposto corona, Montare il gruppo differenziale (7) o (8) impegnandolo
ITA trattenendolo con due prigionieri e due dadi. ITA nel foro dell'attrezzo T7B.
NOTA. Impegnare la corona (4) sull'attrezzo T7B. Montare la corona (4) sul differenziale (7) o (8)
mandandola in battuta sulla flangia.
NOTA. Far coincidere i fori della flangia con i fori della corona.

Das Werkzeug T7B auf der dem Kranz entgegen- Das Differentialaggregat (7) oder (8) montieren und im
D gesetzten Seite montieren und mit zwei Stiftschrauben D Loch des Werkzeuges T7B einrasten.
und zwei Muttern festhalten. Den Kranz (4) auf das Differential (7) oder (8)
BEMERKUNG. Den Kranz (4) in das Werkzeug T7B einrasten. montieren und bis zum Anschlag am Flansch einsetzen.
e f BEMERKUNG. Die FlanschloÈcher muÈssen mit den KranzloÈchern
uÈbereinstimmen.

Montar la herramienta T7B sobre el lado opuesto Montar el grupo diferencial (7) o (8) empegnandolo en
ESP corona, deteniendo con dos prigionieros y dos ESP el agujero de la herramienta T7B.
tuercas. Montar la corona (4) sobre el diferencial (7) y (8)
NOTA. Empegnar la corona (4) sobre la herramienta T7B. mandandola a tope sobre la brida.
NOTA. Hacer coincidir los agujeros de la brida con los agujeros de
la corona.

Monter l'outil T7B du coÃte oppose aÁ la couronne, en le Monter le groupe diffeÂrentiel (7) ou (8) en l'engageant
F tenant aÁ l'aide de deux prisonniers et de deux eÂcrous. F dans le trou de l'outil T7B.
REMARQUE. Engager la couronne (4) sur l'outil T7B. Monter la couronne (4) sur le diffeÂrentiel (7) ou (8) puis
l'envoyer en buteÂe sur la flasque.
REMARQUE. Faire correspondre les trous de la flasque avec les
trous de la couronne.

008 913 76 BOMAG

59 769
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

35
5 A

F1241177 F1241145

GB a GB b
Fit spring washers (6) onto the screws (5). Check the condition and position of the O-ring (30); lubricate the
Coat screws with Loctite 270 and screw them tight into the crown. seal and install the intermediate cover (2) on crown wheel side.
Position the stop block "A"; while holding the crown resting on the
block, tighten the screws (5) to a torque of 135 ± 138 Nm.
CAUTION! Tighten screws using the criss-cross method.

2
T6
31
T7A

F1241178 F1241179

GB c GB d
Lock the intermediate cover (2) with the journals (31) tightened to a Install tool T6 on the journals (31) on the crown wheel side, placing
torque of 129 ± 143 Nm. distance pieces and locking with two nuts. Insert differential
centring and support tool T7A into tool T6.
NOTE. Make sure that the differential unit is tightly engaged in the
intermediate cover (2).

T7B 1
30

F1241180 F1241181

GB e GB f
Remove tool T7B on crown opposite side. Check state and position of O-ring (30); lubricate the seal and fit the
intermediate cover (1) on the crown opposite side.
Lock the intermediate cover (1) with journals (31) tightened to a
torque of 129 ± 143 Nm and remove tools T6 and T7A.

770 BOMAG
60 008 913 76
Axle DANA 193 9.5

Montare sulle viti (5) le rondelle elastiche (6). Controllare lo stato ed il posizionamento dell'anello
ITA Spalmare le viti con Loctite 270 ed avvitarle a fondo ITA OR (30); lubrificare la guarnizione e montare il
nella corona. Posizionare il blocchetto "A" di contra- coperchio intermedio (2) lato corona.
sto; mantenendo in appoggio la corona sul blocchetto, serrare le
viti (5) ad una coppia di 135v138 Nm.
ATTENZIONE! Serrare le viti con il metodo incrociato.

Auf die Schrauben (5) die Federscheiben (6) montieren. Den Zustand und die Position des O-Ringes (30)
D Die Schrauben mit Loctite 270 schmieren und in den D kontrollieren; die Dichtung schmieren und den Zwi-
Kranz schrauben. Den Block "A" positionieren; den schendeckel (2) an der Kranzseite montieren.
Kranz am Block anliegen lassen und die Schrauben (5) mit einem
a Anzugsmoment von 135v138 Nm festziehen. b
ACHTUNG! Die Schrauben im Kreuz festziehen.

Montar sobre los tornillos (5) las arandelas elasticas (6). Controlar el estado y la colocacion del anillo OR (30);
ESP Pasar los tornillos con Loctite 270 y atornillarlos a ESP lubrificar la guarnicion y montar la tapa intermedia (2)
fondo en la corona. Colocar el bloque "A" de contraste; lado corona.
manteniendo en apoyo la corona sobre el bloque, apretar los
tornillos (5) y un par de 135v138 Nm.
ATENCION! Apretar los tornillos con el metodo cruzado.

Monter les vis (5), les rondelles eÂlastiques (6). ControÃler l'eÂtat et le positionnement de l'anneau
F Enduire les vis avec du Loctite 270, puis visser celles- F O'Ring (30); lubrifier la garniture, puis monter le
ci aÁ fond dans la couronne. Mettre le petit bloc "A" de couvercle intermeÂdiaire (2) du coÃte couronne.
contraste; en maintenant la couronne poseÂe sur le petit bloc, serrer
les vis (5) aÁ un couple de 135v138 Nm.
ATTENTION! Serrer les vis avec la meÂthode croiseÂe.

Bloccare il coperchio intermedio (2) con i prigionieri Montare l'attrezzo T6 sui prigionieri (31) lato corona,
ITA (31) serrati ad una coppia di 129v143 Nm. ITA interponendo i relativi distanziali e bloccandolo con
due dadi. Inserire nell'attrezzo T6 l'attrezzo T7A di
centratura e sostegno del differenziale.
NOTA. Assicurarsi che il differenziale sia impegnato a fondo nel
coperchio intermedio (2).

Den Zwischendeckel (2) mit den Stiftschrauben (31) Das Werkzeug T6 an den Stiftschrauben (31) an der
D blockieren und mit einem Anzugsmoment von D Kranzseite montieren und dabei DistanzstuÈcke einsetzen
129v143 Nm festziehen. und mit zwei Muttern befestigen. In das Werkzeug T6 das Werkzeug
T7A zur Zentrierung und Halterung des Differentials einsetzen.
c d BEMERKUNG. Sicherstellen, daû das Differential fest im Zwischen-
deckel (2) sitzt.

Bloquear la tapa intermedia(2) con los prigioneros (31) Montar la herramienta T6 sobre los prigioneros (31)
ESP apretados a un par de 129v143 Nm. ESP lado corona, interponiendo de los distanciales y
bloqueando con dos tuercas. Introducir en la herramienta T6 la
herramienta T7A de centradura y sosten del diferencial.
NOTA. Asegurarse que el diferencial sea empegnado a fondo en la
tapa intermedia (2).

Bloquer le couvercle intermeÂdiaire (2) aÁ l'aide des Monter l'outil T6 sur les prisonniers (31) coÃte cou-
F prisonniers (31) serreÂs aÁ un couple de 129v143 Nm. F ronne, en y intercalant des entretoises, puis bloquer
celui-ci avec deux eÂcrous. Introduire dans l'outil T6,
l'outil T7A de centrage et de support du diffeÂrentiel.
REMARQUE. S'assurer que le diffeÂrentiel soit engage aÁ fond dans
le couvercle intermeÂdiaire (2).

Rimuovere l'attrezzo T7B del lato opposto corona. Controllare lo stato ed il posizionamento dell'anello
ITA ITA OR (30); lubrificare la guarnizione e montare il
coperchio intermedio (1) lato opposto corona.
Fissare il coperchio intermedio (1) con i prigionieri (31) serrati ad
una coppia di 129v143 Nm e rimuovere gli attrezzi T6 e T7A.

Werkzeug T7B an der dem Kranz entgegengesetzten Den Zustand und die Position des O-Ringes (30)
D Seite abnehmen. D kontrollieren; die Dichtung schmieren und den Zwi-
schendeckel (1) an der dem Kranz entgegengesetzten
Seite montieren. Den Zwischendeckel (1) mit den Stiftschrauben
e f (31) und einem Anzugsmoment von 129v143 Nm befestigen und
die Werkzeuge T6 und T7A entfernen.

Remover la herramienta T7B del lado opuesto corona. Controlar el estado y la colocacion del anillo OR (30);
ESP ESP lubrificar la guarnicion y montar la tapa intermedia (1)
lado opuesto corona.
Fijar la tapa intermedia (1) con los prigioneros (31) apretados a un
par de 129v143 Nm y remover las herramientas T6 y T7A.

Enlever l'outil T7B du coÃte oppose aÁ la couronne. ControÃler l'eÂtat et le positionnement de l'anneau
F F O'Ring (30); lubrifier la garniture, puis monter le
couvercle intermeÂdiaire (1) du coÃte oppose aÁ la
couronne.
Fixer le couvercle intermeÂdiaire (1) aÁ l'aide des prisonniers (31)
serreÂs aÁ un couple de 129v143 Nm, enlever les outils T6 et T7A.

008 913 76 BOMAG

61 771
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

1 32

32 T9

34

33 F1241182 F1241183

GB a GB b
Remove the screws (33) and remove the safety tabs (34). Using wrench T9, extract the adjustment ring nuts (32) and remove
any residue of thread locking substances.
Screw ring nuts again after applying Loctite 242.

37 3

36

35

F1241184 F1241185

GB c GB d
Remove the spring ring (35) and extract the cap (36) to allow Coat the surface of the main body (3) with Loctite 510 and install
checking of the clearance between pinion and crown to take place. the reduction gear (37) complete with pinion.
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.

38 32

T9

F1241186 F1241183

GB e GB f
Coat screws (38) with Loctite 242 and screw tight. Tighten screws Screw ring nut (32) on crown wheel side until clearance between
(38), using the criss-cross method and a tightening torque of pinion and crown equals zero, then unscrew by 1/4 turn approx.
129 ± 143 Nm.

772 BOMAG
62 008 913 76
Axle DANA 193 9.5

Asportare le viti (33) e rimuovere le linguette di Utilizzando la chiave T9 rimuovere le ghiere (32) di
ITA sicurezza (34). ITA registrazione ed asportare ogni traccia di frenafiletti.
Riavvitare le ghiere dopo averle spalmate con
Loctite 242.

Die Schraube (33) abschrauben und den Sicherheits- Mit einem SchluÈssel T9, die Nutmuttern (32) zur
D keil (34) abnehmen. D Einstellung entfernen und jede alle uÈberschuÈssigen
Reste der SchraubensicherungsloÈsung sorgfaÈltig ent-
fernen.
a b Nutmuttern mit Loctite 242 schmieren und wieder festschrauben.

Sacar los tornillos (33) y remover les lengues de Utilizando la llave T9, remover las virolas (32) de
ESP seguridad (34). ESP registracion y sacar cada senal de frenaroscas.
Restornillas las virolas despues de haberias pasadas
con Loctite 242.

Enlever le vis (33), puis deÂplacer le languettes de A l'aide de la cle T9, enlever les eÂcrous annulaires (32)
F seÂcurite (34). F de reÂglage et toute trace de l'agent d'arreÃt de vis.
Enduire les eÂcrous annulaires avec Loctite 242 et
visser.

Asportare l'anello elastico (35) e rimuovere il tappo Spalmare la superficie del corpo centrale (3) con
ITA (36) per poter controllare il gioco tra pignone e corona. ITA Loctite 510 ed installare il riduttore (37) completo di
pignone.
NOTA. Assicurarsi che il sigillante crei un velo continuo attorno ai
fori di fissaggio.

Den Kolbenring (35) abnehmen und den Stopfen (363) Die FlaÈche des ZentralkoÈrpers (3) mit Loctite 510
D entfernen, um das Spiel zwischen Kegelrad und Kranz D schmieren und den Reduzierer (37) samt Kegelrad
kontrollieren zu koÈnnen. installieren.
BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleich-
c d maÈûigen Film um die BefestigungsloÈcher herum bildet.

Sacar el anillo elastico (35) y remover la tapa (36) para Pasar la superficie del cuerpo central (3) con Loctite
ESP poder controlar el juego entre pignon y corona. ESP 510 y instalar el reductor (37) completo de pignon.
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor a los agujeros de fisaje.

Enlever l'anneau eÂlastique (35), enlever le bouchon Enduire la superficie du corps central (3) avec du
F (36) pour controÃler le jeu existant entre pignon et F Loctite 510, installer le reÂducteur (37) complet de
couronne. pignon.
REMARQUE. S'assurer que la couche de colle entoure bien les
trous de fixation.

Spalmare le viti (38) con Loctite 242 e avvitarle a fondo. Avvitare la ghiera (32) lato corona fino ad azzerare i
ITA Serrare le viti (38) con il metodo incrociato ad una ITA giochi tra pignone e corona e poi svitare per circa 1/4
coppia di serraggio di 129v143 Nm. di giro.

Die Schrauben (38) mit Loctite 242 schmieren und Nutmuttern (32) an der Kranzseite zuschrauben bis
D festziehen. Die Schrauben (38) im Kreuz mit einem D zwischen Rad und Kranz kein Spiel mehr uÈbrig bleibt;
Anzugsmoment von 129v143 Nm festziehen. danach um 1/4 Umdrehung aufschrauben.

e f
Pasar los tornillos (38) con Loctite 242 y atornillas a Atornillar las virolas (32) lado corona hasta acerar los
ESP fondo. ESP juegos entre el pinion y corona y despues destornillar
Apretar los tornillos (38) con el metodo cruzado y un por cerca 1/4 de giro.
par de torsion de 129v143 Nm.

Enduire les vis (38) avec du Loctite 242, puis visser Visser l'eÂcrou annulaire (32) du coÃte couronne jusqu'aÁ
F celles-ci aÁ fond. F annuler le jeux entre pignon et couronne, puis
Serrer les vis (38) avec la meÂthode croiseÂe aÁ un couple deÂvisser 1/4 de tour.
de serrage de 129v143 Nm.

008 913 76 BOMAG

63 773
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

T3

F1241187 F1241188

GB a GB b
Allow pinion to turn a few times in both directions to allow bearings Introduce a comparator with rotary key "C" through the rear cap
to set. Pre-load the bearings through the ring nut on crown opposite hole (43).
side to increase pinion torque up to a value of 140 ± 210 Ncm Position comparator on the centre of one of the crown teeth (4), pre-
checked by means of a torque meter. set it to 1 mm and reset it to zero.
CAUTION! If bearings are old, check static torque. If new, check Manually move the crown (4) in both directions to check the
continuous torque. existing clearance between pinion and crown.

RATIO - RAPPORTO CLEARANCE - GIOCO - SPIEL

VERHAÈ LTNIS JUEGO - JEU 32
RAPORTE - RAPPORT MIN. MAX.
T9
6v43 0,18 0,23
Difference between MIN and MAX clearance for whole circumference
should not exceed 0.09 mm.
La differenza tra gioco MIN e MAX rilevata sull'intera circonferenza
non deve superare il valore di 0,09 mm.
Der Unterschied zwischen dem MIN e MAX Spiel der gesamten
Kreislinie darf den Wert von 0,09 mm nicht uÈberschreiten.
La diferencia entre el juego Min y Max determinada sobre la entera
circonferencia no debe de superar el valor de 0,09 mm.
La diffeÂrence de jeu entre MIN et MAX releveÂe sur toute la
circonfeÂrence ne doit pas aller au-delaÁ de la valeur de 0,09 mm.
F1241183

GB c GB d
Mark the position of the ring nuts (32) in relation to the intermediate
covers.
Using wrench T9, adjust clearance between pinion and crown by
loosening one ring nut (32) and tightening the opposite proportion-
ally.
Normal clearance: see table.

36
34

33

F1241189 F1241190

GB e GB f
Install safety tabs (41) and lock them with screws (40). Using a driver, fit the cap (36) and position it in its seat with the
Screws tightening torque: 10 ± 11 Nm. snap ring (35).

774 BOMAG
64 008 913 76
Axle DANA 193 9.5

Far compiere al pignone alcuni giri nei due sensi per Posizionare, attraverso il foro per il tappo posteriore
ITA assestare i cuscinetti. Precaricare i cuscinetti tramite la ITA (43), un comparatore a tasto orientabile "C".
ghiera lato opposto corona, per incrementare la coppia di Posizionarlo sul centro di un dente della corona (4),
rotazione pignone fino a 140v210 Ncm controllati con un torsiometro. precaricarlo di circa 1 mm ed azzerarlo.
ATTENZIONE! Con cuscinetti usati, controllare la coppia di spunto; Muovere manualmente nei due sensi la corona (4) per controllare il
con cuscinetti nuovi, controllare la coppia di rotazione continua. gioco esistente tra pignone e corona.

Das Kegelrad um einige Umdrehungen in beide Richtungen Durch das Loch des hinteren Stopfens (43) eine
D drehen, um das Lager in die richtige Position zu bringen. Die D Meûuhr mit schwenkbarer Taste "C" einsetzen.
Lager durch die Nutmutter an der dem Kranz entgegengesetzte Seite Die Meûuhr auf die Mitte eines Zahnes des Kranzes (4)
vorbelasten, um das Gegenmoment des Kegelrads bis auf 140v210 Ncm positionieren und um 1mm vorbelasten; danach zuruÈckstellen.
a zu erhoÈhen. Den Wert mit einem Drehungsmesser kontrollieren.
ACHTUNG! Bei gebrauchten Lagern, das Anlaufdrehmoment kontrollieren; b Von Hand in beide Richtungen den Kranz (4) bewegen, um das
Spiel zwischen Kegelrad und Kranz zu kontrollieren.
bei neuen Lagern, das kontinuierliche Gegenmoment kontrollieren.

Hacer efectuar al pignon algunos giros en los dos sentidos Colocar, atraves el agujero para la tapa posterior (43),
ESP para ordenar los cojinetes. Precargar los cojinetes a ESP un comparador a tecla orientable "C".
traves de las virolas lado opuesto corona, para crecer el par de rotacion Colocarlo sobre el centro de un diente de la corona (4),
pignon hasta 140v210 Ncm controlados con un torsiometro. precargarlo de 1 mm aprox y azerarlo.
ATENCION! Con cojinetes usados, controlar el par de principio; con Mover manualmente en los dos sentidos la corona (4) para
cojinetes nuevos, controlar el par de rotacion continua. controlar el juego esistente entre pignon y corona.

