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Training BW226DH-4 BVC

TRAINING BW226DH-4 BVC

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0% found this document useful (0 votes)

25 views

Training BW226DH-4 BVC

TRAINING BW226DH-4 BVC

Uploaded by

hugoalfredo3974

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

Available Formats

Download as PDF, TXT or read online on Scribd

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Service - Manual

BW 226 DH-4
BVC
S/N 101 582 86 1001 > 101 582 86 1108

Single drum roller

1.1 Introduction
This manual addresses the professionally qualified
personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.

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

Use only genuine BOMAG spare parts.

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

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

10 BOMAG 008 914 20

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

l Use protective clothes like hard hat, safety boots

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

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

008 914 20 BOMAG 11

1.2 Safety regulations

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

12 BOMAG 008 914 20

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

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

008 914 20 BOMAG 13

1.2 Safety regulations

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

14 BOMAG 008 914 20

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

008 914 20 BOMAG 15

1.3 General repair instructions

General Electrics
1.3 General repair instructions

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

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

16 BOMAG 008 914 20

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

008 914 20 BOMAG 17

1.3 General repair instructions

Generator Starter motor

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

18 BOMAG 008 914 20

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

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

008 914 20 BOMAG 19

1.3 General repair instructions

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

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

20 BOMAG 008 914 20

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

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

Notes and measures to be applied before starting

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

008 914 20 BOMAG 21

1.3 General repair instructions

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

22 BOMAG 008 914 20

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

Fig. 2

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

008 914 20 BOMAG 23

1.3 General repair instructions

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

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

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

24 BOMAG 008 914 20

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

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

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

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

008 914 20 BOMAG 25

1.3 General repair instructions

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

26 BOMAG 008 914 20

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

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

6, 8, 10, 12)

Fig. 9 Identification of nuts

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

Strength class of Strength class of associated

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

Nuts for screw joints without specified load factor

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

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

008 914 20 BOMAG 27

1.3 General repair instructions

Identification in clock system Identification of UNF-threads

Fig. 10 Identification of nuts in clock system

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

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

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

Studs and brake rods

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

28 BOMAG 008 914 20

General repair instructions 1.3
Cotter pins

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

008 914 20 BOMAG 29

1.4 Tightening torques

The values specified in the table apply for screws:

1.4 Tightening torques

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

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

Tightening torques for screws with metric unified thread*

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

Tightening torques for screws with metric unified fine thread*

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

30 BOMAG 008 914 20

Tightening torques 1.4
Tightening torques for screws treated with anti-seizure paste OKS 240* (copper paste)

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

Tightening torques for wheel nuts (fine thread) * **

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

008 914 20 BOMAG 31

1.4 Tightening torques

The values specified in the table apply for screws:

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

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

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

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

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

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

32 BOMAG 008 914 20

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

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

008 914 20 BOMAG 33

1.4 Tightening torques

34 BOMAG 008 914 20

2 Technical data

008 914 20 BOMAG 35

2.1 Technical data

Fig. 13

Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 226 DH-4 3355 2440 1700 2300 3072* 430 6582 155 155 40 2130
BVC
* Depending on tire pressure

*
BW 226 DH-4 BVC

Weights
Operating weight (CECE) kg 25760
with ROPS and cabin
Axle load, drum (CECE) kg 17590
Axle load, wheels (CECE) kg 8170
Static linear load kg/cm 82.6

Travel characteristics
Travel speed km/h 0 ... 11
Max. gradability (depend- % 45
ing on soil)

Engine
Engine manufacturer Deutz
Type TCD 2012 L06 2V
Cooling Water
Number of cylinders 6
Rated power ISO 3046 kW 150
Rated speed rpm 2200
Electrical equipment V 12
Drive system hydrostatic
Driven axles 2
Permissible ambient tem- °C -20 ... +50
peratures

Brake
Service brake hydrostatic
Parking brake hydr.-mech.

36 BOMAG 008 914 20

Technical data 2.1
*
BW 226 DH-4 BVC
Steering
Type of steering articulated
Steering operation hydrostatic

Vibration
Vibrating drum
Drive system hydrostatic
Frequency Hz 26
Amplitude m 0 ... 2.3

Tires
Tire size 23.5-25 16PR L-3
Air pressure, nominal val- bar 2
ue
Air pressure, span bar 1-2

Filling capacities
Engine Litres 23,5,5
Coolant Litres 16
Fuel Litres 340
Hydraulic oil Litres 60
* The right for technical modifications remains reserved

Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 800 - 900
High idle speed rpm 2150 - 2250
Specific fuel consumption g/kWh 235
Valve clearance intake mm 0,3
Valve clearance exhaust mm 0,5
Injection valves opening pressure bar 250
Starter power kW 3,1

Travel pump
Manufacturer Sauer
Type 90R100 (EP)
System Axial piston/swash plate
Max. displacement cm3/rev. 100
Max. flow capacity ccm x n l/min 100
High pressure limitation bar 435 ± 15
Charge pressure, high idle bar 26 ± 1

Drum reduction gear

Type 715 C 3B
Transmission ratio 129,2

Drum drive motor

Manufacturer Sauer
Type 51C 110 (EP)
System Axial piston – bent axle
Displacement (stage 1) cm3/rev. 110
Displacement (stage 2) cm3/rev. 31,4
Perm. leak oil rate l/min 2 ± 10
Flushing rate l/min 10

008 914 20 BOMAG 37

2.1 Technical data

Flushing limitation bar 16

Axle drive motor

Manufacturer Sauer
Type 51D 110 (EP)
System Axial piston – bent axle
Max. displacement (stage 1) cm3/rev. 110
Min. displacement (stage 2) cm3/rev. 55,3
Perm. leak oil rate l/min 2 ± 10
Flushing rate l/min 10
Flushing limitation bar 16

Vibration pump
Manufacturer Sauer
Type 90R 075 (EP)
System Axial piston/swash plate
Max. displacement cm3/rev. 75
Start up pressure bar 365 ± 65
Operating pressure (soil dependent) bar approx. 100

