Instructions For Repair: BW 213 DH / PDH - 4 BW 214 DH / PDH - 4
Instructions For Repair: BW 213 DH / PDH - 4 BW 214 DH / PDH - 4
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 .....
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
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
Introduction
1.1 For eword
! 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.
! 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.
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:
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.
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.
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
!
Fig. 1
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
API: CG-4/CH-4
SAE 10W/40
SAE 15W/40
Fuel
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm2/s at 40 °C
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
32 BOMAG Maschinentyp
2 Tests and adjustments
Fig. 1
2. RPM-meter for diesel engine
Fig. 2
3. Hydraulic test case, large
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
i Note
1X 25 bar pressure gauge
1X 150 bar pressure gauge
2X 400 bar pressure gauges
4 pressure test hoses
Fig. 4
Fig. 5
6. Pressure gauge
Fig. 6
7. Adapter for pressure test hose
Fig. 7
8. Gear pump testing device
Fig. 8
Fig. 9
10. Electric test case
Fig. 10
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
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
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
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.
! 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
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.
! 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.
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.
! 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
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
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
Fig. 6
! 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.
! 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
! 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.
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.
Fig. 1
3. Flushing filter (S connection)
Fig. 2
7. Flushing filter (L connection)
Fig. 3
11. SAE-flange 1“ - 20S
Fig. 4
Fig. 5
15. Reducing fitting 18L - 15L
Fig. 6
16. Reducing fitting 25S - 20S
Fig. 7
17. Reducing fitting 20S - 16S
Fig. 8
Fig. 9
19. Connecting socket 16S
Fig. 10
20. Connecting fitting 20S
Fig. 11
21. Connecting fitting 25S
Fig. 12
Fig. 13
23. Elbow 20S
Fig. 14
24. Elbow 25S
Fig. 15
! 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.
Before flushing
Change the filter element
1. Change the hydraulic oil filter element (1).
Fig. 2
Fig. 3
Bleeding
1. Always bleed the closed hydraulic circuit if lines
had been removed or connected.
Fig. 4
Fig. 5
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.
Fig. 2
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
!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.
Fig. 10
Fig. 11
Bleeding the travel circuit
22. Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 12
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
!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.
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
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)
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.
Fig. 2
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
!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
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.
Fig. 13
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.
Fig. 2
4. Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".
Fig. 3
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.
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.
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
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
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
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.
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
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.
Maschinentyp BOMAG 91
Maschinentyp BOMAG 92
4.1 Technical Manual / Basic Electrics
Service Training
Electrics
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
Table of contents
1 Confirmation of changes
1.1 Document
1.2 Software
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.
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)
1) 3)
After reaching the warning limit! Shut-down currently deactivated via parameter
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
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.
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.
„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!
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.
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
7 BVC
8 BVC
9 BVC
Note: Parameter adjustments can only be performed when the engine is not running.
Version/Status: V2.07 / 24.06.05 Functions of ESX control Page 11 of 67
Author: Seis / TE
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:
• 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.
• 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.
Attention: The steering unit can only be changed when the engine is not running!
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.
• The measurements (forward/reverse) must be started by entering a code number. The code number
required to teach the travel direction is as follows:
• 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:
• 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.
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.
START
Machine on level
ground
Machine on level
ground
enter 9999
enter 2010
Travel lever in
neutral position
FINISHED
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: Execute this function only AFTER "Teaching electronic end stops of angle sensor".
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:
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.
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)
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 "- - - - - "
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)
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)
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!
• 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)
•
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.
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 ---
167
4.2
168
4.2
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.
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Signals on the ESX Control
008 913 76
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
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
169
4.2
170
4.2
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
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Signals on the ESX Control
008 913 76
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
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
171
4.2
172
4.2
BOMAG
Version/Status: V2.07 / 24.06.05 Description of Signals on the ESX Control Page 26 of 67
Author: Seis / TE
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Signals on the Data Collector
008 913 76
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.
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 ---
173
4.2
174
4.2
BOMAG
X27:11 Not used ---
X27:12 Not used ---
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Signals on the Travel Lever
008 913 76
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.
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)
175
4.2
176
4.2
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.)
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Signals on the LC-Display
008 913 76
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.
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 ---
177
4.2
178
4.2
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 ---
008 913 76
Technical Manual / Electrics
Service Training WZ - 4 Description of Signals on the DIOS-Module
008 913 76
Technical Manual / Electrics
BOMAG
Version/Status: V2.07 / 24.06.05 Description of Signals on the DIOS-Module Page 33 of 67
Author: Seis / TE
179
4.2
4.2 Technical Manual / Electrics
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!