Faire tourner le pignon plusieurs fois dans les deux sens Placer aÁ travers le trou servant au bouchon arrieÁre
F pour ajuster les paliers. PreÂcharger les paliers au moyen de F (43), un comparateur aÁ touche orientable "C".
l'eÂcrou annulaire, du coÃte oppose aÁ la couronne, pour augmenter le couple Positionner celui-ci au centre d'une des dents de la
de rotation du pignon jusqu'aÁ 140v210 Ncm controÃleÂs par un torsiomeÁtre. couronne (4), preÂcharger celui-ci d'environ 1 mm et mettre aÁ zeÂro.
ATTENTION! Avec des paliers usageÂs, controÃler le couple de pointe; avec DeÂplacer manuellement la couronne (4) dans les deux sens pour
des paliers neufs, controÃler le couple de rotation continu. controÃler le jeu existant entre pignon et couronne.

Contrassegnare la posizione delle ghiere (32) rispetto i

ITA ITA coperchi intermedi.
Con la chiave T9, regolare il gioco tra pignone e
corona allentando una ghiera (32) e serrando la ghiera opposta in
egual misura.
Gioco normale: vedere tabella.

Die Position der Nutmuttern (32) im VerhaÈltnis zu den

D D Zwischendeckeln markieren.
Mit dem SchluÈûel T9, das Spiel zwischen Rad und
Kranz einstellen, in dem eine Nutmutter (32) gelockert und die
c d entgegengesetzte festgezogen wird.
Normales Spiel: siehe Tabelle.

Contrasenalr la colocacion de las virolas (32) respecto

ESP ESP a las tapaderas intermedias.
Con la llave T9, regular el juego entre el pignon y la
corona aflojando una virola (32) y apretando la virola opuesta en la
misma mesura.
Juego normal: vease el prospecto.

Marquer la position de l'eÂcrou annulaire (32) par

F F rapport aux couvercles intermeÂdiaires.
A l'aide de la cle T9, reÂgler le jeu entre pignon et
couronne en deÂvissant l'eÂcrou annulaire (32) et en vissant l'eÂcrou
annulaire oppose de la meÃme mesure.
Jeu normal: voir tableau.

Montare le linguette di sicurezza (41) e fissarle con le Con uno spintore, montare il tappo (36) ed assicurarlo
ITA viti (40). ITA in sede con l'anello elastico (35).
Coppia di serraggio viti: 10v11 Nm

Den Sicherheitskeil (41) montieren und mit den Mit einem StoÈûel den Stopfen (36) montieren und in
D Schrauben (40) befestigen. D seinem Sitz mit dem Kolbenring (35) befestigen.
Anzugsmoment der Schrauben: 10v11 Nm

e f
Montar las lenguetas de seguridad (41) y fijarlas con Con un empujador, montar la tapa (36) y asegurarlo en
ESP los tornillos (40). ESP sed con el anillo elastico (36).
Par de serraje tornillos: 10v11 Nm

Monter les languettes de seÂcurite (41), fixer celles-ci aÁ A l'aide d'un poussoir, monter le bouchon (36), ajuster
F l'aide des vis (40). F celui-ci dans son logement avec l'anneau eÂlastique
Couple de serrage des vis: 10v11 Nm. (35).

008 913 76 BOMAG

65 775
9.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

37
36

40
F1241190 F1241192

GB a GB b
Using a driver and a plastic hammer, install the driving gear (39). Apply Loctite 510 to the surface of the reduction gear body (37) and
install the cover (40).
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.

41 44

40
46

47

42 43
F1241193 F1241194

GB c GB d
Lock the cover (40), using the snap washers (43) and the screws Install the breath union piece (44) with the relative sealing washers
(42) and (41) adequately tightened to a torque of 82 ± 91 Nm. (45) and plugs (47) and (46); tighten to a torque of 35 ± 50 Nm.
Tighten screws (42) and (41) with a tightening torque of 82 ± 91 Nm.

GB e GB f
Complete assembly of the axle by installing, in the following order,
brake cylinders and complete arms.
For details, see «ASSEMBLING THE BRAKING UNITS».

776 BOMAG
66 008 913 76
Axle DANA 193 9.5

Utilizzando uno spintore ed un mazzuolo in materiale Spalmare la superficie del corpo riduttore (37) con
ITA plastico, montare l'ingranaggio conduttore (39). ITA Loctite 510 ed installare il coperchio (40).
NOTA. Assicurarsi che il sigillante crei un velo
continuo attorno ai fori di fissaggio.

Mit einem StoÈûel und einem Gummihammer das Die FlaÈche des KoÈrpers des Reduzierers (37) mit
D Getriebe (39) montieren. D Loctite 510 schmieren und den Deckel (40) installie-
ren.
BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleich-
a b maÈûigen Film um die BefestigungsloÈcher herum bildet.

Utilizando un empujador y un martillo en material Pasar la superficie del cuerpo reductor (37) con Loctite
ESP plastico, montar el engranaje conductor (39). ESP 510 y instalar la tapa (40).
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor de los agujeros de fisaje.

A l'aide d'un poussoir et d'un maillet en matieÁre Enduire la superficie du corps reÂducteur (37) avec du
F plastique, monter l'engrenage conducteur (39). F Loctite 510, installer le couvercle (40).
REMARQUE. S'assurer que la couche de colle
entoure bien les trous de fixation.

Bloccare il coperchio (40) utilizzando le rondelle Montare il raccordo di sfiato (44) con le relative rosette
ITA elastiche (43) e le viti (42) e (41) serrate con una ITA di tenuta (45) ed i tappi (47) e (46); serrarli con una
coppia di 82v91 Nm. coppia di 35v50 Nm.

Den Deckel (40) mit den Federscheiben (42) und (41) Das abgezogene VerbindungsstuÈck (44) mit den
D und den Schrauben (42) und (41) bei einem Anzu- D Dichtscheiben (45) und den Stopfen (47) und (46)
gsmoment von 82v91 Nm blockieren. montieren; Anzugsmoment 35v50 Nm.

c d
Bloquear la tapa (40) utilizando las arandelas elasti- Montar el recorde de escape (441) con las relativas
ESP cas (43) y los tornillos (42) y (41) apretadas con un par ESP rosas de tenida (45) y las tapas (47) y (46); apretarlos
de 82v91 Nm. con un par de 35v50 Nm.

Bloquer le couvercle (40) aÁ l'aide des rondelles Monter le raccord d'eÂvent (44), les relatives rosettes
F eÂlastiques (43) et des vis (42) et (41) serreÂes aÁ un F d'eÂtancheÂite (45) et les bouchons (47) et (46), serrer
couple de 82v91 Nm. ceux-ci aÁ un couple de 35v50 Nm.

Completare l'assemblaggio dell'assale installando

ITA nell'ordine i cilindri freni ed i bracci completi. ITA
Per i dettagli, vedere «ASSEMBLAGGIO GRUPPI
FRENO».

Die Achse fertig zusammenbauen und der Reihe nach

D die Bremszylinder und die kompletten Arme installie- D
ren.
Siehe «ZUSAMMENBAU DER BREMSAGGREGATE».
e f
Completar el asemblaje del axial instalando en el
ESP orden los cilindros frenos y los ejes completos. ESP
Para los detalles, vease «ASEMBLAJE GRUPOS
FRENOS».

Achever l'assemblage de l'essieu en y installant dans

F l'ordre les cylindres freins et les bras complets. F
Pour de plus amples deÂtails voir "ASSEMBLAGE DU
GROUPE FREIN".

008 913 76 BOMAG

67 777
9.5 DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER
Axle DANA 193
UND KEGELRAD
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

1 7

6 5
F1241141 F1241195

GB a GB b
Remove the whole arms and the differential unit. Loosen and remove screws (1) and (2) and the washers (3) locking
For details, see «CHECKING WEAR AND REPLACING THE the cover (4), the plugs (5) and (6) for oil fill and oil drain, and the
BRAKING DISKS» and «REMOVAL OF DIFFERENTIAL UNIT». bleed union piece (7).
NOTE. Leave two screws (2) in position for safety.

4
13 A

11

4 12
F1241196 F1241197

GB c GB d
Using a plastic hammer, remove the cover (4) and move it away. Place a block of tender material (aluminium, etc.) between the
NOTE. If operations on the differential unit need to be performed, reduction body (11) and the gear (12) of the pinion.
remove the complete reduction gear unit (screws (9) and (10)). Loosen and remove the pinion locking nut (13).

14
12

15

14
F1241198 F1241199

GB e GB f
Remove the gear of the pinion (12) and the driving gear (14) Take the driving gear to pieces (14), extracting the bearing (15).
complete with bearing (15). NOTE. If necessary, use an extractor.
NOTE. To remove the gear (14), use a lever.

778 BOMAG
68 008 913 76
Axle DANA 193 9.5

Rimuovere i bracci completi ed il differenziale. Allentare ed asportare le viti (1) e (2) e le rondelle (3) di
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA ritegno coperchio (4), i tappi (5) e (6) di carico e scarico
SOSTITUZIONE DISCHI FRENO» e «RIMOZIONE olio ed il raccordo di sfiato (7).
GRUPPO DIFFERENZIALE». NOTA. Lasciare in posizione per sicurezza due viti (2) contrappo-
ste.

Die kompletten Arme und das Differential abnehmen. Schrauben (1) und (2) abschrauben und die Unter-
D Siehe «VERSCHLEISS KONTROLLIEREN UND D legscheiben (3) zur Halterung des Deckels (4), die
BREMSSCHEIBEN AUSWECHSELN» und «DIFFE- OÈ leinfuÈll- und Ablaûstopfen (5) und (6) sowie das
RENTIALAGGREGAT ABNEHMEN». EndluÈftungsstuÈck (7) abnehmen.
a b BEMERKUNG. Die entgegengesetzten Schrauben (2) zur Sicher-
heit zuruÈck lassen.

Remover los ejes completos y el duferencial. Aflojar y sacar los tornillos (1) y (2) y las arandelas (3)
ESP Para los detalles, vease «CONTROL DESGASTE Y ESP de retencion tapa (4), los tapones (5) y (6) de carga y
SOBSTITUCION DISCOS FRENOS» y «REMOCION descarga aceite y el recorde de escape (7).
GRUPO DIFERENCIAL». NOTA. Dejar en posicion de seguridad dos tornillos (2) contra-
puestas.

Enlever les bras complets et le diffeÂrentiel. Desserrer et enlever les vis (1) et (2), les rondelles (3)
F Pour de plus amples deÂtails, voir "CONTROLE F de fixation du couvercle (4), les bouchons (5) et (6) de
USURE ET SUBSTITUTION DES DISQUES FREIN" remplissage et vidange d'huile et le raccord d'eÂvent (7).
et "DEPOSE DU GROUPE DIFFERENTIEL". REMARQUE. Pour plus de suÃreteÂ, garder deux vis (2) super-
poseÂes.

Utilizzando un mazzuolo in materiale plastico, rimuo- Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)
ITA vere il coperchio (4) ed asportarlo. ITA del pignone un blocchetto "A" di materiale tenero
NOTA. Se si deve intervenire sul gruppo differenziale, (alluminio, ecc.).
rimuovere il gruppo riduttore completo (viti (9) e (10)). Allentare ed asportare il dado (13) di ritegno pignone.

Mit einem Gummihammer den Deckel (4) ausrasten Zwischen dem ReduziererkoÈrper (11) und dem Getrie-
D und abnehmen. D be (12) des Kegelrads einen Block aus weichen
BEMERKUNG. Soll am Differentialaggregat gearbeitet Material einsetzen (Aluminium usw.)
werden, das komplette Reduzieraggregat abnehmen (Schrauben Mutter (13) zur Halterung des Kegelrads abschrauben.
c (9) und (10)). d
Utilizando un martillo en material plastico, remover la Colocar entre el cuerpo reductor (11) y el engranaje
ESP tapa (4) y sacarla. ESP (12) del pinon un bloquete "A" de material tierno
NOTA. Si se debe intervenir sobre el grupo diferen- (aluminio, ect.).
cial, remover el grupo reductor completo (tornillos (9) y (10)). Aflojar y sacar la tuerca (13) de retencion pinon.

A l'aide d'un maillet en matieÁre plastique, deÂplacer le Ajuster, entre le corps reÂducteur (11) et l'engrenage
F couvercle (4) et puis l'enlever. F (12) du pignon, un petit bloc "A" en mateÂriel leÂger
REMARQUE. S'il faut intervenir sur le groupe diffeÂ- (aluminium etc.).
rentiel, enlever le groupe reÂducteur complet (vis (9) et (10)). Desserrer et enlever l'eÂcrou (13) de fixation pignon.

Rimuovere l'ingranaggio del pignone (12) e l'ingra- Scomporre l'ingranaggio conduttore (14) estraendo il
ITA naggio conduttore (14) completo di cuscinetto (15). ITA cuscinetto (15).
NOTA. Per rimuovere l'ingranaggio (14), utilizzare una NOTA. Se necessario, usare un estrattore.
leva.

Das Getriebe (12) des Kegelrads und das Getriebe Das Getriebe (14) zerlegen; dazu das Lager (15)
D (14) samt Lager (15) entfernen. D abziehen.
BEMERKUNG. Um das Getriebe (14) abnehmen zu BEMERKUNG. Wenn noÈtig, einen Abzieher verwen-
koÈnnen, einen Hebel verwenden. den.
e f
Remover el engranaje del pinon (12) y el engranaje Descomponer el engranaje conductor (14) sacando el
ESP conductor (14) completo de cojinete (15). ESP cojinete (15).
NOTA. Para remover el engranaje (14), utilizar una NOTA. Si necesario, usar un extractor.
palanca.

DeÂplacer l'engrenage du pignon (12) et l'engrenage DeÂcomposer l'engrenage conducteur (14) en deÂga-
F conducteur (14) complet de palier (15). F geant le palier (15).
REMARQUE. Pour deÂplacer l'engrenage (14), utiliser REMARQUE. Si besoin, utiliser un extracteur.
un levier.

008 913 76 BOMAG

69 779
9.5 DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER
Axle DANA 193
UND KEGELRAD
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

11

10
F1241200 F1241201

GB a GB b
Loosen all screws (9) and (10) and remove the upper check screws Connect the whole reduction gear body (11) to a hoist and remove
(9) of the reduction gear body. the screws (10) previously left in place for safety.
NOTE. Leave the two lower screws (10) in position for safety. Using a plastic hammer, pull away the whole reduction gear body
(11).

11 16
17
17
19

16 20

17
F1241202 F1241203

GB c GB d
Position the reduction gear body (11) under a press and, using a Remove distance piece (20) and shims (19) from the pinion(16).
driver, extract the pinion (16) complete with internal bearing (17), Position the pinion under a press and remove the internal bearing
shims (19) and distance piece (20). (17).

21
22 17

11 F1241204

GB e GB f
With the help of an extractor, remove the thrust blocks (17) and (21)
of the bearings, and the snap ring (22).
NOTE. Note down direction of assembly of snap ring (22).

780 BOMAG
70 008 913 76
Axle DANA 193 9.5

Allentare tutte le viti (9) e (10) ed asportare le viti (9) Collegare il corpo riduttore completo (11) ad un mezzo
ITA superiori di ritegno del corpo riduttore. ITA di sollevamento ed asportare le viti (10) lasciate in
NOTA. Lasciare in sede le due viti (10) inferiori per sede per sicurezza.
sicurezza. Utilizzando un mazzuolo in materiale plastico, rimuovere il corpo
riduttore (11) completo.

Alle Schrauben (9) und (10) lockern und die oberen Den kompletten ReduziererkoÈrper (11) an ein Hebe-
D Schrauben (9) zur Halterung des ReduziererkoÈrpers D zeug befestigen und die zuvor zur Sicherheit zuruÈck-
abnehmen. gelassenen Schrauben (10) abschrauben.
BEMERKUNG. Die beiden unteren Schrauben (10) zur Sicherheit Mit einem Gummihammer, den kompletten ReduziererkoÈrper (11)
a zuruÈck lassen. b abnehmen.

Aflojar todos los tornillos (9) y (10) y sacar los tornillos Conectar el cuerpo reductor completo (11) a un medio
ESP (9) superiores de retencion del cuerpo reductor. ESP de elevacion y sacar los tornillos (10) dejadas en su
NOTA. Dejar en su lugar los dos tornillos (10) lugar para seguridad.
inferiores para seguridad. Utilizando un martillo en material plastico, remover el cuerpo
reductor (11) completo.

Desserrer toutes les vis (9) et (10), enlever les vis Brancher le corps reÂducteur complet (11) aÁ un moyen
F supeÂrieures (9) de fixation du corps reÂducteur. F de relevage, puis enlever les vis laisseÂe (10) dans leur
REMARQUE. Garder les deux vis infeÂrieures (10) dans sieÁge pour plus de seÂcuriteÂ.
leur sieÁge pour plus de seÂcuriteÂ. A l'aide d'un maillet en matieÁre plastique, enlever le corps
reÂducteur (11) complet.

Posizionare il corpo riduttore (11) sotto una pressa e, Rimuovere dal pignone (16) il distanziale (20) e gli
ITA utilizzando uno spintore, estrarre il pignone (16) ITA spessori (19).
completo di cuscinetto interno (17), spessori (19) ed Posizionare il pignone sotto una pressa e rimuovere il
il distanziale (20). cuscinetto interno (17).

Den ReduziererkoÈrper (11) unter eine Presse legen Vom Kegelrad (16) das DistanzstuÈck (20) und die
D und mit einem StoÈûel das Kegelrad (16) samt dem D Unterlegscheiben (19) abnehmen.
inneren Lager (17), den Unterlegscheiben (19) und Das Kegelrad unter eine Presse legen und das innere
dem DistanzstuÈck (20) abziehen. Lager (17) abnehmen.
c d
Colocar el cuerpo reductor (11) debajo de una prensa Remover del pinon (16) el distancial (20) y los
ESP y, utilizando un empujador (16) completo de cojinete ESP espesores (19).
interno (17), espesores (19) y el distancial (20). Colocar el pinon bajo una prensa y remover el cojinete
interno (17).

Placer le corps reÂducteur (11) sous une presse, aÁ Enlever du pignon (16) l'entretoise (20) et les cales
F l'aide d'un poussoir extraire le pignon (16) complet de F (19).
palier interne (17), cales (19) et entretoise (20). Placer le pignon sous une presse et enlever le palier
interne (17).

Con un estrattore, rimuovere dal corpo riduttore (11) le

ITA ralle dei cuscinetti (17) e (21) e l'anello di tenuta (22). ITA
NOTA. Annotare il senso di montaggio dell'anello di
tenuta (22).

Mit einem Abzieher vom ReduziererkoÈrper (11) die

D Scheiben der Lager (17) und (21) und den Dichtring D
(22) entfernen.
BEMERKUNG. Montagerichtung des Dichtringes (22) notieren.
e f
Con un extractor, remover del cuerpo reductor (11) las
ESP ranguas de los cojinetes (17) y (21) y el anillo de ESP
retencion (22).
NOTA. Anotar el sentido de desmontaje del anillo de retencion
(22).