Vibration motor
Manufacturer Bosch-Rexroth
Type A2FM 80 HDD
System Axial piston/swash plate
Displacement cm3/rev. 80
Flushing rate l/min 6
Flushing pressure limitation bar 13

Check steering/
Type HY/ZFFS11/16+8
System Tandem gear pump
Displacement cm3/rev. 16 / 8
Max. steering pressure bar 205 ± 15

Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool

Swivel motor
Type STF 1-000-21
System Piston rack

Rear axle
Manufacturer Dana
Type CHC 193/55
Differential No-Spin
Degree of locking % 100
Reduction ratio 93,74

38 BOMAG 008 914 20

Technical data 2.1
The following noise and vibration data acc. to

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

- Noise Emission Regulation 2000/14/EC

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

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

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

sound pressure level at the work place of the operator (with cabin):
LpA = 75 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is

guaranteed sound capacity level of the machine:

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

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

Vibration of the entire body (driver’s seat)

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

Hand-arm vibration values

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

008 914 20 BOMAG 39

2.1 Technical data

40 BOMAG 008 914 20

3 Maintenance

008 914 20 BOMAG 41

3.1 General notes on maintenance

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

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

42 BOMAG 008 914 20

Fuels and lubricants 3.2
3.2 Fuels and lubricants

Engine oil
Quality
For use in DEUTZ engines the lubrication oils are
classified in DEUTZ Lubrication Oil Quality Classes
(DQC).

Approved engine oils

Deutz ACEA* API** DHD

DQC II-05 E3-96, CG-4, DHD-1

E5-02,  CH-4,
E7-04, CI-4, 
E4-07, CI-4 Plus,
E6-04 CJ-4

DQC II-05 - - -

DQC IV-05 - - -
* Association des Constructeurs European d’Automobiles
** American Petroleum Institute

The list of approved lubrication oils is also available in

the Internet under the following address:

www.deutz.com Fig. 14
de >>SERVICE >> Betriebsstoffe und Diag- Optimal operating conditions can be achieved by us-
nose >> DeutzQualityClass >> DQC-Frei- ing the oil viscosity chart (Fig. 14) as a reference.
gabeliste
en >>SERVICE >> Fuels and lubricants and At ambient temperatures below -40 °C the lubrication
diagnostics >> DeutzQualityClass >>DQC- oil must be pre-heated (e.g. by parking the machine
release list indoors).
The viscosity is classified acc. to SAE. Multi-purpose
Consult your local service station if in doubt. oils should generally be used.
l Use winter grade engine oil for winter operation!
Oil change intervals
Oil viscosity The longest permissible time a lubrication oil should
Since lubrication oil changes its viscosity with the tem- remain in an engine is 1 year. If the following oil
perature, the ambient temperature at the operating lo- change intervals are not reached over a period of 1
cation of the engine is of utmost importance when year, the oil change should be performed at least once
choosing the viscosity class (SAE-class) . per year, irrespective of the operating hours reached.
Too high viscosity can cause starting difficulties, too DQC II, DQC
low ´viscosity can jeopardize the lubrication effect and III, DQC IV= 500 operating hours
result in a high lubrication oil consumption.
! Caution
When using fuels with a sulphur content of more
than 0,5% to 1% or under permanent ambient tem-
peratures below -10°C and when using biodegrad-
able diesel fuel the oil change intervals must be
halved.

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

008 914 20 BOMAG 43

3.2 Fuels and lubricants

sulphur content has a negative effect on the oil If the values of the analysis deviate, the water must be
change intervals. treated accordingly.
The fuel level should always be topped up in due time l pH-value too low
so that the fuel tank is never run dry, as otherwise filter Adding of caustic lye of soda or caustic potash so-
and injection lines need to be bled. lution.
Quality l Total hardness or chlorides and/or sulphates too
high:
The following fuel specifications are permitted:
Mixing with dehardened water (e.g. distilled water).
l
EN 590
l Total hardness or carbonate hardness too low:
l
DIN 51628
Mixing with hardened water (harder water is in most
l
ASTM D975 Grade-No. 1-D and 2-D. cases available in the form of drinking water).
l
JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lu-
brication properties acc. to EN 590
!Caution
Winter fuel Another analysis must be made after the fresh wa-
For winter operation use only winter diesel fuel, to ter has been prepared.
avoid clogging because of paraffin separation. Diesel Cooling system protection agent
fuels suitable for temperatures down to -44 °C are
available for arctic climates. At very low temperatures As a protection against frost, corrosion and boiling
disturbing paraffin separation can also be expected point anti-freeze agents must be used under any cli-
when using winter diesel fuel. matic conditions.
The admixture of petroleum and the addition of "flow Coolant for fluid cooled engines is prepared by adding
enhancing additives" (fuel additives) is not permitted. an ethylene-glycol based anti-freeze agent with corro-
sion inhibiting properties to the cooling water.
Coolant We therefore highly recommend our BOMAG cooling
system protection agent (BOMAG part-no. 009 940
For fluid cooled engines the cooling fluid must be pre- 08)..
pared by admixing a cooling system protection agent
to the fresh water and should be checked within the If our cooling system protection agent is not available
specified maintenance intervals. for any important reasons, you may, in exceptional
cases, use products that have been approved by the
This prevents damage caused by corrosion, cavita- engine manufacturer.
tion, freezing and overheating.
The list of approved cooling system protection agents
Fresh water quality can be found in the internet under www.deutz.com
The correct quality of water is highly important when >>SERVICE >> Fuels and lubricants and diagnostics
preparing coolant. Clear and clean water within the >> Collig system protection >>Technical circular Cool-
boundaries of the following analysis values should ing System Protection Agents.
generally be used. Products of the same product group (see Deutz Tech-
nical Circular Cooling System Protection Agents) can
Fresh water analysis values be mixed with each other.
pH-value at 20 °C 6.5 - 8.5 The BOMAG cooling system protection agent corre-
Chloride ion content (mg/l) (ppm) max. 100 sponds with product group A.
Sulphate ion content (mg/l) max. 100
(ppm) ! Caution
Total hardness [°dGH] 3 - 12
Do not mix different coolants and additives of any
corresponds with a potash ion 0.54 - 3.56
other kind.
content (mmol/l) of
Carbon hardness proportion of min. 3 Before changing the product you must clean the
the total hardness (°d) entire cooling system.
corresponds with a content of min. 53.4 Consult your local service station if in doubt.
CaCO3 (mg/l) (ppm)
To ensure proper corrosion protection you must use
Information concerning the water quality can be ob- the cooling system protection agent all year around,
tained from the waterworks. whereby the following concentration must not be fall-
If the fresh water analysis values are unknown, these en short of or exceeded.
must be determined with the help of a water analysis.