008 913 76
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
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
Note: Errors with error reaction 1 and 2 are only warning messages and are NOT stored in the error log.
181
4.2
182
4.2
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...
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Fault Codes on Control
008 913 76
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
183
4.2
184
4.2
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
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.
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Fault Codes on Control
008 913 76
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
185
4.2
186
4.2
BOMAG
Version/Status: V2.07 / 24.06.05 Description of Fault Codes on Control Page 40 of 67
Author: Seis / TE
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Fault Codes on Control
008 913 76
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.
187
4.2
188
4.2
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
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Fault Codes on Control
008 913 76
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
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
189
4.2
190
4.2
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)
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Fault Codes on Control
008 913 76
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
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)
191
4.2
192
4.2
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
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Fault Codes on Control
008 913 76
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
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
193
4.2
194
4.2
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
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Fault Codes on Control
008 913 76
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
Version/Status: V2.07 / 24.06.05 Description of Fault Codes on Control Page 49 of 67
Author: Seis / TE
195
4.2
196
4.2
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
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)
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Input Codes on Control
008 913 76
11 Input Codes for ESX Control
Display and adjustment functions can generally only be accessed by entering "service code" 9999 beforehand!
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)
197
4.2
198
4.2
BOMAG
2 = Reverse
1027 Display "Travel lever release" 0 = locked
1 = released
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Input Codes on Control
008 913 76
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
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)
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)
199
4.2
200
4.2
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
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Input Codes on Control
008 913 76
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
BOMAG
Input code Description of display function Display values
1150 Current travel speed (in km/h) 0,00..20,00
201
4.2
202
4.2
BOMAG
Display "Minimum current value steering valve right" Display in mA
2109 Display "Maximum current value steering valve right" Display in mA
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Input Codes on Control
008 913 76
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
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.
203
4.2
204
4.2
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
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Input Codes on Control
008 913 76
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
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
205
4.2
206
4.2
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.
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Input Codes on Control
008 913 76
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
BOMAG
Storing the learned values "saved"
1
Only optional function! The logical sense of rotation is automatically adjusted
207
4.2
208
4.2
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
008 913 76
Technical Manual / Electrics
Service Training WZ – 4 Description of Input Codes on Control
008 913 76
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
Version/Status: V2.07 / 24.06.05 Description of Input Codes on Control Page 63 of 67
Author: Seis / TE
209
4.2
4.2 Technical Manual / Electrics
Service Training WZ – 4
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
Service Training WZ – 4
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)
Service Training WZ – 4
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.
Service Training WZ – 4
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)
Service Training
Table of contents
Foreword A1
Documentation A2
General A3
New developments A5
Maintenance C1
Maintenance chart C2
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
Service Training
Vibration F1
Vibration pump F3
High pressure relief valves F6
Control F7
Vibration motor F8
Drum F11
Test and adjustment points, vibration system F13
Trouble shooting vibration F15
Steering G1
Charge pump G2
Steering pump G3
Steering valve G5
Articulated joint G7
Measuring and adjustment points G9
Trouble shooting steering G10
Electric - Training
Wiring diagram
Hydraulic diagram
Service Training
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 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.
Service Training
Documentation
For valid BOMAG single drum roller serie -4 :
BW 213 DH-4
BW 214 DH-4
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.
Service Training
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.
Service Training
Important characteristics of the new generation of single drum rollers are
• 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.
Service Training
Novelties
The multi-function travel lever and the display
Service Training
Control, operation, data collector,
Service Training
Diesel engine with EMR
Service Training
Travel System
Service Training
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.
Status: 2005-01-28
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
Drum drive:
Manufacturer: Sauer-Danfoss
http://bsa.bomag.spx.com/bsa/tk_components/english/search_components_result.asp?... 28.01.2005
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 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))
http://bsa.bomag.spx.com/bsa/tk_components/english/search_components_result.asp?... 28.01.2005
http://bsa.bomag.spx.com/bsa/tk_components/english/search_components_result.asp?... 28.01.2005
Service Training
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.
Service Training
Maintenance table
Service Training
Service Training
Service Training
Service Training
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.
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 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.
Service Training
Cross-sectional total view
Service Training
Service side
3 4
2
5
6
14
9 8
13 12 11 10
Service Training
Starter side
3
1
1 Flywheel
2 Ground cable
3 Starter
4 Turbo charger
5 Generator
6 Coolant temperature switch
Service Training
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
Service Training
Lubrication oil circuit
3 1
5 4
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
Service Training
Fuelsystem
7
1a
1b
1c
Fuel tank
1d
Service Training
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
Service Training
Fuel prefilter with water separator
1
2
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 dirt / water sediment bowl with water level warning sensor
Service Training
Function:
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.