A l'aide d'un extracteur, enlever le corps reÂducteur

F (11), les crapaudines des paliers (17) et (21) et F
l'anneau d'eÂtancheÂite (22).
REMARQUE. Prendre note du sens de montage de l'anneau
d'eÂtancheÂite (22).

008 913 76 BOMAG

71 781
9.5 DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER
Axle DANA 193
UND KEGELRAD
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

23

16
17
18
19
20

GB a GB b
7

11
9

8 15
14

4
1
13

22 5
21 12
6
GB c GB d
10 2

3
D1240136

GB e GB f

782 BOMAG
72 008 913 76
Axle DANA 193 9.5

CAUTION! 1 - If disassembly has only been carried ATENCION! 1 - Si el desmontaje ha sido efectuado
GB out to replace the snap ring (22), position the new ring ESP solo para la sobstitucion del anillo de retencion (22),
and reassemble the unit, respecting the tightening proceder al alojamiento del nuevo anillo y remontar el
torques specified in the following section and using the specified grupo respectando los pares de serraje indicadas en el paragrafo
locking and sealing products. siguiente y utilizando los productos de bloqueo y tenida prescritos.
2 - If disassembly is performed to replace either crown wheel and 2 - Si el desmontaje viene efectuado para la sobstitucion del par
pinion, bearings, or planetary gears, take the unit to pieces and find conico, de los cojinetes o de los engranajes satelites, proceder a la
shims and clearances as specified in the sections relative to the descomposicion y a la busqueda de los espesores y de los juegos
removal, disassembly, assembly and installation of the differential como indicados en los paragrafos concernientes la remocion, el
unit and bevel pinion. desmontaje, el asemblaje y la instalacion del diferencial y del pinon
conico.

ATTENZIONE! 1 - Se lo smontaggio eÁ stato eseguito ATTENTION! 1 - Si le deÂmontage n'est effectue que

ITA solo per la sostituzione dell'anello di tenuta (22), F pour substituer l'anneau d'eÂtancheÂite (22), positionner
procedere al posizionamento del nuovo anello e le nouvel anneau et remonter le groupe en respectant
rimontare il gruppo rispettando le coppie di serraggio indicate nel les couples de serrage indiqueÂs dans le paragraphe suivant aÁ l'aide
paragrafo seguente ed utilizzando i prodotti di bloccaggio e tenuta des produits de blocage et d'eÂtancheÂite prescrits.
prescritti. 2 - Si le montage est effectue pour substituer le couple conique des
2 - Se lo smontaggio viene eseguito per la sostituzione della coppia paliers et des engrenages satellites, passer aÁ la deÂcomposition et aÁ
conica, dei cuscinetti o degli ingranaggi satelliti, procedere alla la recherche des cales et des jeux comme indique dans les
scomposizione ed alla ricerca degli spessori e dei giochi come paragraphes concernant la deÂpose, le deÂmontage, l'assemblage et
indicato nei paragrafi riguardanti la rimozione, lo smontaggio, l'installation du diffeÂrentiel et du pignon conique.
l'assemblaggio e l'installazione del differenziale e del pignone
conico.

ACHTUNG! 1 - Falls das Teil zum Auswechseln des

D Dichtringes (22) zerlegt wurde, den neuen Ring
einsetzen und das Aggregat wieder montieren; dabei
die Anzugsmomente einhalten, die im nachstehenden Kapitel
angegeben sind und die vorgeschriebenen Materialien zur Blok-
kierung und Abdichtung verwenden.
2 - Falls das Zerlegen zum Auswechseln des Kegelradpaars, der
Lager oder der Planetengetriebe vorgenommen wird, den An-
weisungen der Paragraphen zum Zerlegen, Abmontieren und
Zusammenbauen sowie zur Installation des Differentials und des
Kegelrads folgen und die StaÈrken und Spiele einhalten.

008 913 76 BOMAG

73 783
9.5 Axle DANA 193
INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UND
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

MEASURE (42.35)
MISURA (42,35)
MAß (42,35) St
MESURA (42,35)
MESURE (42,35) B

MARK
CONTRASSEGNO
C C
B KENNZEICHEN
CONTRASENALACION
11
MARQUAGE

17
F1241205 F1241206

GB a GB b
Mark the thrust block and the internal bearing (17) on a faceplate, Lay two 20 mm gauged blocks "C" on the face of the reduction gear
allow the bearing to set by rotating them in both directions and by body (11). With depth gauge "B" (set to zero at the previous point),
applying a vertical thrust. With a centesimal, digital depth gauge measure space between the "C" blocks and the striking surface of
"B", check overall thickness of bearing (e.g.: 42.35 mm) and set the internal bearing (17). The size obtained (e.g.: 0.81 mm) is the
gauge to zero again. theoretical shim "St" (18) to be inserted under the thrust block of
bearing (17).

DIFFERENTIAL AXIS
ASSE DIFFERENZIALE
DIFFERENTIALACHSE
EJE DEFERENCIAL S
ESSIEU DIFFERENTIEL

Y
X
+ --
DEVIATION "X"
SCOSTAMENTI "X"
ABWEICHUNG "X" S = St + (± X)
DESPLAZAMIENTOS "X"
ECARTS "X"
D1240137
F1241225

GB c GB d
On the bar-hold of pinion (16), check the value "X" (in brackets) To calculate final thickness "S", add the negative value of "X" to
relative to the deviation from the theoretical centre distance. "St" or, alternatively, subtract the positive value of "X".
NOTE. "Y" is the number of pinion/crown coupling. For ex.: Deviation X=(±0.13 mm): S=St+X=0.81+0.13=0.94 mm
Deviation X=(+0.12 mm): S=St ± X=0.81 ± 0.12=0.69 mm
CAUTION! Round off to as close to 0.05 mm as possible.

22

T10
21

22

F1241227 F1241207

GB e GB f
Using a driver, mount the sealing ring (22) in the reduction unit (11). Place the reduction gear body (11) under a press and, using tool
NOTES. 1 - Carefully check the direction of assembly. T10, insert the thrust block of external bearing (21).
2 - Lubricate the outer surface of the sealing ring. CAUTION! Insert the thrust block of the bearing that is not
countermarked.

784 BOMAG
74 008 913 76
Axle DANA 193 9.5

Contrassegnare la ralla ed il cuscinetto (17) interno su Appoggiare sul piano di appoggio del corpo riduttore
ITA un piano di riscontro, assestare il cuscinetto con delle ITA (11) due blocchetti calibrati da 20 mm "C". Con il
rotazioni parziali nei due sensi ed esercitando una calibro di profonditaÁ "B" (azzerato nella fase precedente), rilevare la
spinta verticale. Con un calibro di profonditaÁ digitale centesimale misura tra i blocchetti "C" ed il piano di battuta del cuscinetto
"B", rilevare lo spessore totale del cuscinetto (es 42,35 mm) ed interno (17). La misura risultante (es. 0,81 mm) eÁ lo spessore "St"
azzerare il calibro. (18) teorico da inserire sotto la ralla del cuscinetto (17).

Die Scheibe und das innere Lager (17) an einer Auf eine AuflageflaÈche des ReduziererkoÈrpers (11) zwei
D BezugsflaÈche markieren, das Lager durch hin und her D kalibrierte BloÈcke zu 20 mm "C" legen. Mit einer Tiefen-
Drehen und einem senkrechten Druck richtig ein- lehre "B" (zuvor zuruÈckgestellt) das Maû zwischen den BloÈcken "C" und
setzen. Mit einer digitalen hundertteiligen Tiefenlehre "B" die der AnschlagflaÈche des inneren Lagers (17) messen. Das ermittelte Maû
a GesamtstaÈrke des Lagers messen (z.B. 42,35 mm) und die Lehre
zuruÈckstellen.
b (z.B. 0,81 mm) entspricht der theoretischen Unterlegscheibe "St" (18),
die unter die Scheibe des Lagers (17) gelegt werden muû.

Senalar la rangua t el cojinete (17) interno sobre una Colocar sobre la superficie de apoyo del cuerpo reductor
ESP superficie de rescontre, ordenar el cojinete con unas ESP (11) dos bloques calibrados de 20 mm "C". Con el calibre
rotaciones parciales en los dos sentidos y ejercitando de profundidad "B" (azerando en la fase precediente),
un empuje vertical. Con un calibre de profundidad digital centesimal relevar la mesura entre los bloquetes "C" y la superficie del tope del
"B", relevar el espesor total del cojinete (es.:42,35 mm) y azerar el cojinete interno (17). La mesura resultante (es.: 0,81 mm) es el
calibre. espesor "St" (18) teorico de introducir bajo la rangua del cojinete (17).

Estampiller la crapaudine et le palier (17) interne sur DeÂposer sur un plan d'appui du corps reÂducteur (11),
F un marbre de controÃle, ajuster les paliers par des F deux petits blocs calibreÂs aÁ 20 mm "C". A l'aide du
rotations partielles dans les deux sens tout en calibre de profondeur "B" (mis aÁ zeÂro preÂceÂdemment),
poussant verticalement. A l'aide d'un calibre de profondeur relever la mesure existante entre les petits blocs "C" et le plan de
numeÂrique centeÂsimal "B", relever le calage total des paliers (ex. buteÂe du palier interne (17). La mesure reÂsultante (ex. 0,81 mm) est
42,35 mm), mettre le calibre aÁ zeÂro. le calage "St" (18) aÁ introduire sous la crapaudine du palier (17).

Controllare sul codolo del pignone (16) il valore "X" Per calcolare lo spessore "S" definitivo, aggiungere a
ITA (racchiuso tra parentesi) dello scostamento rispetto ITA "St", il valore "X" negativo oppure sottrarre il valore
l'interasse teorico. "X" positivo.
NOTA. Il numero "Y" eÁ il numero di accoppiamento pignone- Es.: Scostamento X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
corona. Scostamento X=(+0,12 mm): S=St ± X=0,81 ± 0,12=0,69 mm
ATTENZIONE! Arrotondare al valore piuÁ prossimo dei 0,05 mm.

Den Wert "X" der Gleitung am Kegelradschaft (16) (in Um die endguÈltige StaÈrke "S" auszurechnen, "St" und
D Klammern angegeben) im VerhaÈltnis zum theoreti- D "X" addieren, wenn "X" neÂgatif ist oder "X" von "St"
schen Achsenabstand kontrollieren. abziehen, falls "X" postif ist.
BEMERKUNG. Die Zahl "Y" entspricht dem Kegelrad-Kranz- Beispiel: Abweichung X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
c Kopplungsgrad. d Abweichung X=(+0,12 mm): S=St ± X ± 0,81 ± 0,12=0,69 mm
ACHTUNG! Auf einen Wert abrunden, der 0,05 mm am naÈchsten liegt.

Controlar sobre al espigon del pinon (16) el valor "X" Para calcolar el espesor "S" definitivo, adicionar a
ESP (serrado entre parantesis) del desplazamiento respec- ESP "St", el valor "X" negativo o detraer el valor "X"
to al intereje teorico. positivo.
NOTA. El numero "Y" y el numero de acoplamiento pinon-corona. Es.: Desplazamiento X=(± 0,13mm): S=St+X=0,81+0,13=0,94 mm
Desplazamiento X=(0,12mm): S=St ± X=0,81 ± 0,12=0.69 mm
ATENCION! Acercar al valor mas cerca de 0,05 mm.

ControÃler sur la queue du pignon (16) la valeur "X" Pour calculer l'eÂpaisseur "S" deÂfinitif, additionner aÁ
F (entre parentheÁses) de l'eÂcart par rapport aÁ l'entraxe F "St" la valeur "X" neÂgative ou soustraire la valeur "X"
theÂorique. positive.
REMARQUE. Le numeÂro "Y" est le numeÂro de l'accouplement Ex. Ecart X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
pignon-couronne. Ecart X=(+0,12 mm): S=St ± X ± 0,81 ± 0,12=0,69 mm
ATTENTION! Arrondir aÁ la valeur plus proche aÁ 0,05 mm.

Utilizzando uno spintore, montare nel corpo riduttore Sistemare il corpo riduttore (11) sotto una pressa e,
ITA (11) l'anello di tenuta (22). ITA utilizzando l'attrezzo T10 inserire la ralla del cusci-
NOTE. 1 - Controllare attentamente il senso di netto esterno (21).
montaggio. ATTENZIONE! Inserire la ralla del cuscinetto non contrassegnato.
2 - Lubrificare la superficie esterna dell'anello di tenuta.

Mit einem StoÈûel den Dichtring (22) in den Reduzierer- Den ReduziererkoÈrper (11) unter eine Presse legen
D koÈrper (11). D und mit dem Werkzeug T10 die Scheibe des aÈuûeren
BEMERKUNG. 1 - SorgfaÈltig die Montagerichtung des Lagers (21) einsetzen.
Dichtrings kontrollieren. ACHTUNG! Die Scheibe des nicht gekennzeichneten Lagers
e 2 - AÈuûere FlaÈche des Dichtrings schmieren. f einsetzen.

Utilizando un espesor, montar en el cuerpo reductor Colocar el cuerpo reductor (11) debajo de una prenso
ESP (11) el anillo de retencion (22). ESP y, utilizando la herramienta T10 insertar la rangua del
NOTA. 1 - Controlar atentamente el sentido de cojinete esterno (21).
montaje. ATENCION! Introducir la rangua del cojinete no segnalado.
2 - Lubrificar la superficie exterior del anillo de retencion.

A l'aide d'un poussoir, monter dans le corps reÂducteur Ajuster le corps reÂducteur (11) sous la presse, aÁ l'aide
F (11) l'anneau d'eÂtancheÂite (22). F de l'outil T10 introduire la crapaudine du palier
NOTE. 1 - Controà ler attentivement le sens de externe (21).
montage. ATTENTION! Introduire la crapaudine du palier non estampilleÂe.
2 - Lubrifier la surface externe de l'anneau d'eÂtancheÂiteÂ.

008 913 76 BOMAG

75 785
9.5 Axle DANA 193
INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UND
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

17 T11

18
21
20
17

F1241208 F1241209

GB a GB b
Turn the reduction gear body (11) upside down and insert shim "S"; Fit tool T12 onto tool T11. Then, install bearings (17) and (21) so
then, with tool T10, insert the thrust block of the internal bearing that they are opposed to each other and spaced by the distance
(17). piece (20).
CAUTION! Insert the thrust block of the countermarked bearing. Position the depth comparator in one of the four radial holes; pre-
set the comparator to 3 ± 4 mm, then set it to zero.

T11
21

17

T11
F1241210 F1241211

GB c GB d
Remove the bearings from tool T11 and fit them in the thrust blocks Install tool T11 and tighten it manually to obtain a safe rolling
of the reduction gear body. torque.
CAUTION! Check that the countermarked bearing is fitted in the NOTE. During tightening, perform a few rotations to set the
centring hub of the body of the reduction gear and in the bearings.
countermarked thrust block too.

H + 0,13 ÷ 0,15 = S1
19 S1

F1241212 F1241221

GB e GB f
Introduce the previously reset comparator, in one of the four radial The deviation found is to be added to a fixed value of 0.13(0.15
holes and measure. The deviation from zero indicates the nominal mm. in order to: obtain shim "S1" (to be inserted between internal
value "H" relative to the shims that are to be inserted. bearing (17) and distance piece (20)) and, hence, produce the
specified pre-load of bearings.
CAUTION! Perform accurate measurements - a variation of 0.001 mm
causes a variation in the torque by 20 ± 40 Nm
786 BOMAG
76 008 913 76
Axle DANA 193 9.5

Capovolgere il corpo riduttore (11) ed inserire lo Montare sull'attrezzo T11 l'attrezzo T12. Quindi mon-
ITA spessore "S" e con l'attrezzo T10 la ralla del ITA tare i cuscinetti (17) e (21) contrapposti ed intervallati
cuscinetto interno (17). con il distanziale (20).
ATTENZIONE! Inserire la ralla del cuscinetto contrassegnato. Posizionare un comparatore di profonditaÁ in uno dei quattro fori
radiali; precaricare il comparatore di 3v4 mm ed azzerarlo.

Den RedurziererkoÈrper (11) wenden und die Unter- Auf das Werkzeug T11 das Werkzeug T12 montieren.
D legscheibe "S" einsetzen; mit dem Werkzeug T10 die D Dann die entgegengesetzten Lager (17) und (21)
Scheibe des inneren Lagers (17) einsetzen. montieren und dazwischen das DistanzstuÈck (20)
ACHTUNG! Die Scheibe des gekennzeichneten Lagers einsetzen. legen.
a b Eine Meûuhr in eines der vier RadialloÈcher positionieren; die
Meûuhr auf 3v4 mm vorbelasten und dann zuruÈckstellen.

Volcar el cuerpo reductor (11) y introducir el espesor Montar sobre la herramienta T11 la herramienta T12.
ESP "S" y con la herramienta T10 la rangua del cojinete ESP Entonces colocar los cojinetes (17) y (12) contra-
interno (17). puestos y intervalados con el distancial (20).
ATENCION! Introducir la rangua del cojinete segnalado. Colocar un comparador de profundidad en uno de los cuatro
agujeros radiales, precargar el comparador de 3-4 mm y acerarlo.

Faire basculer le corps reÂducteur (11), introduire la Monter sur l'outil T11, l'outil T12. Ensuite monter les
F cale "S", et aÁ l'aide de l'outil T10 la crapaudine du F paliers (17) et (21) en les superposant et intercalant
palier interne (17). avec l'entretoise (20).
ATTENTION! Introduire la crapaudine du palier estampilleÂ. Placer un comparateur de profondeur dans l'un des quatre trous
radiaux; preÂcharger le comparateur aÁ 3v4 mm, puis le mettre aÁ
zeÂro.

Rimuovere i cuscinetti dall'attrezzo T11 e montarli Montare l'attrezzo T11 e serrarlo manualmente fino ad
ITA nelle ralle del corpo riduttore. ITA avere una sicura coppia di rotolamento.
ATTENZIONE! Controllare che il cuscinetto contras- NOTA. Durante il serraggio, eseguire alcune rotazioni
segnato sia montato nel mozzo di centratura del corpo riduttore e per assestare i cuscinetti.
quindi nella ralla contrassegnata.

Die Lager vom Werkzeug T11 abnehmen und in den Das Werkzeug T11 montieren und von Hand fest-
D Scheiben des ReduziererkoÈrpers montieren. D ziehen bis ein sicheres Gegenmoment erreicht ist.
ACHTUNG! Kontrollieren, ob das markierte Lager in BEMERKUNG. Beim Festziehen einige Umdrehungen
den Zentriernaben des ReduziererkoÈrpers und folglich in der vornehmen, um die Lager richtig in ihren Sitz zu bringen.
c markierten Scheibe montiert ist. d
Remover los cojinetes de la herramienta T11 y Montar la herramienta T11 y apretarla manualmente
ESP montarlos en las ranguas del cuerpo reductor. ESP hasta obtener una segura pareja de rotacion.
ATENCION! Controlar que el cojinete segnalado sea NOTA. Durante la torsion, efectuar algunas rotaciones
colocado en el cubo central del cuerpo reductor y por lo tanto en la para ordenar los cojinetes.
rangua segnalada.