44 BOMAG 008 914 20

Fuels and lubricants 3.2
Oil for drive axle
Mixing ratio
Quality
Cooling sys- Fresh water Cold protec-
Forthe drive axle use only multi-purpose gear oils of
tem protection tion down to API-GL5-class, SAE 90.
agent
This is a hypoid lubricant of highest quality class for
min. 35% 65% -22 °C
extremely loaded transmissions.
40% 60% -28 °C
max. 45% 55% -35 °C The additives in this oil ensure low wear lubrication
under all operating conditions.
! Caution
A proportion of more than 45% of cooling system Oil for Vario vibration unit
protection agent causes a drop in cooling power. For the Vario vibration unit in the drum you should use
special BOMAG oil (BOMAG part-no. 009 925 05 in
The use of corrosion protection oils as cooling
20 litre drums) or a gear oil SAE 70W-90, API GL5.
system protection agents is not permitted.

Lubrication grease
i Note
For lubrication purposes use an EP-high pressure
When working at temperature below -35 °C you
grease, lithium saponified (penetration 2), acc. to DIN
should consult our local service representative.
51502 KP 2G.

Environment
Coolant must be disposed of environmentally.

Mineral oil based hydraulic oil

The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of 
46 mm2/s at 40 °C. For topping up or for oil changes
use only high-quality hydraulic oil, type HVLP accord-
ing to DIN 51524, part 3, or hydraulic oils type HV ac-
cording to ISO 6743/3. The viscosity index (VI) should
be at least 150 (observe information of manufacturer).

Bio-degradable hydraulic oil

The hydraulic system can also be operated with a syn-
thetic ester based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Pan-
olin HLP Synth.46 meets all demands of a mineral oil
based hydraulic oil according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46
always use the same oil to top up.
When changing from mineral oil based hydraulic oil to
an ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manufactur-
er for details.

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

008 914 20 BOMAG 45

3.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity

Summer Winter Attention

Observe the level marks

Engine

- Engine oil ACEA: E3-96, E5-02, E7-04, E4-07, E6-04 approx. 24 litres incl. oil fil-
API: CG-4, CH-4, CI-4, CI-4 Plus, CJ-4 ter

SAE 10W-40 (-15 °C to +40 °C)

SAE 15W-40 (-5 °C to +40 °C)

SAE 5W-40 (-30 °C to +40 °C)

- Fuel Diesel Winter diesel fuel approx. 340 litres

- Coolant Mixture of water and anti-freeze agent* approx. 16 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. Viscosity approx. 60 litres
46 mm2/s at 40 °C with viscosity index (VI) >150 or
ester based biodegradable hydraulic oil

Exciter unit BOMAG special oil (TN 009 925 05) approx. 16.5 litres
or
SAE 75W 90, API GL5

Drive axle SAE 90, API GL5 approx. 12.5 litres

Wheel hubs SAE 90, API GL5 approx. 3.5 litres (per
side)

Axle reduction gear SAE 90, API GL5 approx. 1.9 litres

Drum drive reduction gear SAE 90, API GL5 approx. 7.5 litres

Drum Water 50% / anti-freeze** 50% approx. 7.5 litres

Tires Water approx. 390 litres

Calcium chloride (CaCl2) or magnesium chloride approx. 130 kg

(MgCl2)

Air conditioning system Refrigerant R134a approx. 1500 g

* see chapter "Fuels and Lubricants - Colant"
** Ethylene or Propylene Glycol

46 BOMAG 008 914 20

Running-in instructions 3.4
3.4 Running-in instructions
The following maintenance work must be per-
formed when running in new machines or over-
hauled engines:

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

After a running-in time of 30 minutes

l Retighten the V-belt

After 250 operating hours

l Tighten all bolted connections on air intake, ex-
haust, oil sump and engine mounts.
l Retighten the bolted connections on the machine.
l Retighten all wheel fastening screws with the spec-
ified tightening torque.
l Change engine oil and oil filter
l Oil change in drive axle
l Oil change in wheel hubs
l Oil change, axle reduction gear
l 1. Oil change in drum drive reduction gear
l 1. Oil change in Vario exciter

No. Maintenance work Comment

as required
5.46 Air filter maintenance min. 1x per year,  X
Safety cartridge at
least every 2 years
5.47 Adjust the scrapers X
5.48 Clean the machine X
5.49 Adjust the parking brake X
5.50 Change the tires X
5.51 Change the fresh air filter in the cab- X
in
5.52 Fill the provision tank for the wind- X
screen washer system
5.53 Tightening torques X
5.54 Engine conservation X
* oil change after 250 and 500 operating hours, then every 500 operating hours
** Also in case of repair in the hydraulic system.
*** Running-in instructions: oil change after 250 and 1000 operating hours, then every 1000 operating hours
**** Running-in instructions: oil change after 250, 500 and 1000 operating hours, then every 1000 operating hours
*****Running-in instructions: oil change after 250 and 1000 operating hours, then every 1000 operating hours