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.
Bleed the system with the manual fuel pump and then tighten the bleeding screw.
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!
Service Training
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).
• 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.
• 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.
• displacement measuring system in the EMR actuator [Y 137] (current position of the injection pump
control rod)
• 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
Service Training
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.
Control unit
EMR II
14 17 18 9 13 22 20 21 11 2 1 5 7
Connecting cable
Engine wiring harness
Control unit EMR II
BOMAG
EMR engine wiring harness
Connection overview EMR sensors/actuators on engine
- D 13 -
251
4.3
4.3 Technical Manual / DH/PDH
Service Training
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
Service Training
Plug assignment X 31 (engine plug on EMR control unit)
Service Training
Plug assignment X 30 (vehicle plug on EMR control unit)
Service Training
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
Service Training
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.
Service Training
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.
Service Training
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 2 (Signal)
Pin 1 (AGND)
Ventilation
Service Training
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.
Service Training
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
Service Training
Trouble shooting
For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)
Service Training
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.
• 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)
• Frequency of fault
Fault messages for non-present / rectified faults can be deleted with SERDIA.
• Function test: With the engine shut down the control outputs and the travel of the governor rod can
be activated.
• 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).
Connection of SERDIA
Service Training
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.
• 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)
• Frequency of fault
Fault messages for non-present / rectified faults can be deleted with SERDIA.
• Function test: With the engine shut down the control outputs and the travel of the governor rod can
be activated.
• 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).
Service Training
For this purpose the PC or Laptop is connected to the diagnostic interface with a special interface cable.
Replacement of system
components
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.
Service Training
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.
• 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
• 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
Service Training
Explanation of pictograms
During the following work the following pictograms are used for the reason of simplicity:
Service Training
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.
• 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.
• the power
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.
Service Training
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.
• cylinder crankcase,
• camshaft,
• plunger
However, in cases of interest for BOMAG engineers the engine will not be overhauled completely, but
individual injection pumps will be replaced.
This results in a certain installation measurement for the engine drive, which is stamped on the engine
type plate.
Note:
If an injection pump and/or nozzle is replaced, the respective high pressure line between pump and
nozzle must also be replaced..
Service Training
Fig. 3:
Fig. 4:
Fig. 5:
Note:
Fig. 6:
Service Training
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:
Fig. 8:
Fig. 9:
Determination of the compensation shim thickness when replacing plug-in fuel injection pumps
Service Training
On the engine type plate column - EP – contains a code for the plug-in fuel injection pump for each
cylinder.
295
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
Service Training
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
Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from
table 1.
Service Training
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
Service Training
A=XXX
Service Training
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
Service Training
Ek Lo+A/100
Z
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..
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.
Service Training
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.
The real compensation shim thickness „Ss“ is determined with the help of table 2.
Service Training
• see table 1
• Ts = Ek - (Lo + A/100)
Ts = 120,875 mm - (117,5 + 42/100 mm)
Ts = 2.995 mm
Ts = 3,0 mm
Fig. 16:
Service Training
9. Turn the injection pump control lever to
approx. middle position.
Fig. 17:
Fig. 18:
Note:
Fig. 19:
Service Training
12. Slightly oil the screws and tighten them
evenly with 5Nm.
Fig. 20:
Fig. 21:
Fig. 22:
Service Training
15. Tighten the screws again for 60° and
continue in stages with tightening torques of
7 Nm, 10 Nm and 30 Nm.
Note:
Fig. 23:
Note:
Fig. 24:
19. Slightly oil the O-ring of the crankcase ventilation. Reassemble the crankcase ventilation. Tightening
torque 9 +/- 1Nm
Service Training
Explanation of pictograms
During the following work the following pictograms are used for the reason of simplicity:
Service Training
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
Service Training
Auxiliary drive, diesel engine
1
3
Service Training
Starter side, diesel engine
Service Training
Exhaust and starter side, diesel engine
Service Training
Travel system
15
Service Training
The travel system of the single drum rollers is a closed hydraulic circuit and consists
mainly of:
• 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.
Service Training
Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.
4
1 2
Charging
Service Training
The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is
proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing
angle of swash plate) of the pump.
7 1
6
5
Fig. 1: Travel pump
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.