Oter les paliers de l'outil T11, puis monter ces Monter l'outil T11 et serrer celui-ci aÁ la main jusqu'aÁ
F derniers dans les crapaudines du corps reÂducteur. F obtenir un couple de roulement assureÂ.
ATTENTION! ControÃler que le palier estampille soit REMARQUE. En serrant, effectuer quelques tours de
monte dans le moyeu de centrage du corps reÂducteur, donc, dans rotation pour ajuster les paliers.
la crapaudine estampilleÂe.

Introdurre in uno dei fori radiali il comparatore Lo scostamento rilevato eÁ da sommare ad una misura
ITA azzerato precedentemente ed eseguire la lettura. ITA fissa di 0,13v0,15 mm, per ottenere lo spessore "S1"
Lo scostamento rispetto lo zero, indica il valore (19) da inserire tra cuscinetto interno (17) e distanziale (20) e
nominale "H" degli spessori da inserire. quindi, determinare il precarico stabilito per i cuscinetti.
ATTENZIONE! Curare le misurazioni in quanto la variazione di
0,01 mm fa variare la coppia di rotazione di 20v40 Ncm.

In eines der RadialloÈcher die zuvor zuruÈckgestellte Die ermittelte Abweichung muû mit einem Festmaû von 0,3 (0,15
D Meûuhr einsetzen und das Maû ablesen. D mm zusammengerechnet werden, um die Unterlegscheibe "S1"
Die Abweichung im VerhaÈltnis zur Null, gibt den (19) zu ermitteln, die zwischen dem inneren Lager (17) und das DistanzstuÈck (20)
Nennwert "H" der einzulegenden Unterlegscheiben an. gelegt werden muû und um die Vorbelastung der Lager festlegen zu koÈnnen.
e f ACHTUNG! Die Messungen sehr sorgfaÈltig vornehmen, da ein Unter-
schied von 0,01 mm das Gegenmoment um 20v40 Ncm veraÈndert.

Introducir en uno de los agujeros radiales el compa- El desplazamiento relevado es de sumarse a una
ESP rador acerado precedentemente y efectuar la lectura. ESP mesura fija de 0,13-0,15 mm, para obtener el espesor
El desplazamiento respecto a lo cero, indica el valor "S1" (19) de introducir entre cojinete interno (17) y distancial (20) y
nominal "H" de los espesores de introducir. entonces, determinar el precario establecido para los cojinetes.
ATENCION! Poner atencion a las mesuraciones porque la variacion
de 0,01 mm hace cambiar de ratacion de 20v40Ncm.

Introduire dans l'un des trous radiaux le comparateur L'eÂcart releve est aÁ additionner aÁ la mesure fixe 0,13v0,15 mm
F mis aÁ zeÂro preÂceÂdemment et en faire la lecture. F pour obtenir la cale "S1" (19) aÁ introduire entre le palier interne
L'eÂcart par rapport au zeÂro, indique la valeur nominale (17) et l'entretoise (20) et deÂfinir la preÂcharge eÂtablie pour les paliers.
"H" des cales aÁ introduire. ATTENTION! Effectuer soigneusement les mesurages parce qu'une diffeÂ-
rence de 0,01 mm ameÁne une variation du couple de rotation de 20v40 Ncm.

008 913 76 BOMAG

77 787
9.5 Axle DANA 193
INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UND
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

16
16 11

17

F1241213 F1241214

GB a GB b
With the help of the press, install the internal, countermarked Fit the pinion (16), the shims (19), the distance piece (20) and the
bearing (17) onto the pinion (16). external bearing (21) into the body of the reduction gear (11) and
CAUTION! Lubricate pinion with oil. assemble the unit with a press.
CAUTION! Lubricate pinion with oil.

23
11
15
12
13

F1241215 F1241216

GB c GB d
Fit the reduction gear (11) into the main body (23) without Fit the gear (12) of the pinion; coat the nut (13) with Loctite 242 and
differential unit; lock temporarily with the two lower screws (9). hand-screw it.
Fit the bearing (15) of the motion in gear and lock it.

12
11

F1241217

GB e GB f
Between the body of the reduction gear (11) and the gear (12) of the
pinion, place block "A" used for disassembling, and tighten the nut
(13) to a minimum required tightening torque of 500 Nm, using a
box wrench and a dynamometric wrench.

788 BOMAG
78 008 913 76
Axle DANA 193 9.5

Con la pressa, montare il cuscinetto interno e Montare nel corpo riduttore (11) il pignone (16), gli
ITA contrassegnato (17) sul pignone (16). ITA spessori (19), il distanziale (20) ed il cuscinetto esterno
ATTENZIONE! Lubrificare il pignone con olio. (21) ed assemblare il gruppo con la pressa.
ATTENZIONE! Lubrificare il pignone con olio.

Mit einer Presse, das innere und markierte Lager (17) In den ReduziererkoÈrper (11) das Kegelrad (16), die
D auf das Kegelrad (16) montieren. D Unterlegscheiben (19), das DistanzstuÈck (20) und das
ACHTUNG! Rad mit O È l schmieren. aÈuûere Lager (21) montieren und das Aggregat mit der
Presse zusammenbauen.
a b ACHTUNG! Rad mit O È l schmieren.

Con la prensa, montar el cojinete interno y segnalado Montar en el cuerpo reductor (11) el pinon (16) los
ESP (17) sobre el pinon (16). ESP espesores (19), el distancial (20) y el cojinete esterno
ATENCION! Lubrificar el pinon con aceite. (21) y asemblar el grupo con la prensa.
ATENCION! Lubrificar el pinon con aceite.

A l'aide de la presse, monter le palier interne Monter dans le corps reÂducteur (11), le pignon (16), les
F estampille (17) sur le pignon (16). F cales (19), l'entretoise (20) et le palier externe (21),
ATTENTION! Lubrifier le pignon avec de l'huile. assembler le groupe aÁ l'aide de la presse.
ATTENTION! Lubrifier le pignon avec de l'huile.

Montare il corpo riduttore (11) sul corpo centrale (23) Montare l'ingranaggio (12) del pignone; spalmare il
ITA privo di differenziale e fissarlo provvisoriamente con le ITA dado (13) con Loctite 242 ed avvitarlo manualmente.
due viti inferiori (9).
Montare il cuscinetto (15) dell'ingranaggio di entrata del moto e
mandarlo in battuta.

Den ReduziererkoÈrper (11) auf den zentralen KoÈrper Das Getriebe (12) des Kegelrads montieren; Mutter
D (23) ohne Differential montieren und voruÈbergehend D (13) mit Loctite 242 schmieren und von Hand
mit den zwei unteren Schrauben (9) befestigen. zuschrauben.
Das Lager (15) des Einganggetriebes montieren und bis zum
c Anschlag einsetzen. d
Montar el cuerpo reductor (11) sobre el cuerpo central Asemblar el engranaje (12) del pinon, pasar la tuerca
ESP (23) sin el diferencial y fijarlo provisoriamente con los ESP (13) con Loctite 242 y atornillarla manualmente.
dos tornillos inferiores (9).
Asemblar el cojinete (15) del engranaje de entrada del movimiento
y mandarlo a tope.

Monter le corps reÂducteur (11) sur le corps central (23) Monter l'engrenage (12) du pignon; enduire l'eÂcrou
F sans diffeÂrentiel et fixer provisoirement ce dernier F (13) avec du Loctite 242 et visser celui-ci aÁ la main.
avec les deux vis infeÂrieures (9).
Monter le palier (15) de l'engrenage d'acceÁs au mouvement, puis
l'envoyer en buteÂe.

Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)

ITA del pignone il blocchetto "A" usato per lo smontaggio ITA
e serrare il dado (13) alla coppia minima di 500 Nm,
utilizzando una chiave a bussola ed una chiave dinamometrica.

Zwischen dem ReduziererkoÈrper (11) und dem Getrie-

D be (12) des Kegelrads den Block «A» legen, der zum D
Abmontieren verwendet wurde, und Mutter (13) mit
einem Anzugsmoment von mindestens 500 Nm mit einem
e InbuûschluÈssel und einem Dynamometer festziehen. f
Colocar entre el cuerpo reductor (11) y el engranaje
ESP (12) del pinon el bloquete "A" usado para el ESP
desmontaje y apretar la tierca (13) al valor minimo
de 500 Nm, utilizando una llave a manguito y una llave
dinamometrica.

Placer, entre le corps reÂducteur (11) et l'engrenage

F (12) du pignon, le petit bloc "A" utilise au deÂmontage, F
serrer l'eÂcrou (13) au couple minimum de 500 Nm aÁ
l'aide d'une cle aÁ pipe et d'une cle dynamomeÂtrique.

008 913 76 BOMAG

79 789
9.5 Axle DANA 193
INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UND
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

T13

F1241217

GB a
Allow the pinion to rotate a few times in both directions to enable
bearings to set.
Apply bar-hold T13 onto pinion (16) and, with a torque meter, check
the torque of the pinion.
Torque: 140 ± 150 Ncm.
CAUTION! If torque exceeds the maximum value, then the shim
"S1" (19) placed between bearing (17) and distance piece (20)
needs to be increased.
If torque does not reach the set value, increase the tightening
torque setting of nut (13), in different stages, until the maximum
admitted value of 700 Nm is obtained.
CAUTION! If torque does not reach the minimum value, then the
shim "S1" (19) needs to be reduced.
CAUTION! In order to be able to calculate the increase or reduction
of shim "S1", it is necessary to bear in mind that a 0.01 mm
variation in the size of shim (19) results in the torque of the pinion
(16) varying by 20 ± 40 Ncm.

11

F1241226

GB b
Remove the whole reduction gear body (11) and continue with the
assembly of the differential unit and arms.
For details, see «ASSEMBLY AND INSTALLATION OF THE
DIFFERENTIAL UNIT - ASSEMBLING THE BRAKING UNIT».

790 BOMAG
80 008 913 76
Axle DANA 193 9.5

Far compiere al pignone alcuni giri nei due sensi per Das Kegelrad um einige Umdrehungen in beide
ITA assestare i cuscinetti. D Richtungen drehen, um die Lager richtig einzusetzen.
Applicare sul pignone (16) il codolo T13 e con un Am Kegelrad (16) den Schaft T13 anbringen und mit
torsiometro, controllare la coppia di rotazione del pignone. einem Drehungsmesser das Gegenmoment des Ke-
Coppia di rotazione: 140v150 Ncm gelrads kontrollieren.
ATTENZIONE! Se la coppia supera il valore massimo bisogna Gegenmoment: 140v150 Ncm.
aumentare lo spessore "S1" (19) tra cuscinetto (17) e distanziale ACHTUNG! Falls der Wert den Maximalwert uÈberschreitet, braucht
(20). es eine groÈûere Unterlegscheibe "S1" (19) zwischen Lager (17) und
Se la coppia di rotazione non raggiunge il valore stabilito, DistanzstuÈck (20).
aumentare la coppia di serraggio del dado (13) in piuÁ tempi fino a Falls das Gegenmoment den festgelegten Wert nicht erreicht, das
raggiungere il valore massimo ammesso di 700 Nm. Anzugsmoment der Mutter (13) schrittweise erhoÈhen, bis der
ATTENZIONE! Se la coppia di rotazione non raggiunge il valore maximal zulaÈssige Wert von 700 Nm erreicht worden ist.
minimo, eÁ necessario diminuire lo spessore "S1" (19). ACHTUNG! Falls das Gegenmoment den Mindestwert nicht
ATTENZIONE! Al fine di poter calcolare gli incrementi o la erreicht, muû die Unterlegscheibe "S1" (19) kleiner sein.
diminuzione dello spessore "S1", eÁ necessario considerare che la ACHTUNG! Um das hoÈhere oder niedrigere Maû der Unter-
variazione dello spessore (19) di 0,01 mm, fa variare la coppia di legscheibe "S1" ausrechnen zu koÈnnen, darauf achten, daû ein
rotazione del pignone (16) di 20v40 Ncm. Unterschied von 0,01 mm der Unterlegscheibe (19) das Gegen-
moment des Kegelrads (16) um 20v40 Ncm aÈndert.

a
Hacer efectuar al pinon algunos giros en los dos Faire faire quelques tours au pignon dans les deux
ESP sentidos para ordenar los cojinetes. F sens de manieÁre aÁ ajuster les paliers.
Aplicar sobre el pinon (16) el codolo T13 y con un Appliquer sur le pignon (16), la queue T13, puis aÁ
torsiometro, controlar el par de rotacion del pinon. l'aide d'un torsiomeÁtre, controÃler le couple de rotation du pignon.
Par de rotacion: 140v150 Ncm. Couple de rotation: 140v150 Ncm.
ATENCION! Si el par supera el valor maximo hay que augmentar el ATTENTION! Si le couple de rotation deÂpasse la valeur maximum,
espesor "S1" (19) entre cojinete (17) y distancial (20). augmenter la cale "S1" (19) entre le palier (17) et l'entretoise (20).
Si el par de rotacion no llega al valor establecido, augmentar el par Si le couple de rotation n'atteint pas la valeur eÂtablie, augmenter le
de torsion de la tuerca (13) en mas tiempos hasta llegar al valor couple de serrage de l'eÂcrou (13), en plusieurs temps, jusqu'aÁ
maximo admitido de 700 Nm. atteindre la valeur maximum admise de 700 Nm.
ATENCION! Si el par de rotacion no llega al valor minimo, es ATTENTION! Si le couple de rotation n'atteint pas la valeur
necesario disminuir el espesor "S1" (19). minimum, diminuer la cale "S1" (19).
ATENCION! Al fin de poder calcular los encrementos o la ATTENTION! Pour pouvoir calculer les augmentations et les
disminuciones del espesor "S1", es necesario considerar que la diminutions de la cale "S1", tenir compte que la diffeÂrence de
variacion del espesor (19) de 0,01 mm, hacer cambiar el par de 0,01 de la cale (19) fait varier le couple de rotation du pignon (16) de
rotacion del pinon (16) de 20v40 Ncm. 20v40 Ncm.

Rimuovere il corpo riduttore completo (11) e procedere

ITA con il montaggio del differenziale e dei bracci.
Per i dettagli, vedere «ASSEMBLAGGIO ED INSTAL-
LAZIONE GRUPPO DIFFERENZIALE - ASSEMBLAGGIO GRUP-
PO FRENO».

Den kompletten ReduziererkoÈrper (11) abnehmen und

D das Differential und die Arme montieren.
Siehe «ZUSAMMENBAU UND INSTALLATION DES
DIFFERENTIALAGGREGATS - ZUSAMMENBAU DES BREMSAG-
b GREGATS».

Remover el cuerpo reductor completo (11) y proceder

ESP con el montaje del diferencial y de los ejes.
Para los detalles, vease «ASEMBLAJE Y INSTALA-
CION GRUPO DIFERENCIAL - ASEMBLAJE GRUPO FRENO».

Enlever le corps reÂducteur complet (11) et aller de

F l'avant avec le montage du diffeÂrentiel et des bras.
Pour de plus amples deÂtails, voir "ASSEMBLAGE ET
INSTALLATION DU GROUPE DIFFERENTIEL - ASSEMBLAGE
DU GROUPE FREIN".

008 913 76 BOMAG

81 791
9.5 SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
Axle DANA 193
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL

4.3 T1 T2

45°

20
25
1

=
32
32

200
=
90
= =

50
160
110

120± 0.1

120± 0.1
32

32

25
1

840
45°

10 4.5 930

2313 D1240046 2305 D1240043

T3 Ø40
T4
Ø40
32

3 x45°
3 x45°

150
150

190
195

0
R1
10
0
R1

8
17 13
40
25

32
45

32
32
3 x45°
32
Ø153
32

125
Ø154
20°
Ø178 Ø178
Ø189
Ø184
Ø200

1502 D1240120 1742 D1240121

T5
295
136 10 150
65 3 x45°
27.5
20
3 x15°
-- 0.05

-- 0.4
-- 0.6
-- 0.3
-- 0.4

-- 0.1
Ø80

Ø61

Ø35

Ø25
Ø45
Ø63

Ø46

R1

32 32
0

32
32

107.5 ---- 0.2

0.3

1501 D1240122

792 BOMAG
82 008 913 76
Axle DANA 193 9.5

75 Ø290
T6
5 Ø271
12
Ø20

Ø16
A Sez. B - B
1° 30'
° 2
32 17

°
17
32

7°
° 30' 17° 30' 1
3x15°
B
Ø150 H 7
Ø150 Hn 67
Ø318
B

43.60
° 17

82.13
113.48
17

134.91
°
17
°
Ø22
Ø16

17
21° 30'
Ø26

Ø22
Ø15

53.14
32
32

12 A
90.26
68 12
119.50
80 82
139.29
Sez. A - A n°2 pezzi
1545 D1240124

119.50 T7
190
53.14
Ø20
Ø16

9
Ø25

32 32
20
0 0 2 x30°
R1 R1 32 1° 30'
° 2
17
°

134.91
17
T7B

82.13
7°
17° 30' 7° 30' 1
Ø161.5 ±0.1

Ø264 ---- 0.15

0.25
Ø185 ---- 0.08
0.12

Ø262 ---- 0.15

0.25
Ø250
Ø172

Ø320

43.60
17°

113.49
32
°
17

17°
R5
'
21° 30
15°
15°
Ø16

5 x15° 90.26
16 20 138.29
110
32

Ø290 ±0.15
143
153
70
T7A 30 30
3 x15° 32
PROFILO HURT 45.5 x 40.5

A
Ø24

R5
Ø150 ---- 0.08
0.12

2
Ø140
Ø30

Ø38

0
R1 0
R1
Ø25 gH 67

Ø24
Ø23,9

40 74
1.2 h 11
200 200
Particolare A 400

1769 D1240125

008 913 76 BOMAG

83 793
9.5 SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
Axle DANA 193
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL

T8 T9

5 - +0
.5
-0
Ø9
Ø25

13 ± 0..2
Ø102 +-- 0.2
Ø120
0
3 x45°
160
192

Sez. A-A
0
R1
22 10

0.8 600
Ø40
0.8

Es Ch 22
␣✽

15 20
30
Ø✽
Ø129

Ø16
] Bearing ref. 32017 DIN720 Acciaio Fe 42
] Ref. cuscinetto 32017 DIN720
] Lager Ref. 32017 DIN720
] Ref. cojinete 32017 DIN720
] ReÂf. palier 32017 DIN720
Acciaio Fe 42

0355 D1240123

Ø85.5

T10

490
Ø40

Ø25
R1
30

0
3 x45°

78

R2
48

40
10
22
150

A A
188

135

Acciaio 18 Ni Cr Mo 5
Cementazione 0.6÷0.8
Temprato HRC 60÷63
0
R1

35.5

32
1.5

40
8

32
30

3
4.5
32
32

20°
Ø23.9 ±-- 00.05
Ø104
H7
Ø25 g7
Ø109
Ø30
32

-- 0.1
Ø40.5-- 0.15

Ø80
Ø92

1487/B D1240126 1495 D1240128

794 BOMAG
84 008 913 76
Axle DANA 193 9.5

T11 Ø49.8
T12
Ø41.5

4 x45°

15

93
M14 x1

40 300

Ø110 2323 D1240127

Ø65

T13
M14 x1
Ch
22
Ø20

20
M14 x1

61 –– 0.01
0.02
R5
3/4"
4"

41
1/
30
25 25

50

Ø20

Ø9
Ø41.2 +-- 0.03
0 14
195
95

25

45
35
Ø11

60
10
Ø80
10

50

Ø6.5 25
Ø35
2312 D1240075 0870 D1240129

008 913 76 BOMAG

85 795
9.5 Axle DANA 193

796 BOMAG 008 913 76

10 Circuit diagrams

008 913 76 BOMAG 797

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.