50 BOMAG 008 914 20

4 Connection overview

008 914 20 BOMAG 51

4.1 Connection overview travel/vibration pump

Fig. 1

52 BOMAG 008 914 20

Connection overview travel/vibration pump 4.1
1 Proportional valve, vibration low frequency 16 Charge pressure test port
2 Proportional valve, vibration high frequency 17 Multi-function valve 400 bar (boost check and
3 Proportional valve, travel drive forward pressure relief valve), vibration high frequency
4 Proportional valve, travel drive reverse 18 Multi-function valve 400 bar (boost check and
pressure relief valve), vibration low frequency
5 Multi-function valve 400 bar (boost check and
pressure relief valve), travel system 19 Pressure test port, vibration low frequency
6 Multi-function valve 400 bar (boost check and 20 Pressure test port, vibration high frequency
pressure relief valve), travel system 21 High pressure port, high frequency
7 High pressure port B, reverse 22 High pressure port, low frequency
8 High pressure port A, forward 23 Charge pressure relief valve vibration pump
9 Charge pressure relief valve, travel pump 24 Port L2 (connection to travel pump 12)
10 Charge pressure (connection to travel pump 15) 25 Leak oil port (connection to thermostat housing
11 Charge oil to steering valve port T (BVC), charge port A)
oil to filter (DH/PDH) 26 Port S, suction line between hydraulic oil tank and
12 Port L2 (connection to vibration pump 24) charge pump (charge pump in vibration pump)
13 Pressure test port MA, high pressure forward 27 Charge pump (only in vibration pump)
14 Pressure test port MB, high pressure reverse 28 Pressure test port X1/X2, travel pump, control
chamber
15 Charge pressure to solenoid valve for brake and
speed range selection (charge oil vibration 10) 29 Adjustment screw, mechanical neutral position

008 914 20 BOMAG 53

4.1 Connection overview travel/vibration pump

54 BOMAG 008 914 20

5 Tests and adjustments

008 914 20 BOMAG 55

5.1 Special tools, tests and adjustments

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

Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
BOMAG part-no.: 059 710 02

Fig. 2
3. Anti-freeze tester, quick and accurate measuring,
sturdy plastic housing, automatic temperature
correction, no after-dripping, instructions for use
on unit, reading down to -40 °C. Material: Plastic,
Temperature range: down to -40 °C

BOMAG part-no.: 050 100 75

Fig. 3
4. Digital rpm-meter for petrol engines

BOMAG part-no.: 079 948 99

Fig. 4

56 BOMAG 008 914 20

Special tools, tests and adjustments 5.1
5. Digital rpm-meter for petrol engines

BOMAG part-no.: 059 711 12

Fig. 5
6. Digital rpm-meter, optical/mechanical, universal
use

BOMAG part-no.: 079 948 98

Fig. 6
7. Infrared manual thermometer, -18 to 275°C

BOMAG part-no.: 057 668 06

Fig. 7
8. Hydraulic test case, large

BOMAG part-no.: 007 610 03

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

Fig. 8

008 914 20 BOMAG 57

5.1 Special tools, tests and adjustments

9. Hydraulic test case, small

BOMAG part-no.: 079 930 01

i Note
2X 60 bar pressure gauge
2X 600 bar pressure gauges
4 pressure test hoses

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

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

Fig. 11
12. Adapter for pressure test hose

BOMAG part-no.: 055 439 02

Fig. 12

58 BOMAG 008 914 20

Special tools, tests and adjustments 5.1
13. Gear pump testing device

BOMAG part-no.: 007 610 05

Fig. 13
14. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)

Fig. 14

008 914 20 BOMAG 59

5.2 Activate service mode

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

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

Fig. 1
Activate service mode
T

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

Fig. 3

60 BOMAG 008 914 20

Activate service mode 5.2
i Note
If the access code has been entered correctly,
the "spanner" symbol appears in the display and
the first digit flashes again.

Individual operating states can now be inter-

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

Deactivating the service mode

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

Fig. 4

008 914 20 BOMAG 61

5.3 Driving against the closed brake

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

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

62 BOMAG 008 914 20

Driving against the closed brake 5.3
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.

Deactivating the brake function

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

008 914 20 BOMAG 63

5.4 Turn the steering against an end stop.

i Note
The steering is actuated against an "electronic"
stop by the ESX-control. To actuate the steering
against the mechanical stop the ESX-control
must be switched to the mode "Teaching the
electronic end stops of the angle transducer
(BVC)".
Activate the input mode
1. Set the travel lever to braking position

Fig. 1
Activate service mode
T

Fig. 3

64 BOMAG 008 914 20

Turn the steering against an end stop. 5.4
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 mode
5. Enter code number "2010" (Fig. 5) to activate the
mode "teaching the steering stops".
The steering can now be actuated against the
mechanical stop.
The display shows the nominated steering posi-
tion (0..1000).

Deactivating the mode

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

Fig. 5

008 914 20 BOMAG 65

5.5 Pressure tests in the travel circuit

Special tools
Hydraulic test case

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

Fig. 1

! Danger
The closed brake mode must be activated!

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

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

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

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

66 BOMAG 008 914 20

Pressure tests in the travel circuit 5.5
6. Move the travel lever (Fig. 4) quickly forward and
backward, read the pressure gauge.

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

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

Deactivate the closed brake mode

7. Quit this mode by switching the ignition off.

008 914 20 BOMAG 67

5.6 Checking / adjusting the neutral positions of the travel pump

5.6 Checking / adjusting the neutral posi-

tions of the travel pump
Special tools
Hydraulic test case

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

Fig. 1

! Danger

The closed brake mode must be activated!

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

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

Fig. 3

68 BOMAG 008 914 20

Checking / adjusting the neutral positions of the travel pump 5.6
! Danger

The closed brake mode must be activated!

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

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

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

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

Fig. 5
Evaluation of test

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

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

Fig. 6

008 914 20 BOMAG 69

5.7 Pressure measurements in the vibration circuit

5.7 Pressure measurements in the vibra-

tion circuit
Special tools
Hydraulic test case

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

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

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

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

70 BOMAG 008 914 20

Check the leakage rate of the vibration motor 5.8
5.8 Check the leakage rate of the vibration
motor

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

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

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

Nominal value
max. 1.5 litre/min

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

008 914 20 BOMAG 71

5.9 Pressure test in steering circuit

Special tools
Hydraulic test case, gear pump testing equipment

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

Measurement 1
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).

Fig. 1
Activate teach mode

i Note
Turn the steering against the mechanical stop,
see corresponding chapter.
2. Enter code number "2010" (Fig. 2).
3. Start the engine and run it at idle speed.