Service Training
Cross-sectional view of travel pump
2
4
5
1 3
9
10
8
11
Service Training
View of the rotating group
4 3
5
1 Working pistons
2 Slipper pad
3 Pre-tensioning spring
4 Cylinder block
5 Drive shaft
Service Training
Description of function
2 3 4 5 6
1
8 6 7
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).
Service Training
When moving the swash plate out of neutral position, the working pistons will perform a stroke
movement with every rotation of the cylinder block.
The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.
During a full rotation of the cylinder block each working piston will move through the bottom and top dead
centre back to the initial position. During this movement each piston performs a complete stroke.
During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.
Service Training
Tandem pump, connections and adjustment points
38
Thermostat
housing
Service Training
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
Service Training
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
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:
Service Training
Multi-function valves
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
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.
Service Training
In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the
pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override
works as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the
high pressure relief valve is higher than the pressure level of the pressure override. The high pressure
relief valves will only respond if the pressure override is not able to swash the pump back quick enough
in case of sudden pressure peaks.
2 3
4
5
1
6
9 7
8
10
11
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!
Service Training
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
Service Training
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
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)
Service Training
.
5 7 8
6
9
11
10
4
2
Service Training
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 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.
Service Training
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.
Service Training
Manual releasing of brake on axle drive
For manual releasing of the brakes on the rear axle you should proceed as follows:
• Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.
• To release the brake tighten the screw for max. 1 complete turn.
Attention!
Service Training
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
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.
Service Training
Brake control
During operation the closed hydrostatic travel circuit has the function of a service brake. When moving
the travel lever from full forward or reverse position towards neutral, the travel pump will follow towards
zero position relative to the movement of the travel lever. The oil flow is thereby reduced and the
machine is hydraulically braked. When moving the travel lever to neutral position, the pump will also
return to neutral, the supply of oil is interrupted and the hydraulic circuit brakes the machine to standstill.
However, since minor leaks cannot be avoided in any hydraulic circuit and such minor leaks will cause
creeping of the machine when it is parked on a slope with the engine running, the machine is additionally
equipped with multi-disc brakes in drum drive and both wheel drives. When engaging the travel lever in
neutral position the multi-disc brakes will close and the machine can be parked on slopes with the
engine running and without the risk of creeping.
However, these parking brakes can also be operated via a 3/2-way solenoid valve. In de-energized
condition the multi-disc brakes in the travel drives are unloaded. The charge pressure to the brakes is
interrupted and the oil from the brake housings flows as leak oil back into the tank.
If the brake solenoid valve is supplied with current while the engine is running and the brake is open,
the connection of the brake line to the tank is interrupted and oil from the charge circuit is guided to the
brake pistons. The oil pressure works against the spring force of the brake spring and relieves the brake
discs.
Service Training
Manual drum drive brake release (in the reduction gear)
Brake releasing device
in operation position
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.
Service Training
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
Service Training
Brake control BW 213 (with Sauer motor 51C110 and CR 31)
Brake valve
Charge pressure
Brake releasing pressure
Leak oil
Service Training
Test and adjustment points, travel system
Service Training
Travel pump
2
2
3
1
1
Service Training
Travel and vibration pump
Service Training
Travel motor (drum drive)
3 4
5
2 1
3
2
4 1
Service Training
Travel motor (axle drive)
2
1
3
5
Service Training
Speed sensor and travel pressure sensor
Service Training
Brake valve
3 4
1
Service Training
Travel lever
Service Training
Trouble shooting
For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)
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.
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.
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
Service Training
Vibration
3
4
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.
vibration pump,
Vibration motor
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.
Service Training
Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract
from the basic weights.
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.
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
Service Training
Function
1 2
5 4 3
1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate
Service Training
1
2
5
4 3
1 Control
2 Servo piston
4 Attachment plate
5 Spool valve
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.
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.
2 Closed circuit
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.
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.
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.).
A MA
3 1
B MB
1 Vibration motor
2 Flushing valve
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
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.
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.
Service Training
Drum
4
14
5 9
7 13
6
10
3 8 11
12
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
Service Training
Vibration motor
5 3
1
1 2
2
4
3
2 31
Service Training
Service Training
Trouble shooting
For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)
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.
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.
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
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
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.
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.
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
1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals
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.
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
Service Training
240 bar
∆p = 175 bar
240 bar
0,5 bar
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.
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.
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.
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.
Service Training
Test and adjustment points steering points
3 4
1
2
2
Steering pump
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.
Service Training
Trouble shooting
For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)
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.
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
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).
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.
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)
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.
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
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.
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.
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
! 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.
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!
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.
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.+
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.
! 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
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.
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.
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.
* Optional equipment
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.
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.
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.
! 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.