798 BOMAG 008 913 76

10.1 Wiring diagram

008 913 76 BOMAG 799

10.1 Wiring diagram

800 BOMAG 008 913 76

Inhaltsverzeichnis: BW177..226DH−4

008 913 76
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
Wiring diagram

001 582 700 95 Stromlaufplan Circuit Diagram

002 582 700 95 Versorgung, Starten, Hupe supply, starting unit, signal horn
003 582 700 95 Motor Deutz EMR II engine Deutz EMR II
004 582 700 95 Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch
005 582 700 95 Datensammler, LC−Display data−collector, LC−display
006 582 700 95 Lenkung, Vibration steering, vibration
007 582 700 95 Fahrhebel, Vibrationsplatten joystick, vibration−plates
008 582 700 95 Variocontrol, Messtechnik Variocontrol, measurement equipm.
009 582 700 95 Bomag Compaction Management BCM Bomag Compaction Management BCM
010 582 700 95 Beleuchtung und StvZO illumination and StvZO
011 582 700 95 Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph
012 582 700 95 Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater
101 582 700 95 Bauteilliste component listing

BOMAG
28.06.2004
001 001
Seis Stromlaufplan 582 700 95
28.06.2004

801
10.1

circuit diagram 001

Werner
802
30
10.1

K11
2:10
87
K30 11:1
30 4:1 K11:87 5:1

X1:15E X1:16E X1:27E X1:28E X1:30E

X1:9
F13 1 F05 1 F95 1 F23 1 F39 1

X1:10
30A 15A 15A 15A 15A
2 2 2 2 2
X1:15A X1:16A X1:27A X1:28A
X1:30A
X37:A X1:151

6:17
4:9
30 21 11 31 41 51 61

X36:B

X36:A
S00 S01 X3:3

22 12 32 42 52 62
Startschalter NOT−Aus
K32:86
starting swwitch 15 54 58 19 17 50a Emerg.−Stop 11:1

2 x 10qmm
X1:152 X1:155
X1:79
S01:22 3:1
X37:B
F05:2
V01 X1:3 X1:4 5:8
K05 30

2 1 7:3
5

125mA
87 87a

X34:P
K14 86 30
K61 K61

Sicherung Heizflansh
heating−flange
Hauptsicherung
main fuse
13 23
3:19 3 2:6 S03
2 2
F48 F00
125A 125A 85 87 87a X1:7 X1:8 Taster Hupe
push button, horn 14 24

BOMAG
1 1 D+ 5:2
B+ 2:11 2:6 B+
D+ MESX 8:2
G01 G03 X38:A X1:97 X1:98
+ +
− −
X1:1 X1:101 X1:102
X1:109

nur bei Klimaanlage

only acc.to air conditioning
30 Anzugsw.:50A / Haltew.:10A 50

167A
1 B+ D+ 86 86 B11 B11
1 K09 K11 1 2 2 1
G02 M01 V02 XS +
R19 S30 M
12V
2 2 1 V03 1 2 −
85 85 −
2
31 EMR 3:5 B− W

X1:110 X1:168 X1:123 X1:103 X1:104

31 31 3:1

Trennschalter Batter 2:8 12:7 2:16 Starter Signalhörer Steckdose

break switch battery starter warning horns socket

Heizflansch Batterie Batterie Generator Nur bei Geländer/ROPS/SD

heating−flange battery battery generator only at hand−rail/ROPS/sun−roof

28.06.2004
1 1

008 913 76
Wiring diagram

Seis Versorgung, Starten, Hupe 582 700 95

28.06.2004
Werner supply, starting unit, signal horn 002
2:17 S01:22 S01:22 6:1

X1:95
1
K14

008 913 76
Relais Heizflansch
relay heating−flange 2

X1:179 X1:96
Wiring diagram

X1:185
Steckerschnittstelle Deutz
connector interface Deutz
X33:7
X33:2
X33:3
X33:5
X33:6
X33:1
X33:4
X33:8

8−polig PNEUTRON

max 7A
A48
Motorsteuerung EMR2
engine−controller EMR2

X30:14
X31:21
X31:22
X31:13
X31:11
X31:14
X31:15
X31:24
X31:25
X31:4
X31:9
X31:5
X31:6
X31:3
X31:2
X31:7

X30:10
X30:11
X30:12
X30:13
X30:1
X30:2
X31:20
X31:12
X31:10
X31:17
X31:18
X31:19
X31:16
X31:23
X31:8
X31:1

L
K
+5V
+5V

STG−
STG+

AGND
AGND
AGND
AGND
AGND

Signal
Signal
Signal
Signal

Ubat −

CAN low

CAN high
Signal Druck
Signal Temperatur

BOMAG
X1:180
X1:181
CAN2− 4:11
CAN2+ 4:11

X57:20
X57:21
X57:22
X57:12
X57:13
X57:10
X57:11
X57:14
X57:15
X57:17
X57:18
X57:19
X57:16
X57:23
X57:24
X57:25
X57:4
X57:9
X57:8
X57:1
X57:6

X1:183
X1:184
ESX Fahrst.
RF−
RF REF
1 2 3 1 2 1 2 7 2 6 1 1 4 3 2 1 2

RF MESS
EMR Stellglied
EMR commander

B88 B114 B130 Y137 5 B115 B113

X32:L
X32:K
X32:B

X32:H
X32:G

X32:A
X1:182
Diagnosestecker EMR

X34:N
diagnosis interface EMR
2:4
31 EMR

X1:186
2:20 31 31 4:1
2:2
Motordrehzahlsensor
sender engine rpm 2
Motordrehzahlsensor EMR Kühlmitteltemperatur
sender engine rpm 1 EMR coolant temperature
EMR Motoröldruck Ladeluftdruck + Temp
EMR engine oil pressure charging air pressure + temperature

28.06.2004
1 1 582 700 95
Seis Motor Deutz EMR II

803
28.06.2004
10.1

Werner engine Deutz EMR II 003

804
2:14 30 30 5:1
F24:2 5:3 X1:2 3:4 CAN2+ CAN2+ 7:6
EMR Deutz Fahrhebel
3:4 CAN2− CAN2− 7:6
X1:145
10.1

X1:42 CAN1+ 5:8

31 LC−Display, OPUS 21
CAN1− 5:8
X1:119 X1:120
S01
2:16
120 OHM 120 OHM
X1:146 32 1 2 1 2

X52:1
X52:2
R22 R20
rt sw X1:17E X1:34E
Diagnosestecker Fahrzeug
F67 1 F84 1 X34:G X34:H X34:C X34:D X34:A X34:B diagnosis interface equipment
B112
15A 10A
2 2
Drucksensor Fahrpumpe X1:17A X1:34A
pressure sensor drive pump
X1:34A

X1:51
X1:52
X1:53
X1:54
X1:47
X1:48
X1:49
X1:50
8:2
120 OHM 120 OHM
1 2 1 2
R23 R21

Drucksensor
Leistung
Elektronik
TxD
RxD
CAN2+
CAN2−
CAN1+
CAN1−

A34
Fahr−Steuerung

X35:5
driving controller

X35:4

X35:31
X35:56
X35:57
X35:59
X35:60
X35:53
X35:33

X35:58
X35:27
X35:26

X35:28
X35:54

X35:38
X35:12
X35:37
X35:34
X35:30
X35:15
X35:24
X35:49
X35:64
X35:46
X35:47
X35:55
X35:65
X35:66
X35:67
X35:68

BOMAG
speed
speed
Neigung

Richtung
Richtung
Gehäuse
housing

Achsmotor

Sitzkontakt
Bandagenmotor

Fahrpumpe vorw.
Fahrpumpe rückw.

Rückfahrwarnsum.

X1:45
X1:44
+45_G=4,5V X1:158 X1:114 X1:121 X1:122 X1:143 X1:141
+ −45_G=0,5V
B57 1V

X1:171
X1:173
X1:175
X1:177
X1:176

bl

br
ws
br
ws
bl
+ +
dir. dir.

0,46A
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA

B60 B59 2,5V X14:B X9:1

speed
speed
S06 + + X16:1 1 X15:1 1 1 1
− X1:172 −
8:2
4V H14 Y17 Y16 Y30 Y31

sw
sw
DIR MESX −
− 2 2 2 2
11:6 − S X1:46 X14:A X9:2 X16:2 X15:2
SPEED TAC
X1:82
X1:124
X1:142
X1:142
X1:143
X1:143

X1:174 8:2 X1:178 X1:55 6:4 8:2 X1:149 X1:117 X1:123 X1:123 X1:144 X1:144
SPEED MESX
31 PITCH MESX
3:20 31 5:1

Sensor Achse Sensor Bandage Neigungssensor Sitzkontaktschalter Prop.−Pumpe Vorw. Prop.−Ventil Bandagenmotor
sender axle sender drum slope sensor switch, seat contact prop.−pump forwards prop.−Valve drum motor

Rückfahrwarnsummer Prop.−Pumpe Rückw. Prop.−Ventil Achsmotor

back up alarm buzzer prop−pump backwards prop.−Valve axle motor

28.06.2004
1 1

008 913 76
Wiring diagram

Seis Fahrantrieb, Neigungssensor, Sitzkontakt 582 700 95

28.06.2004
Werner driving system, slope sensor, seat contakt switch 1 004
30
4:20 30 8:1
2:20 K11:87 K11:87 7:14
4:3 F24:2 F24:2 6:15
2:17 F05:2 F05:2 2:17
X1:29E
4:17 CAN1+ CAN1+ 7:14
1

008 913 76
F24 ESX Fahrsteuerung CAN1− DIOS Platten
15A
4:17 CAN1− 7:14
2
X1:29A
Wiring diagram

X1:87 X1:88 X1:80 X1:86

X1:41

X1:39
X1:40
X34:R

VCC
CAN1 high
CAN1 low
CAN1 high
CAN1 low
Ub "30"
Ub "15"
not connected
not connected
Ub out

X27:8
Steckerfarbe: X26−grau; X27−schwarz
A80 connector−colour: X26−grey; X27−black
A81
Datensammler LC−Display
X28:6
X29:8

data−collector LC−display
X28:1

X27:6
X27:7
X29:7

X28:3
X28:5

X28:4

X26:3
X26:5
X26:8
X26:10
X27:4
X27:9
X27:2
X26:7
X26:9
X26:1
X26:2
X26:6
X26:4
X26:11
X27:10
X27:11
X27:12
X27:1
X27:3
X29:2
X29:1
X29:3
X29:4
X29:5
X29:6

X27:5
X26:12
X28:2

GND
GND
GND

UIN1
DIN1
DIN1

AIN1

UIN3
UIN2

DIN3
DIN5
DIN7
DIN9
DIN6
DIN3
DIN5
DIN6

DIN8
DIN2
DIN2

AIN2

DIN4
DIN4

DIN11

DIN10
Sepa1
Sepa2
GND/UIN3
X1:106 X1:111 X1:112 X1:107 X1:108 X1:105

BOMAG
BL 10:17 ECO
Low High down up
BR 10:17 23 13 23 13
BEL S120
10:4
KLIMA
12:6 S139
24 14 24 14

Hydraulikölfilter
hydraulic oil filter
Luftfilter
air cleaner
Kühlmittelvorrat
coolant stock level
Wasserabscheider
water−seperator
Füllstand Diesel
fuel−level
X21:1 X8:1 X10:2
B21 1 B03 1 B55 B124
D+ R03
2:6 P P Q
Schalter Motordrehzahl
2 2 switch engine−rpm mode switch frequency−control
X21:2 X8:2 X10:3 Schalter Frequenzverstellung

0 .. 67 OHM
X1:117 X1:94 X1:94 X1:117 X1:154 X1:149 X1:82
31
4:20 31 6:1

28.06.2004
1 1 582 700 95
Seis Datensammler, LC−Display

805
28.06.2004
10.1

Werner data−collector, LC−display 005

806
3:20 S01:22 S01:22
5:20 F24:2 F24:2
X1:148 Lenkwinkelsensor
X23:1 steering angle sensor
7:1
10.1

X1:41
X1:201
X51:1 Lenkeinheit X1:187
B65 + A45 steering unit
Aufnehmer Vibrationsmotor
S X22:1 sensor vibration motor
br +
X1:161 X41:1 X39:1 VCC B X39:2 X22:2
S1 −
−
X1:160 X41:3 X40:1 X40:2 bl
VCC B B16
X1:159 X41:4 X40:4 S2 X40:3 sw

X1:203
B132 2 2 2 0V A ws X22:3
VIB
X1:162 X41:2 X39:4 0V A X39:3 X22:4 11:6
S1

X1:55 X1:202
Lenkwink.
1 1 1

−
BTS BREMSE 7:2

X41:5
X41:7
X41:8
X41:6
Vib.− Richtung

Sig.
AGND

X34:J
X1:60 FM5 X1:61
X1:56 FM1 X1:57

X1:58 FM2 X1:59

X1:189

armrest−switch
X1:55

Schalter Armlehne
Vib.− Frequenz
BTS Bremse

4:6

X1:205
X1:207
X1:206

X1:208
8,5V
X1:42 X1:188

nur BVC
A34

only BVC
Fahr−Steuerung

X35:1
driving controller

X35:19
X35:17

X35:18
X35:41
X35:35

X35:29
X35:23
X35:40
X43:2 X43:1

X35:21
X35:20
X35:25
X35:16
X35:22
X35:2
X35:48
X35:3
X35:61

K57 30 K56 30

BOMAG
30
Bremse

Armlehne
Prop. out

6:9 6:8 30
Warnsummer

K48 7:2

X51:3

X51:2
87 87a 87 87a X1:89

Umsch. Amplitude
K43 6:12 87 87a

Pumpe Vib.−Platten
X1:154 87 87a X1:147
KA MESX
8:2 11
X35:16 X1:38
X1:199 X1:198 X1:196 X1:195 X35:16 X35:22 GA MESX
6:9 6:2 7:14 8:2 S01
X1:37
2:16
X1:116 X1:115 12
X1:150
8:2

400 ... 1.200mA

400 ... 1.200mA
X1:113
150mA

X6:1 X7:1 BRAKE MESX

400 ... 1.200mA

Y113 1 Y112 1 1 1 K56 86 K57 86 K43 86 Y08 1 Y07 1 H07

+ Y04 1
Y93 Y92
2 2 2 2 85 85 85 2 2 − 2
X6:2 X7:2
max.1.8A

X1:149 X1:200 X1:200 X1:197 X1:197 X1:82 X1:117 X1:190

X1:118
5:20 7:1
31
31 Anbau 177DH: h.r. Anbau 177DH: h.l.
6:4 6:3 6:14 Anbau 213DH: oben Anbau 213DH: unten

Prop.−Ventil Vibration klein Magnetventil Bremse

prop. valve vibration small solenoid valve brake

Notlenkung links Prop. Ventil lenken links Prop−Ventil Vibration groß

emerg. valve steering left prop. valve steering left prop. valve vibration big

Notlenkung rechts Prop. Ventil lenken rechts Warnsummer Störung

emrg. valve steering right prop. valve steering right warning buzzer, failure

28.06.2004
1 1

008 913 76
Wiring diagram

Seis Lenkung, Vibration 582 700 95

28.06.2004
Werner TS022 steering, vibration 006
6:2 X23:1 4:17 CAN2+ 5:14 CAN1+ CAN1+ 8:16
ESX Fahrst. CAN2− LC−Display BTM
4:17 5:14 CAN1− CAN1− 8:16
5:20 K11:87 K11:87 8:1
Taster 1 = Platten rechts
push button 1 = plates right X1:31E
Taster 2 = Platten heben
push button 2 = lift plates

008 913 76
1 F145
Taster 3 = Vibration EIN/AUS Näherungssch. Platten oben
push button 3 = vibration ON/OFF 15A
Taster 4 = Platten links
sensor plates up 2
push button 4 = plates left
Taster 5 = platten senken
Näherungssch. Platten Mitte X1:31A
push button 5 = lower plates sensor plates centered
Taster 7 = Infotaste 1 X1:209
push button 7 = info button 1
Wiring diagram

X1:213
X1:214

Taster 8 = Infotaste 2

X1:156
push button 8 = Info button 2

X1:157
BTS BREMSE B135 + B134 +
6:18 − −
3 2
1 7 Fahrstufenschalter
4 S S
5 8 speed range selector

S42
X62:12
+ − A54
S Platten Steuerung
X62:1

X62:3
X62:9
X62:2

X62:4
X62:10

plate−controller
Ub in CAN−

X25:4
X25:2
X25:3
Bremse zu = 0V 1 7
Bremse auf = Ub BTS Bremse CAN+
3 S55 6 X35:22
BTS zus. Fahrhebel +5V out
6:11
X1:153 4 5
travel lever
0V in 0V (Ref PIN5)
X62:5
X62:6
X62:7
X62:8