! Danger
Danger of crushing, do not access the articu-
lation area of the machine!
Fig. 2
4. Turn the steering against an end stop.
5. Set the travel lever to neutral position (no braking
function).
6. Read the pressure gauge.

Nominal value
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.

Deactivate the steering mode

7. Quit the teach mode by switching the ignition off.

72 BOMAG 008 914 20

Pressure test in steering circuit 5.9
Measurement 2
8. Disconnect the hydraulic hoses from ports L and
R (Fig. 3) on the steering cylinders and close
them with plugs.
9. Start the engine and run it at idle speed.
10. Turn the steering wheel.
11. Read the pressure gauge.

Nominal value
see technical data for steering/charge pump.

Evaluation of test 2
Fig. 3 If the nominal value is reached, replace the steer-
ing cylinder.
If the nominal value is not reached, check the
steering/charge pump.
12. Reconnect the hydraulic hoses to the steering
cylinders.
Measurement 3
13. Close the pump outlet port (Fig. 4) with the gear
pump test equipment.
14. Crank the engine with the starter

Nominal value
see technical data for steering/charge pump.

Evaluation of test 3
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
Fig. 4 steering/charge pump.

008 914 20 BOMAG 73

5.9 Pressure test in steering circuit

74 BOMAG 008 914 20

6 Flushing and bleeding

008 914 20 BOMAG 75

6.1 Special tools for flushing

1. Filling and filtering unit

BOMAG part-no.: 058 240 22

Fig. 1
2. Flushing filter (S connection)

BOMAG part-no.: 007 000 01

3. Filter element 1

BOMAG part-no.: 079 930 52

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

BOMAG part-no.: 055 509 19

5. Screw socket R1“ - 25S (2 pieces)

BOMAG part-no.: 055 400 52

Fig. 2
6. Flushing filter (L connection)

BOMAG part-no.: 079 390 29

7. Filter element

BOMAG part-no.: 079 390 14

8. Flushing hose 15L (2 pieces)

BOMAG part-no.: 055 510 09

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

BOMAG part-no.: 055 400 89

Fig. 3
10. SAE-flange 1“ - 20S

BOMAG part-no.: 058 142 60

11. O-ring

BOMAG part-no. 062 203 30

Fig. 4

76 BOMAG 008 914 20

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

BOMAG part-no.: 007 160 18

13. O-ring

BOMAG part-no. 062 202 22

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

BOMAG part-no.: 055 422 92

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

BOMAG part-no.: 055 422 98

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

BOMAG part-no.: 055 423 26

Fig. 8

008 914 20 BOMAG 77

6.1 Special tools for flushing

17. Connecting socket 15L

BOMAG part-no.: 055 426 55

Fig. 9
18. Connecting socket 18L

BOMAG part-no.: 055 426 06

Fig. 10
19. Connecting socket 16S

BOMAG part-no.: 055 459 43

Fig. 11
20. Connecting fitting 20S

BOMAG part-no.: 055 459 44

Fig. 12

78 BOMAG 008 914 20

Special tools for flushing 6.1
21. Connecting fitting 25S

BOMAG part-no.: 055 459 45

Fig. 13
22. Angular fitting 18L

BOMAG part-no.: 055 421 26

Fig. 14
23. Elbow fitting 16L

BOMAG part-no.: 055 421 36

Fig. 15
24. Elbow 20S

BOMAG part-no.: 055 421 37

Fig. 16

008 914 20 BOMAG 79

6.1 Special tools for flushing

25. Elbow 25S

BOMAG part-no.: 055 421 38

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

BOMAG part-no.: 493 301 01

Fig. 18
27. Connecting hose 15L

BOMAG part-no.: 055 510 09

Fig. 19

80 BOMAG 008 914 20

Flushing - general 6.2
6.2 Flushing - general 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.

Fig. 1 Chips (abrasion) in the oil

Effect of contamination l Open and clean all components in the oil
circuit, replace if necessary.
Coarse particles (> 15 µm)
Sudden failure of components. l Clean all high pressure hoses in the oil cir-
cuit, replace if necessary.
Fine particle contamination (5 – 15 µm)
l If abrasion is found in the travel circuit you
Wear of components, internal leaks, inaccurate
should also flush the vibration circuit.
controlling behaviour, blockage of valves.
l If abrasion is found in the vibration circuit
Extra fine particle contamination (< 2 – 5 you should also flush the travel circuit.
µm)
Silting of oil, accelerated aging of oil, corrosion.

Water in oil
Increased wear, accelerated aging of oil.

008 914 20 BOMAG 81

6.2 Flushing - general

Before flushing Bleeding

Change the filter element

Fig. 3

Fig. 1
l Always bleed closed hydraulic circuits if
lines had been removed or connected.
Clean the hydraulic tank
Servicing the flushing filter kit

Fig. 4
Fig. 2
l Replace the filter element of the flushing fil-
ter when the red control pin of the contami-
!Caution nation indicator is pressed out during the
Change the oil in case of excessive contam- filtering process.
ination, oil discoloration or if the oil change l Clean hoses and connections and store the
interval is almost due. flushing kit in a clean and protected envi-
l Filter the tank content with the filling and fil- ronment.
tering unit and pump it into an oil container.
l Mark all hoses and disconnect them from
the hydraulic oil tank.
l Clean the oil tank thoroughly from inside, if
necessary remove the tank cover.
l Reconnect all hoses.
l Fill the hydraulic oil tank again with the fill-
ing and filtering unit.

82 BOMAG 008 914 20

Flushing schematic travel circuit (distribution travel pump) 6.3

008 914 20 BOMAG 83

6.3 Flushing schematic travel circuit (distribution travel pump)

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

84 BOMAG 008 914 20

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

Flushing the drum drive

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

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

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

Fig. 2

008 914 20 BOMAG 85

6.4 Flushing the travel circuit (travel pump distribution)

Bleeding the travel circuit

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

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

Fig. 4

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

Fig. 5

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

86 BOMAG 008 914 20

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

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

Fig. 7

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

Fig. 8

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

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

008 914 20 BOMAG 87

6.4 Flushing the travel circuit (travel pump distribution)

Flushing the axle drive

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

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

Fig. 11

Bleeding the travel circuit

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

Fig. 12

88 BOMAG 008 914 20

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

Fig. 13

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

Fig. 14

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

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

Fig. 16

008 914 20 BOMAG 89

6.4 Flushing the travel circuit (travel pump distribution)

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

Fig. 17

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

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

Bleeding the travel circuit

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

Keep circulating the tank content.