Fig. 1
1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap
Fig. 1
2. Suction lifter
commercial
Fig. 2
Commercial
Fig. 1
4. Window glass bonding agent
Fig. 2
5. Activator
Fig. 3
Fig. 4
! 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
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
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
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
Fig. 1
2. Assembly device for side plate
Fig. 2
3. Assembly device for coupling hub abd flanged
hub
Fig. 3
4. Pressing plate for cylinder roller bearing
Fig. 4
Fig. 5
6. Pressing bushing for radial seal
Fig. 6
7. Lifting device for exciter unit
Fig. 7
Fig. 1
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
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
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
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
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
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
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
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
Fig. 3
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
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
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
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
i Note
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 18
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
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
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
Fig. 27
3. Attach the disassembly device to the side plate
(Fig. 28) and force off the side plate.
Fig. 28
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
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
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
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
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
! 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
! 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
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
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
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
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
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
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
Fig. 77
! 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
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
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
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
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
! 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
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
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
! 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
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
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
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
Fig. 4
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
i Note
There must be play.
Fig. 8
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
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
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
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
Fig. 5
6. Disassembly device
Fig. 6
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
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
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
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
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
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
Fig. 16
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
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
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
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.
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
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
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
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.
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
Fig. 33
RDE 91 001-03-R/05.03
Konstantmotor A2FM/E ersetzt / replaces 04.00
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.
A2F A2F
A2FM Pos.B
Pos.D
Pos.A
Schnittbild
Sectional view
A2FE
Schnittbild
Sectional view
A2FE
Triebwerk ausbauen
Removal the rotary group
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
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
Printed in Germany
RDE 91 001-03-R/05.03
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
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
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
D1240138
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
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
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
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
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.
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
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).
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.
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.
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
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.
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.
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).
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.
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.
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).
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.
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).
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).
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
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).
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).
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).
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.
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).
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.
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
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).
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.
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).
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.
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
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
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).
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
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.
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.
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).
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
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
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.
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).
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).
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.
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
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.
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.
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.
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.
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.
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.
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).
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.
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.
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).
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.
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.
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.
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.
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.
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
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
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
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
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
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
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
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
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
Wiring diagram
BOMAG
28.06.2004
001 001
Seis Stromlaufplan 582 700 95
28.06.2004
801
10.1
K11
2:10
87
K30 11:1
30 4:1 K11:87 5:1
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
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
31 31 3:1
28.06.2004
1 1
008 913 76
Wiring diagram
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
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
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
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
28.06.2004
1 1
008 913 76
Wiring diagram
008 913 76
F24 ESX Fahrsteuerung CAN1− DIOS Platten
15A
4:17 CAN1− 7:14
2
X1:29A
Wiring diagram
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
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
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
28.06.2004
1 1
008 913 76
Wiring diagram
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
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
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−
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
Pot. 15
Leistung
Elektronik
8.5V
AGND MESX
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
BRAKE MESX
v.l.
v.r.
6:17 −
D+ MESX BEL MESX 2 2
2:6 10:4
31.1
28.06.2004
1 1
008 913 76
Wiring diagram
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
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
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
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
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
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
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
28.06.2004
1 1 582 700 95
Seis Kabinenausrüstung, Beleuchtung, Radio, Tachograph
811
28.06.2004
10.1
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
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
28.06.2004
1 1
008 913 76
Wiring diagram
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
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
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
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
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
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
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
1 05756417
6 05756537
7 3 x 05756540 "R" + 793-501
10 05756537
11 05756540 "R" + 793-501
13 05756537
14 2 x 05756538 "R" + 793-501
18 05756537
19 4 x 05756540 "R" + 793-501
23 05756537
24 4 x 05756540 "R" + 793-501
30 05756537
31 05756540 "R" + 793-501
33 05756537
34 4 x 05756540 "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 :
44 05756537
45 05756540 "R" + 793-501
47 05756537
48 05756540 "R" + 793-501
50 05756537
51 05756538 "R" + 793-501
55 05756537
56 3 x 05756540 "R" + 793-501
60 05756537
61 3 x 05756540 "R" + 793-501
65 05756537
66 2 x 05756540 "R" + 793-501
69 05756537
70 3 x 05756540 "R" + 793-501
74 05756537
75 2 x 05756540 "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 :
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 :
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 :
1 05756417
6 05756537
7 2 x 05756540 "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 :
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 :
1 05756417
5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501
10 05756537
11 2 x 05756540 "R" + 793-501
14 05756537
15 05756540 "R" + 793-501
16 05756538 "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 :
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 :