X62:11
X62:13
X62:14

2 8
Add1 AK Ext1
9 11
Add2 AK Ext2
10 12
Stecker X23
Stecker X24
1 2 3 4 5 6 7 8

BOMAG
Ub out
OV out

DK Ext1
DK Ext3
DK Ext5
DK Ext6

DK Ext2
DK Ext4
X50:3
X50:2
X50:1
400 .. 1.200 mA

X1:210
S − + Y123 1 Y143 1 Y145 1

S35 K0G S09 13 S64 13 S36 13 S139 X72:1

13 23 2 2 2
86 86 1 Y122 1 Y142 1 Y144 1
K48 K05 Y98
14 14 14 14
24
2 2 2 2
85 85
X72:2

X1:149 X1:211 X1:212

6:20 31
8:1
6:17 2:12 31

nicht bei BVC Nur bei BVC Schalter Schwimmstellung Platten MV Platten heben MV Platten rechts
not at BVC Only at BVC sw. swimming pos. plates plates up plates right
Frequenzverstellung Platten
freq. adjust plates MV Platten senken MV Platten Schwimmst
Schalter Amplitude Schalter Vibration Ein/Aus Schalter Betriebsart Platten Prop−Pumpe Platten plates down plates float−pos.
switch amplitudes switch vibration on/off modesw. plates prop.−valve plates MV Platten links MV Platten Priorität
plates left plates priority

28.06.2004
1 1 582 700 95
Seis Fahrhebel, Vibrationsplatten

807
28.06.2004
10.1

Werner TS022 joystick, vibration−plates 007

808
Beschleunigungssensoren Beschleunigungssensoren Aufnehmer Verstellmotor Drucker Bedieneinheit BEM Display Messtechnik BOP
acc. sensor front acc. sensor rear sens. adjust. motor printer control−unit BEM display measurem. BOP
X1:34A
4:9 GND
30
10.1

5:20 30 10:1
Pot 30
7:20 K11:87 K11:87 10:1
Pot 15
X2:48 X2:49
X2:47
31.1

+ −
X2:66
X2:70
8:19

X42:1

X1:32E X1:35E
X42:5
X42:3

X42:2

X2:77 P16 F1 F2
1 1 1
F148 F146
nur bei BEM
only at BEM

10A 15A
X2:56 X2:53 X2:60 X2:57 FM4 X2:71
2 2 2
X1:32A X1:35A X48:2 X48:1 X49:2 X49:1 X2:78 P33

CAN+
CAN−

F148:2 B62 B62 X2:67 X2:68

9:15

X4:C
X4:E

X4:D

+/sw
+/sw
−/gg −/gg X47:A X47:B
nur bei BTM+/BTM prof
only at BTM+/BTM prof

X42:6
X42:7
X42:8

X42:4

15g/bl 15g/bl

−/sw
X74:3
X74:5
X74:4
7:20
X2:57 B61 P11 CAN1−

20g/br
20g/br
+/rt 7:20
DIOS Platten

X48:3 X48:4 X49:3 X49:4 S/ws

CAN1+

nur bei BTM prof

X74:1 X74:2

only at BTM prof

1 R20 2
X2:54 X2:55 X2:58 X2:59 X47:C
X4:A X4:B 120 OHM
X2:50 X2:51
R21
X2:69 X2:64 X2:65 1 2

Pot. 15
Leistung
Elektronik
8.5V
AGND MESX

Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
Erregerpos.
RxD TxD CAN1+ 120 OHM CAN1−

BOMAG
X44:1

X44:7
X44:9
X44:5
X44:27
X44:26

X44:4

X44:31

X44:56
X44:57
X44:59
X44:60
X44:30

X44:58
X44:29
X44:23

X44:28
X44:54
A83
Messtechnik−Rechner
measurement calc. unit

X44:15
X44:38
X44:35
X44:14
X44:32
X44:36
X44:37
X44:41
X44:47
X44:46
X44:53
X44:33

X44:3

X44:55
X44:65
X44:66
X44:67
X44:68

CAN3+ CAN3−
6:15 KA MESX
EVIB

GA MESX

Prop.
Prop.
GND
0..6VDC

6:15
SPEED MESX X1:85 9:15
4:3 CAN3−

400 .. 1.200mA
400 .. 1.200mA

DIR MESX X2:75 X2:73 X2:60 +

4:3
PITCH MESX Y140 1 Y141 1 P07 E 9:15
4:8 VIB CAN3+
8:20

BRAKE MESX

v.l.
v.r.

6:17 −
D+ MESX BEL MESX 2 2
2:6 10:4
31.1

X2:76 X2:74 X2:63 X2:66 X1:82

31 31 9:1
7:20

Prop−Ventil Erreger auf EVIB−Meter

solenoid−valve exciter up EVIB−meter
Prop−Ventil Erreger ab
solenoid valve exciter down

28.06.2004
1 1

008 913 76
Wiring diagram

Seis Variocontrol, Messtechnik 582 700 95

28.06.2004
Werner TS022 Variocontrol, measurement equipm. 008
F148:2
8:4

008 913 76
CAN3−
8:18

8:18 CAN3+
Wiring diagram

CAN3+ CAN3−
1 R242
120 OHM
X2:61 X2:62
R25
1 2
120 OHM

X4:N X4:M

X75:7 X75:2

A87
USB−CAN Schnittst.
USB−CAN Interface BCM

X2:70

BOMAG
X76:1 X4:G

P15 X76:2

X4:F
X2:63

BCM 05
BCM 05
nur bei BCM
only at BCM

8:20 31 31 10:1

28.06.2004
1 1 582 700 95
Seis Bomag Compaction Management BCM

809
28.06.2004
10.1

Werner TS022 Bomag Compaction Management BCM 009

810
8:3 K11:87 K11:87
8:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
10.1

F11 F18 F07 F08

15A 10A 15A 15A
30
X1:18A K06 X1:19A X1:25A
X1:26A
10:4 X1:305
X1:83

X1:301
Schalter StvZO 87 87a
switch, StvZO
13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO L0R Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:306
X1:307

X3:4 X3:5 with cabin 30 49L 49R

STV1

X1:302
11:17 A02
STV2
11:17
X1:23E X1:24E
K16 30 31 82 L R
10:9 F09 F10
15A 15A
87 87a X1:23A X1:24A

BEL 5:9 BL
5:9
13 BR
5:9

S16 14

BOMAG
switch, working head lights
X1:304

13 23

Schalter Arbeitsbele
01
01

X1:311

X1:310
X1:319
X1:313

X1:312
X1:321
X1:314

X1:309
X1:303

X1:320
X1:322

S14

lights without StvZO

Anschluß Arbeitsschein−
werfer ohne StvZO
connection working head
X1:84
Warnblinkschalter 14 24
BEL MESX
X61:1

X61:3
X60:1

X59:5
X60:3
X59:3

X58:5
X58:3
X59:2

X58:2

switch, hazard light

Arbeitsscheinwerfer hinten links

working head lights, rear lh.
Arbeitsscheinwerfer hinten rechts
working head lights, rear rh.
Arbeitsscheinwerfer vorne links
working head lights, front lh.
Arbeitsscheinwerfer vorne rechts
working head lights, front rh.

8:7
X1:43

0,125A
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 E08 1 E09 1 E10 1 E11 1

0,125A
2 2 86 2 2 2 2 86 2 2 2 2 + 2 2 2 2
K06 K16

4,6A
4,6A
4,6A
4,6A

H06
85 85 −

4,6A
4,6A
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A

X3:1

X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6

X1:323 X60:4
X1:323 X60:2
X1:324 X61:2

X1:324 X61:4
9:20 11:1
31 10:10 Schlußleuchte links 10:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
Anschluß Arbeitsscheinwerfer
parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
Scheinwerfer rechts
Parkleuchte rechts Blinkleuchte HL
head light RH parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schlußleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH

28.06.2004
1 1

008 913 76
Wiring diagram

Seis Beleuchtung und StvZO 582 700 95

28.06.2004
Werner illumination and StvZO 010
K30 X3:6
2:14 K32:87 12:2
X3:7
K32 30 STV2
X3:8 10:13
11:1 STV1

008 913 76
10:13
87 87a
G H A B C E F
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3 6
5
Wiring diagram

F42 12:8
F130 11:9 F130 F130 12:7
11:14

A12
15

1,75A
0,83A
K141 30 1 B51 + 30 01W 7 2 01W 7 2 1 S163 5 1 S38 5
+ + + B51
01 01 E72
K32:86 11:16 E29 E70
− − − − 1
87 87a 2 2 2 1
2:19 31 S21 5 4 S20 5 4
Radio
radio
1 Tachographenmodul
E71 1 module, tachograph
R80 A2+A3
X3:17
4,6A
4,6A
4,6A
4,6A

2 4 6 A1

Nachtleuchte
4:3 P09 +

indicator
X55:1
X56:1

X55:3
X56:3
2 1 XS

X55:4
X56:4
SPEED TAC A16 night illumination E27 1 E28 1 E23 1 E25
1 B3 12V

Kontrolleuchte
Innenleuchte
inside light, cabin
−
socket
Steckdose

+ 7,8,9 2 B4 2 2 2 2

max. 13A
A01 VIB X3:18 5 3 C3
6:18
A5+A6
S45 TK −

Heizung Heckscheibe

BOMAG
heating rear screen
3,8A
3,8A

Schalter Innenleuche
switches interior lights
3
5A

86 S86 + + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
− − M07 − M06 4 −
85

2,9A
3 min

ZA
4,7A

X55:2 X56:2 option

Abfallverzögert

12:18
KABINE 31
Relais Kabine Türkontaktschalter Tachograph Schalter Nachtleuchte
relais cabin door switch tachograph switch, night illumination

X3:1
X3:2
Schalterbel.
switch illum.

10:20 31 31 12:1

11:6 Wascher hinten Wascher vorn 11:2 Arbeitsscheinwerfer vorn

washer rear washer front working head lights, front

Wischer hinten Wischer vorne Arbeitsscheinwerfer hinten Rundumkennleuchte

windscreen wiper, rear windscreen wiper, rear working head lights, rear rotary beacon

28.06.2004
1 1 582 700 95
Seis Kabinenausrüstung, Beleuchtung, Radio, Tachograph

811
28.06.2004
10.1

Werner cabin−equipment, headlights, radio, tachograph 011

812
11:19 K32:87
Potential 15 aus Kabine
11:17 F130
F42 Potential 15 aus Kabine
11:9
10.1

D Potential 30 aus Kabine H A

F31 F40 F15
20A 20A 5A
4 8 1

Bedienteil Kabinenheizung/Klimaanlage
1 2 3 12 11 13 14 16
X53:B X53:C control−unit cab−heater /air conditioning X54:4 X54:3 X54:2
0123 4 3 2
S44 A72
Steuergerät 5
control unit
6 11 12 1 Regel aus = 0,4A 0123
Schalter Kabinenlüfter
E30 Kleine Stufe = 0,67A S28
switch blower cabin X54:6 X54:11 X54:12 X54:1 Zusatzheizung mittleter Stufe = 1,0A
add. heater große Stufe = 1.9A
X3:13 Power Stufe = 2,8A
6 2 1 3
Anlaufstrom beim Start = 8,3A

K09 30
X3:14
switch, cab add.−heater

X53:L
X53:H

X53:M
2:8
Schalter Kabinenzusatzheizung

87 87a X1:167 10 9 5 6 8 7 4 15

X1:169 X18:1

X3:9
X3:11

X3:10
X3:12
X19:1
B131
B103 1 1
_t

BOMAG
_t 2 2
X19:2
X20:1 X18:2

X17:1 X1:163
Thermofühler Klimaan
temperature sensor air conditioning

X17:3 X1:166

X17:2 X1:165
Thermofühler Heizung
temperature sensor heating unit
B104 4
P
HP

1A
LP 3

ge rt or ge rt or
Y138 1 1
X1:170 11:19

X20:4
X20:3
V06 Y14 KABINE 31

monitoring coolant pressure

M09 M M09 M 5:9
KLIMA 2 2

Überwachung Kühlmitt
Stromaufnahme Lüfter / current blower br br
Stufe 1: 3.0A pro Lüfter
X20:2
Stufe 2: 4.5A pro Lüfter
Stufe 3: 11.5A pro Lüfter
Y15 1 2
X17:4 V04 X1:168
2 1

3,5A
X1:164
11:20 31 31

Kabinenlüfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit
Kabinenlüfter
cab ventilator

28.06.2004
1 1

008 913 76
Wiring diagram

Seis Kabinenheizung, Klimaanlage, Zusatzheizung 582 700 95

28.06.2004
Werner cabin−heater, air conditioning, add. heater 012
Name Bl. Pf. Benennung title TYP
A02
Wiring diagram
A12
A16
010
011
011
17
5
6
Blinkrelais
Radio
Elektronik Tachograph
indicator relay
Radio
Electronic system, tachograph
10.1
A34 004 6 Prozessorplatine Prozessing circuit board
A34 006 5 Prozessorplatine Prozessing circuit board
A45 006 9 Lenkrad Steering wheel
A48 003 3 Elektronische Motorsteuerung Electronic engine management
A54 007 17 Modul Pumpenansteuerung Modul pump control
A72 012 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A80 005 3 Modul Datensammler modul data−collector
A81 005 18 Anzeigeeinheit Display−Unit
A83 008 6 Elektronik Messtechnik electronic measurement−equipment
A87 009 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
Werner
28.06.2004
Seis
28.06.2004

B03 005 3 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B11 002 16 Signalhorn Warning horn
B11 002 18 Signalhorn Warning horn
B16 006 16 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 005 2 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B51 011 4 Lautsprecher Radio Speaker radio
B51 011 6 Lautsprecher Radio Speaker radio
B55 005 4 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B57 004 6 Neigungssensor Stufenumschaltung Slope sensor, speed range selection
B59 004 4 Aufnehmer Bandagengeschwindigkeit Sensor, drum speed
B60 004 2 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 008 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 008 8 Beschleunigungsaufnehmer Acceleration sensor
B62 008 10 Beschleunigungsaufnehmer Acceleration sensor
B65 006 4 Sensor, Lenkwinkel vorn Sensor, angularity steering, front
B88 003 6 Druckgeber Motoroel Sender, engine oil pressure
B103 012 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 012 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B112 004 3 Druckgeber Fahrpumpe pressure sender, driving pump
B113 003 13 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 003 7 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B115 003 11 Geber Ladeluftdruck Sender, charging air pressure
B124 005 5 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 003 14 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B130 003 8 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
B131 012 10 Temperaturschalter Heizung Temperature switch, heating
B132 006 2 Inititator Armlehne links proximity switch left arm rest
B134 007 17 Näherungsschalter Platten oben proximity switch, plate up
B135 007 16 Näherungsschalter Platten mitte proximity switch, plate middle
component listing

E08 010 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
Bauteilliste

E09 010 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 010 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 010 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 010 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 010 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 010 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 010 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 010 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 010 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E23 010 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 011 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 010 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 011 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 010 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 011 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 010 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 011 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 011 3 Innenleuchte Kabine Inside light, cabin 1,75A
E30 012 13 Heizgeraet Heating unit
E32 011 19 Kennleuchte Warning light 5A
E70 011 15 Nachtleuchte Night lamp 0,83A
E71 011 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 011 16 Beleuchtung Bedienschalter illum. Switches

F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A

F05 002 14 Sicherung Steckdose Fuse, socket 15A
F07 010 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 010 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 010 6 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 010 8 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 010 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F15 012 18 Sicherung Heizgeraet Fuse, heating unit 5A
F18 010 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 010 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 010 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 002 18 Sicherung Signalhorn Fuse, warning horn 15A
1

F24 005 2 Sicherung Ueberwachungsmodul Fuse, monitoring module 15A

F31 012 3 Sicherung Kabinenluefter Fuse, cabin ventilator 20A
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 012 13 Sicherung Kabinenheizung Fuse, heating unit cab 20A
F41 011 19 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A
9

F42 011 3 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A

F43 011 10 Sicherung Wischermotor hinten Fuse, wipermotor rear 15A
F44 011 13 Sicherung Wischermotor vorn Fuse, wipermotor front 15A
F48 002 3 Sicherung Gluehanlage Fuse, glow plug system 125A
582 700 95

F67 004 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 15A
F84 004 9 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F95 002 16 Sicherung Motormanagement intern Fuse, engine controller (internal) 15A
FM1 006 6 Platinensicherung Multifuse MULTIFUSE
FM2 006 5 Platinensicherung Multifuse MULTIFUSE
101

FM4 008 11 Platinensicherung Multifuse MULTIFUSE

FM5 006 5 Platinensicherung Multifuse MULTIFUSE
008 913
F130 76 011 15 Sicherung Nachtleuchte BOMAG
Fuse, night lamp 10A 813
Name Bl. Pf. Benennung title TYP

10.1 F143
F144
F145
011
011
007
2
20
18
Sicherung Heckscheibenheizung
Sicherung Kabinensteckdose
Sicherung Anhängeplatten
fuse rear screen heating unit
Fuse cabin−socket
fuse vibration plates
15A
Wiring diagram
15A
15A
F146 008 5 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30) 15A
F148 008 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15) 10A

G01 002 3 Batterie Battery 103A

G02 002 5 Generator Generator
G03 002 4 Batterie Battery 103A

H06 010 15 Meldeleuchte Warnblinker Indicator light, hazard light LED ROT
H07 006 16 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0.15A
H14 004 11 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX O,46A
Werner
28.06.2004
Seis
28.06.2004

K05 007 3 Relais Startstrom Relay, starting current BOSCHW

K06 010 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K14 003 19 Relais Vorgluehen Relay, glow plug system TYCOX
K16 010 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K32 011 1 Relais Kabine Relay, cabin BOSCHW
K43 006 12 Relais Vibration Relay, vibration BOSCHW
K48 007 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K56 006 8 Relais Lenkung Relay, steering system BOSCHW
K57 006 9 Relais Lenkung Relay, steering system BOSCHW
K61 002 6 Relais Ladekontrolle Relay, charge control BOSCHW
K141 011 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW

M01 002 11 Starter Starter 2.3 KW

M04 011 12 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 011 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 011 13 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 011 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 012 3 Kabinenluefter Cabin ventilator
M09 012 4 Kabinenluefter Cabin ventilator

P07 008 15 Omegameter Omegameter

P09 011 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 008 14 Drucker Printer
P15 009 16 BCM 03 Bildschirm BCM 03 terminal
P16 008 16 Diagnose, Variomatic Diagnostics, varimatic
P33 008 18 Opus 21 Opus 21
component listing

R03 005 6 Geber Tankanzeige Sender, level gauge 0 .. 67 OHM

R19 002 2 Heizflansch heater flange 167A
Bauteilliste

R20 004 15 Widerstand Resistor 120 OHM

R20 008 17 Widerstand Resistor 120 OHM
R21 004 15 Widerstand Resistor 120 OHM
R21 008 17 Widerstand Resistor 120 OHM
R22 004 12 Widerstand Resistor 120 OHM
R23 004 12 Widerstand Resistor 120 OHM
R24 009 15 Widerstand Resistor 120 OHM
R25 009 15 Widerstand Resistor 120 OHM
R80 011 2 Heizung Heckscheibe heating rear screen MAX. 13A