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

Fig. 19

90 BOMAG 008 914 20

Flushing schematic travel circuit (distribution axle motor) 6.5

008 914 20 BOMAG 91

6.5 Flushing schematic travel circuit (distribution axle motor)

92 BOMAG 008 914 20

Flushing schematic travel circuit (distribution axle motor) 6.5

008 914 20 BOMAG 93

6.5 Flushing schematic travel circuit (distribution axle motor)

94 BOMAG 008 914 20

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

008 914 20 BOMAG 95

6.6 Flushing the travel circuit (axle motor distribution)

6.6 Flushing the travel circuit (axle motor

distribution)

Flushing the drum drive

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

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

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

Fig. 2

96 BOMAG 008 914 20

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

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

Fig. 3
Flushing the hoses

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

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

Fig. 5

008 914 20 BOMAG 97

6.6 Flushing the travel circuit (axle motor distribution)

Flushing the drum drive motor

Fig. 7

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

Fig. 8

Fig. 9

98 BOMAG 008 914 20

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

Fig. 10

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

Fig. 11

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

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

Bleeding the travel circuit

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

Keep circulating the tank content.

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

008 914 20 BOMAG 99

6.6 Flushing the travel circuit (axle motor distribution)

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

Fig. 13

100 BOMAG 008 914 20

Flushing schematic for vibration drive 6.7

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

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

008 914 20 BOMAG 101

6.8 Flushing the vibration circuit

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

i Note
Observe the chapter "Flushing - General"

Installing the flushing filter

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

Fig. 2

102 BOMAG 008 914 20

Flushing the vibration circuit 6.8
Bleeding the vibration circuit

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

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

Fig. 4

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

Fig. 5

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

008 914 20 BOMAG 103

6.8 Flushing the vibration circuit

Flushing the vibration motor

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

Fig. 7

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

Fig. 8

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

Keep circulating the tank content.

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

104 BOMAG 008 914 20

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

Fig. 10

008 914 20 BOMAG 105

6.9 Bleeding the travel circuit

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

! Danger
The engine should not start.

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

Fig. 2
7. Unlock the emergency stop switch

Fig. 3

106 BOMAG 008 914 20

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

Fig. 4

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

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

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

008 914 20 BOMAG 107

6.10 Bleeding the vibration circuit

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

Fig. 2
7. Unlock the emergency stop switch

Fig. 3

108 BOMAG 008 914 20

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

Fig. 4

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

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

008 914 20 BOMAG 109

6.10 Bleeding the vibration circuit

110 BOMAG 008 914 20

7 Caddy wiring diagrams

008 914 20 BOMAG 111

7.1 Understanding circuit diagrams

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

Structure
l Table of contents (Fig. 6)
l Function groups (Fig. 7)
l List of components (Fig. 9)

112 BOMAG 008 914 20

Understanding circuit diagrams 7.1
Table of contents (Fig. 6)
The table of contents lists all function groups.

Fig. 6 Table of contents

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

008 914 20 BOMAG 113

7.1 Understanding circuit diagrams

Function groups (Fig. 7)

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

Arrangement of current paths

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

Fig. 7 Function groups

Potential cross references

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

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

Relay cross reference

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

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

114 BOMAG 008 914 20

Understanding circuit diagrams 7.1
Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 8) (0 ..... 20).

Fig. 8 Current paths

008 914 20 BOMAG 115

7.1 Understanding circuit diagrams

List of components (Fig. 9)

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

Fig. 9 List of components

Component cross references

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

116 BOMAG 008 914 20

Circuit symbols in the circuit diagram 7.2
7.2 Circuit symbols in the circuit diagram
Circuit symbol
l Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a sim-
plified representation of complete systems, from which, however, the function can be clearly identified. This
standardization is in compliance with the globally valid regulations of the IEC (International Electrical Commis-
sion). The standardization serves the purpose of global understanding and fault free connection of appliances,
especially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects,
the circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance
of mistakes.

Fig. 1 Example: Circuit symbol

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

008 914 20 BOMAG 117

7.3 Identification of switch blocks in the Caddy wiring diagram

Switches of modular design

l For normally open contacts the contact symbols "_3/_4" are used.
l For normally closed contacts the contact symbols "_1/_2" are used.
In combination with the contact block numbering described above each individual connection is clearly defined.

Example of terminal designations

Fig. 2 Terminal designations

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

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

118 BOMAG 008 914 20

8 E-Plan wiring diagrams

008 914 20 BOMAG 119

8.1 Understanding wiring diagrams

Electric circuit diagrams

Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do
not contain any information on the type of wiring, their purpose is solely the clarification of control logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, etc.
l The sequence in which current flows through the individual elements in the electric circuit.
l Connections between the examined electric circuit and other circuits in the vehicle wiring system.
l Pin assignment of plug-and-socket connections.

Structure of a wiring diagram

l Cover sheet, see section "Cover sheet"
l Table of contents, see section "Table of contents"
l Structuring symbol overview, see section "Structuring symbol overview"

i Note
The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local iden-
tification!
l Sheets with illustration of function, see section"Sheets with illustration of function"
l List of fuels and lubricants, see "List of fuels and lubricants"
l Terminal strip overview, see section "Terminal strip overview"
l Plug overview, see section "Plug overview"
l Pin overview, see section "Pin overview"

120 BOMAG 008 914 20

Understanding wiring diagrams 8.1
Cover sheet
The cover sheet, see example (Fig. 3), contains general information.

Fig. 3 Example: Cover sheet

008 914 20 BOMAG 121

8.1 Understanding wiring diagrams

Table of contents
The table of contents, see example (Fig. 4), lists the individual functions and identifies the corresponding sheets
in the wiring diagram.

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Fig. 4 Example: Table of contents

122 BOMAG 008 914 20

Understanding wiring diagrams 8.1
Sheets with representations of functions
l
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l All sheets are successively numbered.
l BOMAG used the resolved type of representation. In this case parts and components with different functions,
which belong to the same components (e.g. relay coil and relay contact), can be represented on different
sheets. Cross-references, which refer to the sheet and current path, serve as linkage between these partial
components (Fig. 5).

Structuring symbols
Relay cross-reference Potential cross-reference

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Mimic diagram of relay Current paths

Fig. 5 Example: Sheet with functions

Current paths (Fig. 5)

l Current paths are successively numbered from 0 to 9.

Potential cross references (Fig. 5)

l Potential cross references serve the purpose of tracking signals, which are transmitted from one representa-
tion of a function to another. Potential cross-references may additionally have structuring symbols assigned
to them.
Example: Potential  15_54  +SEAT/16.1 (on sheet 4, current path 8) continues to the right on sheet 16,
current path 1. +SEAT is the structuring symbol.

008 914 20 BOMAG 123

8.1 Understanding wiring diagrams

Relay cross references (Fig. 5)

l Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring
diagram is additionally attached to the bottom of each contactor coil.
Example: The relay cross-reference (-K61/4.2) (on sheet 4, current path 4) indicates that the relay coil on sheet
4 is found in current path 2.

124 BOMAG 008 914 20

Understanding wiring diagrams 8.1
List of component
The list of components, see example (Fig. 6), is the first evaluation list that follows the representation of function.
This list contains all components used in the wiring diagram, except terminal strips and plugs.

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Fig. 6 Example: List of components

An electric component is a part, assembly or device in an electrical installation.
l
Components are marked with a combination of letters and numbers. The identification with letters follows the
standard DIN - EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same
component. In this context the term "component" is always considered a function specific assignment and
does not represent a parts or article number. This ensures that the component with the designation "S04" al-
ways refers to the "Brake Switch", irrespective of whether the abbreviation is used in a wiring diagram for a
single drum roller, a tandem roller, a finisher or a milling machine.
l
The component identifications are alphabetically sorted in the list of components. Each component has the
corresponding cross-references assigned, identifying where it can be found in the wiring diagram, which in-
stallation location it is assigned to and to which part of the system it belongs to. Moreover, the functions (func-
tion text) and the technical characteristics are also described.

i Note
Component identifications are used in both the electrical and the hydraulic documentation and are identical.

008 914 20 BOMAG 125

8.1 Understanding wiring diagrams

Overview of terminal strips

The overview of terminal strips, see axample (Fig. 7), contains all terminal strips used in the circuit diagram.
Each terminal strip starts on a new page and can be localized via the cross-reference in the wiring diagram.

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Fig. 7 Example: Terminal strip overview X1

126 BOMAG 008 914 20

Understanding wiring diagrams 8.1
Overview of plugs
The overview of plugs, see example (Fig. 8), contains all plugs used in the circuit diagram.
The following information is listed for each plug:
l Contact numbering
l Structuring symbols
l Function text
l Use in wiring diagram.

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Fig. 8 Example: Plug overview X0

008 914 20 BOMAG 127

8.1 Understanding wiring diagrams

Overview of pins
The overview of pins, see example (Fig. 9), informs about the type of inputs and outputs of the electronic controls
(E-BOX) used in the machine, as well as their signals and potentials.

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Fig. 9 Example: Overview of pins, control A66

128 BOMAG 008 914 20

Circuit symbols in the circuit diagram 8.2
8.2 Circuit symbols in the circuit diagram

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

Fig. 10 Example: Circuit symbol

1 Current source
2 Conductor
3 Switch
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10Fuse
11Terminal strip
12Plug
Different symbols are used to simplify the differentiation of terminal strips 11 (Fig. 10) and plugs (12) in a wiring
diagram.

i Note
Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable
connection and mating plug.

008 914 20 BOMAG 129

8.2 Circuit symbols in the circuit diagram

Representation of electric devices

Electronic devices and components are increasingly used in the construction equipment industry. Controls with
software, control elements (e.g. joysticks and man/machine interface (e.g. screens, LC Displays) are frequently
used to represent and control machine functions. The internal construction of such components is in most cases
protected or just too complex to be illustrated in the wiring diagram within the context of the actual machine func-
tion. There are two different ways to simplify the representation of such devices in the diagram.

Black-Box representation(Fig. 11)

The Black-Box representation shows the device as a Box with the connections required for the machine function.
Connections which are not needed do not need to be represented.
The Black-Box representation is mainly used when no differentiated information (e.g. signals on pins) is availa-
ble.

Fig. 11 Example: Central lubrication system

Identification of externally supplied documentation (Fig. 12)

In industrial technology of today it is quite common to integrate externally supplied electric sub-systems into the
projecting of machines. These systems may be composed of various components and wirings. For easier differ-
entiation of BOMAG designation and manufacturer identification the latter appears under the BOMAG designa-
tion with a text frame and a reduced character height.

Fig. 12 Example: Identification of externally supplied documentation

PLC representation(Fig. 13)

The PLC-Box representation of connecting pins uses a table with associated connecting plugs, which are used
in connection with the machine functions. The table symbols can be arranged in a line, if necessary. Connections

130 BOMAG 008 914 20

Circuit symbols in the circuit diagram 8.2
which are not needed do not need to be represented. The PLC-Box representation enables the representation
of further reaching functional descriptions to the individual component connections.

Fig. 13 PLC representation

The PLC-Box representation is mainly used for controls with BOMAG software, or for electronic devices which
were specified accordingly, and where information on the assignment of signals is available.

Identification of similar, adjacent switching symbols

In wiring diagrams you will frequently find the situation that symbols of the same type appear in a line or are
arranged just next to each other. In such cases it is common practice to reduce the identification on the subse-
quent symbol to the criteria, which are different to the previous symbol to the left.

Example: -X0 36 and -X0 37 (Fig. 13)

In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right
plug symbol.