S00 002 10 Startschalter Starter switch

S01 002 16 Schalter NOT AUS Switch, emergency off NOTAUSH
S03 002 18 Taster Signalhorn Push button, warning horn
S06 004 10 Sitzkontaktschalter links Switch, seat contact, lh.
S09 007 8 Vibrationsschalter vorne Switch, vibration, front
S14 010 15 Warnblinkschalter Switch, hazard light
S15 010 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S16 010 4 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 011 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 011 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 012 18 Schalter Kabinenheizung Switch, cabin heating
S30 002 3 Batterietrennschalter Switch, battery disconnect
S35 007 7 Vibrationsschalter klein/gross Switch, vibration low/high
S36 007 11 Vibrationsschalter Switch, vibration
S37 010 18 Schalter Blinker Switch, indicator
S38 011 19 Schalter Kennleuchte Switch, warning light
S42 007 11 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S44 012 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 011 3 Schalter Kabineninnenleuchte Switch, cabin inside light
S55 007 6 Schalter Fahrhebel Switch, travel control lever
S64 007 10 Schalter Schwimmstellung Switch, float position
S86 011 3 Schalter Tuer, links Switch door, lh.
S120 005 17 Schalter Motordrehzahl Switch, engine speed
S139 005 19 Schalter Frequenzverstellung Switch, frequency control
S139 007 13 Schalter Frequenzverstellung Switch, frequency control
S158 011 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 011 16 Schalter Heckscheibenheizung switch rear screen heating unit
2

V01 002 7 Diode Diode FE5B

V02 002 17 Diode Diode FE5B
V03 002 18 Diode Diode FE5B
V04 012 8 Diode Diode FE5B
9

V06 012 9 Diode Diode

X1:1 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:2 004 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
582 700 95

X1:2 010 10 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:3 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:4 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:7 002 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:8 002 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
102

X1:9 002 5 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:10 002 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
814 X1:37 006 15 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 008 913 76
Name Bl. Pf. Benennung title TYP
X1:38
Wiring diagram
X1:39
X1:40
006
005
005
15
2
2
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO E−BOX
WAGO E−BOX
WAGO E−BOX
10.1
X1:41 005 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:41 006 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:42 004 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:42 006 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:43 010 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:44 004 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:45 004 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:46 004 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:47 004 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:48 004 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:49 004 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
Werner
28.06.2004
Seis
28.06.2004

X1:50 004 16 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:51 004 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:52 004 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:53 004 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:54 004 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:55 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:56 006 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:57 006 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:58 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:59 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:60 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:61 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:79 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:80 005 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 004 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 005 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 006 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 008 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:83 010 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:84 010 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:85 008 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:86 005 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:87 005 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:88 005 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:89 006 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:94 005 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:94 005 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:95 003 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:96 003 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

X1:97 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:98 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:101 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:102 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:103 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:104 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:105 005 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:106 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:107 005 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:108 005 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:109 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:110 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:111 005 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:112 005 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:113 006 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:114 004 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:115 006 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:116 006 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:117 004 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:117 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:117 005 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:117 006 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:118 006 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:119 004 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:120 004 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:121 004 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:122 004 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:123 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:123 004 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:123 004 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:124 004 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:141 004 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:142 004 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:142 004 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:143 004 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:143 004 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:143 004 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:144 004 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:144 004 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
3

X1:145 004 9 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:146 004 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:147 006 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:148 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:149 004 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
9

X1:149 005 12 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:149 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:149 007 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:150 006 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
582 700 95

X1:151 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:152 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:153 007 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:154 005 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:154 006 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
103

X1:155 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:156 007 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
008 913
X1:15776 007 9 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 815
Name Bl. Pf. Benennung title TYP

10.1 X1:158
X1:159
X1:15A
004
006
002
10
7
10
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO E−BOX
WAGO E−BOX
WAGO E−BOX
Wiring diagram
X1:15E 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:160 006 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:161 006 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:162 006 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:163 012 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:164 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:165 012 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:166 012 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:167 012 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:168 002 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:168 012 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
Werner
28.06.2004
Seis
28.06.2004

X1:169 012 7 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:16A 002 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:16E 002 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:170 012 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:171 004 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:172 004 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:173 004 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:174 004 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:175 004 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:176 004 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:177 004 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:178 004 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:179 003 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:17A 004 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:17E 004 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:180 003 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:181 003 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:182 003 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:183 003 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:184 003 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:185 003 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:186 003 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:187 006 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:188 006 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:189 006 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:18A 010 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:18E 010 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:190 006 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:195 006 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

X1:196 006 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:197 006 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:197 006 7 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:198 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:199 006 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:19A 010 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:19E 010 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:200 006 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:200 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:201 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:202 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:203 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:205 006 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:206 006 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:207 006 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:208 006 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:209 007 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:210 007 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:211 007 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:212 007 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:213 007 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:214 007 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:21A 010 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:21E 010 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:22A 010 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:22E 010 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:23A 010 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:23E 010 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:24A 010 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:24E 010 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:25A 010 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:25E 010 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:26A 010 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:26E 010 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:27A 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:27E 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:28A 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:28E 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:29A 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
4

X1:29E 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:301 010 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:302 010 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:303 010 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:304 010 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
9

X1:305 010 18 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:306 010 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:307 010 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:309 010 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
582 700 95

X1:30A 002 19 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:30E 002 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:310 010 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:311 010 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:312 010 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
104

X1:313 010 17 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:314 010 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
816 X1:315 010 2 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 008 913 76
Name Bl. Pf. Benennung title TYP
X1:315
Wiring diagram
X1:315
X1:316
010
010
010
7
17
2
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO E−BOX
WAGO E−BOX
WAGO E−BOX
10.1
X1:316 010 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:316 010 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:319 010 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:31A 007 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:31E 007 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:320 010 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:321 010 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:322 010 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:323 010 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:323 010 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:324 010 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
Werner
28.06.2004
Seis
28.06.2004

X1:324 010 19 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:32A 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:32E 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:34A 004 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:34E 004 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:35A 008 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:35E 008 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X2:47 008 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:48 008 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:49 008 19 WAGO−MESSTECHNIK Wago−measurement equip.
X2:50 008 17 WAGO−MESSTECHNIK Wago−measurement equip.
X2:51 008 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:53 008 8 WAGO−MESSTECHNIK Wago−measurement equip.
X2:54 008 7 WAGO−MESSTECHNIK Wago−measurement equip.
X2:55 008 8 WAGO−MESSTECHNIK Wago−measurement equip.
X2:56 008 7 WAGO−MESSTECHNIK Wago−measurement equip.
X2:57 008 2 WAGO−MESSTECHNIK Wago−measurement equip.
X2:57 008 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:58 008 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:59 008 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:60 008 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:60 008 13 WAGO−MESSTECHNIK Wago−measurement equip.
X2:61 009 15 WAGO−MESSTECHNIK Wago−measurement equip.
X2:62 009 16 WAGO−MESSTECHNIK Wago−measurement equip.
X2:63 008 13 WAGO−MESSTECHNIK Wago−measurement equip.
X2:63 009 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:64 008 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:65 008 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:66 008 14 WAGO−MESSTECHNIK Wago−measurement equip.
component listing

X2:66 008 14 WAGO−MESSTECHNIK Wago−measurement equip.

X2:67 008 11 WAGO−MESSTECHNIK Wago−measurement equip.
Bauteilliste

X2:68 008 12 WAGO−MESSTECHNIK Wago−measurement equip.

X2:69 008 12 WAGO−MESSTECHNIK Wago−measurement equip.
X2:70 008 15 WAGO−MESSTECHNIK Wago−measurement equip.
X2:70 009 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:71 008 13 WAGO−MESSTECHNIK Wago−measurement equip.
X2:73 008 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:74 008 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:75 008 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:76 008 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:77 008 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:78 008 11 WAGO−MESSTECHNIK Wago−measurement equip.
X3:1 010 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 011 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:2 011 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:3 002 19 SETCKER KABINE/ROPS Con cabin/ROPS
X3:4 010 10 STECKER ROPS/SD conn. ROPS/SR
X3:5 010 12 STECKER ROPS/SD conn. ROPS/SR
X3:6 011 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:7 011 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:8 011 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:9 012 3 STECKER KABINE/ROPS conn. cabin/ROPS
X3:10 012 3 STECKER KABINE/ROPS conn. cabin/ROPS
X3:11 012 4 STECKER KABINE/ROPS conn. cabin/ROPS
X3:12 012 4 STECKER KABINE/ROPS conn. cabin/ROPS
X3:13 012 7 STECKER KABINE/ROPS conn. cabin/ROPS
X3:14 012 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:17 011 6 STECKER KABINE/ROPS conn. cabin/ROPS
X3:18 011 6 STECKER KABINE/ROPS conn. cabin/ROPS
X4:A 008 14 KABINENST. MESST. con. measurem.equipm.
X4:B 008 14 KABINENST. MESST. con. measurem.equipm.
X4:C 008 14 KABINENST. MESST. con. measurem.equipm.
X4:D 008 14 KABINENST. MESST. con. measurem.equipm.
X4:E 008 15 KABINENST. MESST. con. measurem.equipm.
X4:F 009 18 KABINENST. MESST. con. measurem.equipm.
X4:G 009 18 KABINENST. MESST. con. measurem.equipm.
X4:M 009 16 KABINENST. MESST. con. measurem.equipm.
X4:N 009 15 KABINENST. MESST. con. measurem.equipm.
5

X6:1 006 13 STECKER VIBRATION GRO conn. vibration big

X6:2 006 14 STECKER VIBRATION GRO conn. vibration big
X7:1 006 15 STECKER VIBRATION KLE conn. vibration small
X7:2 006 14 STECKER VIBRATION KLE conn. vibration small
X8:1 005 5 STECKER WASSERABSCHEI connector water separator
9

X8:2 005 5 STECKER WASSERABSCHEI connector water separator

X9:1 004 11 STECKER RÜCKFAHRALARM conn. backupalarm
X9:2 004 11 STECKER RÜCKFAHRALARM conn. backupalarm
XS 002 19 Steckdose Socket
582 700 95

XS 011 20 Steckdose Socket

X10:2 005 6 STECKER TAUCHROHRGEBE connector fuel level sensor
X10:3 005 6 STECKER TAUCHROHRGEBE connector fuel level sensor
X14:A 004 10 STECKER SITZKONTAKT connector seat contact switch
X14:B 004 10 STECKER SITZKONTAKT connector seat contact switch
105

X15:1 004 13 STECKER FAHRPUMPE RÜC connectoe driving pump back

X15:2 004 13 STECKER FAHRPUMPE RÜC connectoe driving pump back
008 913
X16:1 76 004 12 STECKER FAHRPUMPE VOR BOMAG
connector driving pump front 817
Name Bl. Pf. Benennung title TYP

10.1 X16:2
X17:1
X17:2
004
012
012
12
3
3
STECKER FAHRPUMPE VOR
STECKER LÜFTER HKL
STECKER LÜFTER HKL
connector driving pump front
conn. blower
conn. blower
Wiring diagram
X17:3 012 4 STECKER LÜFTER HKL conn. blower
X17:4 012 5 STECKER LÜFTER HKL conn. blower
X18:1 012 10 STECKER THERMOFÜHLER conn. sender temp.
X18:2 012 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 012 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X19:2 012 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X20:1 012 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:2 012 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:3 012 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:4 012 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X21:1 005 4 STECKER KÜHLMITTEL connector coolant sensor
Werner
28.06.2004
Seis
28.06.2004

X21:2 005 4 STECKER KÜHLMITTEL connector coolant sensor

X22:1 006 16 ST. VIBRATIONSAUFNEHM connector vibration sensor
X22:2 006 17 ST. VIBRATIONSAUFNEHM connector vibration sensor
X22:3 006 17 ST. VIBRATIONSAUFNEHM connector vibration sensor
X22:4 006 16 ST. VIBRATIONSAUFNEHM connector vibration sensor
X25:2 007 11 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X25:3 007 11 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X25:4 007 10 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X26:1 005 8 STECKER DATENSAMMLER connector data collector
X26:2 005 8 STECKER DATENSAMMLER connector data collector
X26:3 005 2 STECKER DATENSAMMLER connector data collector
X26:4 005 9 STECKER DATENSAMMLER connector data collector
X26:5 005 2 STECKER DATENSAMMLER connector data collector
X26:6 005 9 STECKER DATENSAMMLER connector data collector
X26:7 005 7 STECKER DATENSAMMLER connector data collector
X26:8 005 3 STECKER DATENSAMMLER connector data collector
X26:9 005 7 STECKER DATENSAMMLER connector data collector
X26:10 005 4 STECKER DATENSAMMLER connector data collector
X26:11 005 9 STECKER DATENSAMMLER connector data collector
X26:12 005 12 STECKER DATENSAMMLER connector data collector
X27:1 005 11 STECKER DATENSAMMLER connector data collector
X27:2 005 6 STECKER DATENSAMMLER connector data collector
X27:3 005 10 STECKER DATENSAMMLER connector data collector
X27:4 005 5 STECKER DATENSAMMLER connector data collector
X27:5 005 11 STECKER DATENSAMMLER connector data collector
X27:6 005 9 STECKER DATENSAMMLER connector data collector
X27:7 005 10 STECKER DATENSAMMLER connector data collector
X27:8 005 2 STECKER DATENSAMMLER connector data collector
X27:9 005 5 STECKER DATENSAMMLER connector data collector
component listing

X27:10 005 10 STECKER DATENSAMMLER connector data collector

X27:11 005 10 STECKER DATENSAMMLER connector data collector
Bauteilliste

X27:12 005 10 STECKER DATENSAMMLER connector data collector

X28:1 005 16 STECKER LC−DISPLAY 1 connector LC−display 1
X28:2 005 13 STECKER LC−DISPLAY 1 connector LC−display 1
X28:3 005 13 STECKER LC−DISPLAY 1 connector LC−display 1
X28:4 005 14 STECKER LC−DISPLAY 1 connector LC−display 1
X28:5 005 16 STECKER LC−DISPLAY 1 connector LC−display 1
X28:6 005 17 STECKER LC−DISPLAY 1 connector LC−display 1
X29:1 005 14 STECKER LC−DISPLAY 2 connector LC−display 2
X29:2 005 14 STECKER LC−DISPLAY 2 connector LC−display 2
X29:3 005 15 STECKER LC−DISPLAY 2 connector LC−display 2
X29:4 005 15 STECKER LC−DISPLAY 2 connector LC−display 2
X29:5 005 17 STECKER LC−DISPLAY 2 connector LC−display 2
X29:6 005 17 STECKER LC−DISPLAY 2 connector LC−display 2
X29:7 005 18 STECKER LC−DISPLAY 2 connector LC−display 2
X29:8 005 17 STECKER LC−DISPLAY 2 connector LC−display 2
X30:1 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:2 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:3 003 8 EMR−Stecker Fahrzeug EMR−connector compactor
X30:4 003 7 EMR−Stecker Fahrzeug EMR−connector compactor
X30:5 003 7 EMR−Stecker Fahrzeug EMR−connector compactor
X30:10 003 2 EMR−Stecker Fahrzeug EMR−connector compactor
X30:11 003 2 EMR−Stecker Fahrzeug EMR−connector compactor
X30:12 003 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:13 003 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:14 003 2 EMR−Stecker Fahrzeug EMR−connector compactor
X30:15 003 7 EMR−Stecker Fahrzeug EMR−connector compactor
X30:17 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X30:22 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:23 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X30:24 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X30:25 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X31:1 003 16 EMR−Stecker Motor EMR−connector engine
X31:2 003 17 EMR−Stecker Motor EMR−connector engine
X31:3 003 17 EMR−Stecker Motor EMR−connector engine
X31:4 003 12 EMR−Stecker Motor EMR−connector engine
X31:5 003 14 EMR−Stecker Motor EMR−connector engine
X31:6 003 15 EMR−Stecker Motor EMR−connector engine
6

X31:7 003 17 EMR−Stecker Motor EMR−connector engine

X31:8 003 13 EMR−Stecker Motor EMR−connector engine
X31:9 003 13 EMR−Stecker Motor EMR−connector engine
X31:10 003 8 EMR−Stecker Motor EMR−connector engine
X31:11 003 8 EMR−Stecker Motor EMR−connector engine
9

X31:12 003 7 EMR−Stecker Motor EMR−connector engine

X31:13 003 7 EMR−Stecker Motor EMR−connector engine
X31:14 003 9 EMR−Stecker Motor EMR−connector engine
X31:15 003 9 EMR−Stecker Motor EMR−connector engine
582 700 95

X31:16 003 11 EMR−Stecker Motor EMR−connector engine

X31:17 003 10 EMR−Stecker Motor EMR−connector engine
X31:18 003 10 EMR−Stecker Motor EMR−connector engine
X31:19 003 10 EMR−Stecker Motor EMR−connector engine
X31:20 003 6 EMR−Stecker Motor EMR−connector engine
106

X31:21 003 6 EMR−Stecker Motor EMR−connector engine

X31:22 003 6 EMR−Stecker Motor EMR−connector engine
818 X31:23 003 11 EMR−Stecker Motor BOMAG
EMR−connector engine 008 913 76
Name Bl. Pf. Benennung title TYP
X31:24
Wiring diagram
X31:25
X32:A
003
003
003
11
12
2
EMR−Stecker Motor
EMR−Stecker Motor
EMR − Diagnose
EMR−connector engine
EMR−connector engine
EMR−diagnosis
10.1
X32:B 003 3 EMR − Diagnose EMR−diagnosis
X32:G 003 3 EMR − Diagnose EMR−diagnosis
X32:H 003 3 EMR − Diagnose EMR−diagnosis
X32:K 003 2 EMR − Diagnose EMR−diagnosis
X32:L 003 2 EMR − Diagnose EMR−diagnosis
X33:1 003 19 Trennstelle EMR II conector EMR II
X33:2 003 18 Trennstelle EMR II conector EMR II
X33:3 003 18 Trennstelle EMR II conector EMR II
X33:4 003 19 Trennstelle EMR II conector EMR II
X33:5 003 18 Trennstelle EMR II conector EMR II
X33:6 003 19 Trennstelle EMR II conector EMR II
Werner
28.06.2004
Seis
28.06.2004

X33:7 003 17 Trennstelle EMR II conector EMR II

X33:8 003 20 Trennstelle EMR II conector EMR II
X34:A 004 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:B 004 16 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:C 004 12 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:D 004 13 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:G 004 10 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:H 004 11 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:J 006 3 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:N 003 5 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:P 002 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:R 005 2 DIAGNOSESTECKER ESX connector diagnosis ESX
X35:1 006 4 ESX STECKER esx connector
X35:2 006 12 ESX STECKER esx connector
X35:3 006 16 ESX STECKER esx connector
X35:4 004 11 ESX STECKER esx connector
X35:5 004 10 ESX STECKER esx connector
X35:12 004 3 ESX STECKER esx connector
X35:15 004 10 ESX STECKER esx connector
X35:16 006 10 ESX STECKER esx connector
X35:17 006 18 ESX STECKER esx connector
X35:18 006 11 ESX STECKER esx connector
X35:19 006 11 ESX STECKER esx connector
X35:20 006 4 ESX STECKER esx connector
X35:21 006 3 ESX STECKER esx connector
X35:22 006 10 ESX STECKER esx connector
X35:23 006 5 ESX STECKER esx connector
X35:24 004 11 ESX STECKER esx connector
X35:25 006 8 ESX STECKER esx connector
component listing

X35:26 004 16 ESX STECKER esx connector

X35:27 004 15 ESX STECKER esx connector
Bauteilliste

X35:28 004 2 ESX STECKER esx connector

X35:29 006 4 ESX STECKER esx connector
X35:30 004 9 ESX STECKER esx connector
X35:31 004 5 ESX STECKER esx connector
X35:33 004 13 ESX STECKER esx connector
X35:34 004 5 ESX STECKER esx connector
X35:35 006 17 ESX STECKER esx connector
X35:37 004 5 ESX STECKER esx connector
X35:38 004 2 ESX STECKER esx connector
X35:40 006 11 ESX STECKER esx connector
X35:41 006 11 ESX STECKER esx connector
X35:46 004 15 ESX STECKER esx connector
X35:47 004 16 ESX STECKER esx connector
X35:48 006 14 ESX STECKER esx connector
X35:49 004 12 ESX STECKER esx connector
X35:53 004 12 ESX STECKER esx connector
X35:54 004 9 ESX STECKER esx connector
X35:55 004 18 ESX STECKER esx connector
X35:56 004 7 ESX STECKER esx connector
X35:57 004 7 ESX STECKER esx connector
X35:58 004 8 ESX STECKER esx connector
X35:59 004 8 ESX STECKER esx connector
X35:60 004 8 ESX STECKER esx connector
X35:61 006 17 ESX STECKER esx connector
X35:64 004 13 ESX STECKER esx connector
X35:65 004 18 ESX STECKER esx connector
X35:66 004 19 ESX STECKER esx connector
X35:67 004 19 ESX STECKER esx connector
X35:68 004 19 ESX STECKER esx connector
X36:A 002 4 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 5 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 10 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X37:B 002 12 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 12 STECKER STARTER E−KAS connector starter, e−Box
X39:1 006 9 STECKER 1 LENKRAD connector 1 steering unit
X39:2 006 10 STECKER 1 LENKRAD connector 1 steering unit
X39:3 006 10 STECKER 1 LENKRAD connector 1 steering unit
7

X39:4 006 9 STECKER 1 LENKRAD connector 1 steering unit

X40:1 006 9 STECKER 2 LENKRAD connector 2 steering unit
X40:2 006 10 STECKER 2 LENKRAD connector 2 steering unit
X40:3 006 10 STECKER 2 LENKRAD connector 2 steering unit
X40:4 006 9 STECKER 2 LENKRAD connector 2 steering unit
9

X41:1 006 8 ST. LENKRADKABELBAUM conn. steer. wire harn.

X41:2 006 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:3 006 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:4 006 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
582 700 95

X41:5 006 11 ST. LENKRADKABELBAUM conn. steer. wire harn.

X41:6 006 11 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:7 006 11 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:8 006 11 ST. LENKRADKABELBAUM conn. steer. wire harn.
X42:1 008 18 STECKER OPUS21 conn. OPUS21
107

X42:2 008 18 STECKER OPUS21 conn. OPUS21

X42:3 008 19 STECKER OPUS21 conn. OPUS21
008 913
X42:4 76 008 18 STECKER OPUS21 BOMAG
conn. OPUS21 819
Name Bl. Pf. Benennung title TYP

10.1 X42:5
X42:6
X42:7
008
008
008
19
18
19
STECKER OPUS21
STECKER OPUS21
STECKER OPUS21
conn. OPUS21
conn. OPUS21
conn. OPUS21
Wiring diagram
X42:8 008 19 STECKER OPUS21 conn. OPUS21
X43:1 006 2 STECKER SCHALTER ARML connector switch arm rest
X43:2 006 1 STECKER SCHALTER ARML connector switch arm rest
X44:1 008 13 MESX STECKER MESX Stecker
X44:3 008 15 MESX STECKER MESX Stecker
X44:4 008 14 MESX STECKER MESX Stecker
X44:5 008 14 MESX STECKER MESX Stecker
X44:7 008 10 MESX STECKER MESX Stecker
X44:9 008 12 MESX STECKER MESX Stecker
X44:14 008 5 MESX STECKER MESX Stecker
X44:15 008 4 MESX STECKER MESX Stecker
Werner
28.06.2004
Seis
28.06.2004

X44:23 008 11 MESX STECKER MESX Stecker

X44:26 008 18 MESX STECKER MESX Stecker
X44:27 008 17 MESX STECKER MESX Stecker
X44:28 008 2 MESX STECKER MESX Stecker
X44:29 008 7 MESX STECKER MESX Stecker
X44:30 008 9 MESX STECKER MESX Stecker
X44:31 008 8 MESX STECKER MESX Stecker
X44:32 008 5 MESX STECKER MESX Stecker
X44:33 008 18 MESX STECKER MESX Stecker
X44:35 008 5 MESX STECKER MESX Stecker
X44:36 008 6 MESX STECKER MESX Stecker
X44:37 008 6 MESX STECKER MESX Stecker
X44:38 008 4 MESX STECKER MESX Stecker
X44:41 008 7 MESX STECKER MESX Stecker
X44:46 008 11 MESX STECKER MESX Stecker
X44:47 008 10 MESX STECKER MESX Stecker
X44:53 008 17 MESX STECKER MESX Stecker
X44:54 008 6 MESX STECKER MESX Stecker
X44:55 008 13 MESX STECKER MESX Stecker
X44:56 008 4 MESX STECKER MESX Stecker
X44:57 008 5 MESX STECKER MESX Stecker
X44:58 008 5 MESX STECKER MESX Stecker
X44:59 008 5 MESX STECKER MESX Stecker
X44:60 008 6 MESX STECKER MESX Stecker
X44:65 008 13 MESX STECKER MESX Stecker
X44:66 008 13 MESX STECKER MESX Stecker
X44:67 008 14 MESX STECKER MESX Stecker
X44:68 008 14 MESX STECKER MESX Stecker
X47:A 008 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
component listing

X47:B 008 12 STECKER AUFN. PLEIGER conn. sender PLEIGER

X47:C 008 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
Bauteilliste

X48:1 008 8 STECKER AUFN. VORNE conn. sender front

X48:2 008 7 STECKER AUFN. VORNE conn. sender front
X48:3 008 7 STECKER AUFN. VORNE conn. sender front
X48:4 008 8 STECKER AUFN. VORNE conn. sender front
X49:1 008 10 STECKER AUFN. HINTEN conn. sender rear
X49:2 008 9 STECKER AUFN. HINTEN conn. sender rear
X49:3 008 9 STECKER AUFN. HINTEN conn. sender rear
X49:4 008 10 STECKER AUFN. HINTEN conn. sender rear
X50:1 007 13 ST. PLATTENFREQ. conn. plate−freq.
X50:2 007 13 ST. PLATTENFREQ. conn. plate−freq.
X50:3 007 13 ST. PLATTENFREQ. conn. plate−freq.
X51:1 006 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X51:2 006 1 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X51:3 006 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X52:1 004 3 STECKER DRUCKSENSOR connector pressure sensor
X52:2 004 3 STECKER DRUCKSENSOR connector pressure sensor
X53:B 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 012 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 012 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:L 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 012 11 STECKER HEIZSTEUERUNG conn. heating controller
X54:2 012 11 STECKER HEIZSTEUERUNG conn. heating controller
X54:3 012 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:4 012 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:6 012 7 STECKER HEIZSTEUERUNG conn. heating controller
X54:11 012 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:12 012 11 STECKER HEIZSTEUERUNG conn. heating controller
X55:1 011 11 STECKER WISCHER HINTE connector wiper rear
X55:2 011 10 STECKER WISCHER HINTE connector wiper rear
X55:3 011 10 STECKER WISCHER HINTE connector wiper rear
X55:4 011 10 STECKER WISCHER HINTE connector wiper rear
X56:1 011 14 STECKER WISCHER VORNE conn. wiper front
X56:2 011 13 STECKER WISCHER VORNE conn. wiper front
X56:3 011 13 STECKER WISCHER VORNE conn. wiper front
X56:4 011 12 STECKER WISCHER VORNE conn. wiper front
X57:1 003 15 Stecker Motor connector engine
8

X57:2 003 13 Stecker Motor connector engine

X57:3 003 14 Stecker Motor connector engine
X57:4 003 12 Stecker Motor connector engine
X57:5 003 14 Stecker Motor connector engine
X57:6 003 15 Stecker Motor connector engine
9

X57:8 003 13 Stecker Motor connector engine

X57:9 003 13 Stecker Motor connector engine
X57:10 003 8 Stecker Motor connector engine
X57:11 003 8 Stecker Motor connector engine
582 700 95

X57:12 003 7 Stecker Motor connector engine

X57:13 003 7 Stecker Motor connector engine
X57:14 003 9 Stecker Motor connector engine
X57:15 003 9 Stecker Motor connector engine
X57:16 003 11 Stecker Motor connector engine
108

X57:17 003 10 Stecker Motor connector engine

X57:18 003 10 Stecker Motor connector engine
820 X57:19 003 10 Stecker Motor BOMAG
connector engine 008 913 76
Name Bl. Pf. Benennung title TYP
X57:20
Wiring diagram
X57:21
X57:22
003
003
003
6
6
6
Stecker Motor
Stecker Motor
Stecker Motor
connector engine
connector engine
connector engine
10.1
X57:23 003 11 Stecker Motor connector engine
X57:24 003 11 Stecker Motor connector engine
X57:25 003 12 Stecker Motor connector engine
X58:2 010 17 STECKER STVZO VL Con. STVZO FL
X58:3 010 7 STECKER STVZO VL Con. STVZO FL
X58:5 010 2 STECKER STVZO VL Con. STVZO FL
X58:6 010 2 STECKER STVZO VL Con. STVZO FL
X58:6 010 7 STECKER STVZO VL Con. STVZO FL
X58:6 010 17 STECKER STVZO VL Con. STVZO FL
X59:2 010 19 STECKER STVZO VR Con. STVZO FR
X59:3 010 7 STECKER STVZO VR Con. STVZO FR
Werner
28.06.2004
Seis
28.06.2004

X59:5 010 2 STECKER STVZO VR Con. STVZO FR

X59:6 010 2 STECKER STVZO VR Con. STVZO FR
X59:6 010 7 STECKER STVZO VR Con. STVZO FR
X59:6 010 19 STECKER STVZO VR Con. STVZO FR
X60:1 010 18 STECKER STVZO HL Con. STVZO BL
X60:2 010 18 STECKER STVZO HL Con. STVZO BL
X60:3 010 6 STECKER STVZO HL Con. STVZO BL
X60:4 010 6 STECKER STVZO HL Con. STVZO BL
X61:1 010 19 STECKER STVZO HR Con. STVZO BR
X61:2 010 19 STECKER STVZO HR Con. STVZO BR
X61:3 010 8 STECKER STVZO HR Con. STVZO BR
X61:4 010 8 STECKER STVZO HR Con. STVZO BR
X62:1 007 19 STECKER DIOS PLATTEN con. DIOS−plates
X62:2 007 19 STECKER DIOS PLATTEN con. DIOS−plates
X62:3 007 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:4 007 16 STECKER DIOS PLATTEN con. DIOS−plates
X62:5 007 16 STECKER DIOS PLATTEN con. DIOS−plates
X62:6 007 17 STECKER DIOS PLATTEN con. DIOS−plates
X62:7 007 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:8 007 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:9 007 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:10 007 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:11 007 16 STECKER DIOS PLATTEN con. DIOS−plates
X62:12 007 17 STECKER DIOS PLATTEN con. DIOS−plates
X62:13 007 19 STECKER DIOS PLATTEN con. DIOS−plates
X62:14 007 20 STECKER DIOS PLATTEN con. DIOS−plates
X72:1 007 14 ST. PROP.−PUMPE PLATT con. plate−pump
X72:2 007 14 ST. PROP.−PUMPE PLATT con. plate−pump
X74:1 008 14 STECKER DRUCKER con. printer
component listing

X74:2 008 14 STECKER DRUCKER con. printer

X74:3 008 14 STECKER DRUCKER con. printer
Bauteilliste

X74:4 008 15 STECKER DRUCKER con. printer

X74:5 008 14 STECKER DRUCKER con. printer
X75:2 009 16 SUB−D STECKER BCM INT con. SUB−D BCM
X75:7 009 15 SUB−D STECKER BCM INT con. SUB−D BCM
X76:1 009 17 STECKER VERS. BCM con. Power−sup. BCM
X76:2 009 17 STECKER VERS. BCM con. Power−sup. BCM

Y04 006 17 Magnetventil Bremse Solenoid valve, brake MAX. 1.8A

Y07 006 15 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high 0.4 .. 1.2A
Y08 006 13 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low 0.4 .. 1.2A
Y14 012 14 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 012 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y16 004 13 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 0.4 .. 1.2A
Y17 004 12 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 0.4 .. 1.2A
Y30 004 15 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 0.4 .. 1.2A
Y31 004 16 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear 0.4 .. 1.2A
Y92 006 7 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. 0.4 .. 1.2A
Y93 006 6 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. 0.4 .. 1.2A
Y98 007 14 Magnetventil Vibrationsfrequenz, hinten Solenoid valve, vibrat.freq.,rear 0.4 .. 1.2A
Y112 006 4 Magnetventil Lenkung (Y1) Solenoid valve, steering (Y1) MAX. 1.8A
Y113 006 3 Magnetventil Lenkung (Y2) Solenoid valve, steering (Y2) MAX. 1.8A
Y122 007 16 Magnetventil Platten heben Solenoid valve, lift plates MAX. 1.8A
Y123 007 17 Magnetventil Platten senken Solenoid valve, let down plates MAX. 1.8A
Y137 003 10 EMR Verstellung EMR adjustment
Y138 012 10 Magnetveentil Heizung Solenoid valve, heating unit 1A
Y140 008 10 Magnetventil Erreger auf solenoid valve exciter up 0.4 .. 1.2A
Y141 008 11 Magnetventil Erreger ab solenoid valve exciter down 0.4 .. 1.2A
Y142 007 18 Magnetventil Plattenverschieben Links solenoid valve, plate displace left MAX. 1.8A
Y143 007 18 Magnetventil Plattenverschieben rechts solenoid−valve, plate displace right MAX. 1.8A
Y144 007 19 Magnetventil Platten Schwimmstellung solenoid−valve, plate swimming−position MAX. 1.8A
Y145 007 20 Magnetventil Platten (Priorität) solenoid−valve, plate (priority) MAX. 1.8A
99
582 700 95
109

008 913 76 BOMAG 821

10.1 Wiring diagram

822 BOMAG 008 913 76

Wiring diagram 10.1

008 913 76 BOMAG 823

10.1 Wiring diagram
WAGO smart DESIGNER 4.0

1 05756417

2 3 x 05756540 "R" + 793-501

5 05756539 "R" + 793-501

6 05756537
7 3 x 05756540 "R" + 793-501

10 05756537
11 05756540 "R" + 793-501

12 05756535 "R" + 793-501

13 05756537
14 2 x 05756538 "R" + 793-501

16 2 x 05756539 "R" + 793-501

18 05756537
19 4 x 05756540 "R" + 793-501

23 05756537
24 4 x 05756540 "R" + 793-501

28 2 x 05756539 "R" + 793-501

30 05756537
31 05756540 "R" + 793-501

32 05756539 "R" + 793-501

33 05756537
34 4 x 05756540 "R" + 793-501

38 05756539 "R" + 793-501

39 05756537
40 4 x 05756540 "R" + 793-501

Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:04:26 Seite 1

824 BOMAG 008 913 76

Wiring diagram 10.1
WAGO smart DESIGNER 4.0

44 05756537
45 05756540 "R" + 793-501

46 05756535 "R" + 793-501

47 05756537
48 05756540 "R" + 793-501

49 05756535 "R" + 793-501

50 05756537
51 05756538 "R" + 793-501

52 2 x 05756540 "R" + 793-501

54 05756539 "R" + 793-501

55 05756537
56 3 x 05756540 "R" + 793-501

59 05756538 "R" + 793-501

60 05756537
61 3 x 05756540 "R" + 793-501

64 05756535 "R" + 793-501

65 05756537
66 2 x 05756540 "R" + 793-501

68 05756539 "R" + 793-501

69 05756537
70 3 x 05756540 "R" + 793-501

73 05756535 "R" + 793-501

74 05756537
75 2 x 05756540 "R" + 793-501

77 05756539 "R" + 793-501

78 05756537
79 05756417

Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:04:26 Seite 2

008 913 76 BOMAG 825

10.1 Wiring diagram
WAGO smart DESIGNER 4.0

Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:16:28 Seite 6

826 BOMAG 008 913 76

Wiring diagram 10.1
WAGO smart DESIGNER 4.0

Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:16:28 Seite 7

008 913 76 BOMAG 827

10.1 Wiring diagram
WAGO smart DESIGNER 4.0

1 05756417

2 4 x 05756540 "R" + 793-501

6 05756537
7 2 x 05756540 "R" + 793-501

9 4 x 05756538 "R" + 793-501

13 2 x 05756539 "R" + 793-501

15 05756537
16 05756417

Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Optionen Beleuchtung Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:19:48 Seite 1

828 BOMAG 008 913 76

Wiring diagram 10.1
WAGO smart DESIGNER 4.0

Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Optionen Beleuchtung Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:22:27 Seite 2

008 913 76 BOMAG 829

10.1 Wiring diagram
WAGO smart DESIGNER 4.0

1 05756417

2 2 x 05756540 "R" + 793-501

4 05756539 "R" + 793-501

5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501

9 05756539 "R" + 793-501

10 05756537
11 2 x 05756540 "R" + 793-501

13 05756539 "R" + 793-501

14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501

17 05756540 "R" + 793-501

18 05756537
19 05756540 "R" + 793-501
20 05756539 "R" + 793-501

21 05756537
22 2 x 05756438 "R" + 793-501

24 05756421
25 05756417

Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Klemmenleiste X2 / Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:27:03 Seite 1

830 BOMAG 008 913 76

Wiring diagram 10.1
WAGO smart DESIGNER 4.0

Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Klemmenleiste X2 / Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:29:27 Seite 2

008 913 76 BOMAG 831

10.1 Wiring diagram

832 BOMAG 008 913 76

10.2 Hydraulic diagram

008 913 76 BOMAG 833

10.2 Hydraulic diagram

834 BOMAG 008 913 76

Hydraulic diagram 10.2

008 913 76 BOMAG 835

10.2 Hydraulic diagram

836 BOMAG 008 913 76