008 914 20 BOMAG 131

8.3 Identification of switch blocks in the wiring diagram

Switches of modular design

5 C 6

3 B 4

1 A 2

Travel direction

Fig. 14

Example:
The contact block marked with the "circle" is referred to as "43"/ "44" if it is a normally open contact and "41" /
"42" if it is a normally closed contact.
The contact block marked with "X" is referred to as "23"/ "24" if it is a normally open contact and "21" / "22" if it
is a normally closed contact.
The contact block marked with "Z" is referred to as "13"/ "14" if it is a normally open contact and "11" / "12" if it
is a normally closed contact.
The contact block marked with "Y" is referred to as "53"/ "54" if it is a normally open contact and "51" / "52" if it
is a normally closed contact.

132 BOMAG 008 914 20

9 Electrics

008 914 20 BOMAG 133

9.1 Designation of components in the wiring diagram

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

Component designa- Meaning

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

134 BOMAG 008 914 20

Terminal designations in wiring diagram 9.2
9.2 Terminal designations in wiring diagram
l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a
terminal designation. In Germany the designation of the individual connection terminals is determined by the
standard DIN 72552. The following table shows some examples from this DIN standard.

Terminal designation Meaning

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

15a Output from dropping resistor to ignition coil and starter

17 Preheating starter switch, preheating

19 Preheating starter switch, starting

30 Battery plus direct

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

31 Battery minus direct or ground

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

49 Input flasher relay

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

50 Starter, starter control

50a Battery changeover relay, output for starter control

53 Wiper motor input (+)

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

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

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

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

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

61 Generator control

75 Radio, cigarette lighter

76 Loudspeaker

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

008 914 20 BOMAG 135

9.2 Terminal designations in wiring diagram

Terminal designation Meaning

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

88 Relay contact for maker

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

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

136 BOMAG 008 914 20

Battery ground and analog ground 9.3
9.3 Battery ground and analog 9.4 Current and voltage
ground
General
GND, battery ground If one wants to describe electric current, this can most
simply be accomplished by means of a comparison:
The term "ground" (abbreviated GND) describes a
conductive body which is normally defined with the One simply compares electric current with water.
potential of "Zero" Volt and represents the reference
potential for operating voltages. Voltage
The positive pole of the supply voltage (symbol + ) and
all other electric voltages and electical signals in an
electrical circuitry refer to the ground potential.
On motor vehicles and also on motorbikes and bicy-
cles the ground potential is represented by the chas-
sis or the frame. As a conductive part, which covers
the entire vehicle, it also serves a return conductor for
the vehicle wiring system - the consumers only need
to be wired up.

Terminal designation for GND = terminale 31

AGND, analog ground

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

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

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

008 914 20 BOMAG 137

9.4 Current and voltage

The following statements concerning electric volt- Current

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

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

The electric amperage (I) is measured in Ampere

(A).

The technical flow direction is specified from

PLUS to MINUS.

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

Circuit

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

138 BOMAG 008 914 20

Current and voltage 9.4
Types of current
Direct current (D.C.)

Fig. 1 Direct current (D.C.)

Direct current flows with steady voltage and amper-
age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
tors or batteries.
The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
the consumers switched on, the voltage is not con-
stant, but drops gradually according to the battery
charge condition.
The internal resistance of the battery also causes per-
manent changes in the vehicle voltage, as soon as
consumers are switched on or off.

Alternating current (A.C.)

Fig. 2 Alternating current (A.C.)

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

008 914 20 BOMAG 139

9.5 Pulse Width Modulation (PWM)

Pulse width modulation (PWM)
PWM is the abbreviation for Pulse Width Modulation, frequently also referred to as "Pulse Pause Modulation"
(PPM). It is used in the field of controls for mobile and robust applications, mainly to control proportional valves
(PWM-valves).
The following applies:
l The signal voltage cannot be measured.
l The current can be measured.

Caution
!

PWM-solenoid valves must not be interference suppressed with suppressor diodes.

What does a PWM-output do?

Digital outputs normally deliver a fixed output voltage, as soon as they are switched on. The value of the output
voltage can in this case not be changed. In contrast to this, PWM-outputs divide the voltage into a quick se-
quence of many square-wave pulses. The ratio of pulse period "switched on" to pulse period "switched off" de-
termines the effective value of the desired output voltage. One refers to the duty cycle (in percent).

Fig. 1
(Fig. 1)Course of PWM-voltage U and coil current I at 10 % duty cycle The effective coil current Ieff is also 10 %.

Fig. 1
(Fig. 1) Course of PWM-voltage U and coil current I at 50 % duty cycle The effective coil current Ieff is also 50 %.

140 BOMAG 008 914 20

Pulse Width Modulation (PWM) 9.5

Fig. 1
(Fig. 1) Course of PWM-voltage U and coil current I at 100 % duty cycle The effective coil current Ieff is also 100
%.

What does Dither mean?

When a proportional hydraulic valve is triggered, its spool will not move immediately and at the beginning it will
also not move proportionally to the coil current. Due to this "Slip-Stick effect" - a kine of "breakaway torque" - the
valve right at the beginning requires a slightly higher current to be able to move the spool out of rest position.
The same takes place with any other position change of the valve spool. Especially with very low actuating
speeds this effect becomes apparent by jerky movements.
Engineering tackles this problem by subjecting the valve spool to an almost insignificant shuttle movement (the
dither). The piston thereby permanently performs a shuttle movement and can therefore not "stick". Even very
small position changes now take place without delay, just like a "flying start".
Advantage: The hydraulic cylinder actuated this way can be controlled with a much higher sensitivity.
Disadvantage: With dither the valves becomes noticeably warmer, because the valve spool is permanently in
action.

008 914 20 BOMAG 141

9.6 Resistance

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

Bad

Fig. 1 Various size resistors

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

Fig. 2 Spring clamps

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

Symbol, R

Unit, Ohm 

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

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

142 BOMAG 008 914 20

Resistance 9.6
Sometimes the flanks of flat plugs bend open. If these
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.

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

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

Fig. 4 Balistol oil

008 914 20 BOMAG 143

9.7 Series / parallel connection

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

Fig. 1 Series connection

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

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

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

Series connection of batteries

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

144 BOMAG 008 914 20

Series / parallel connection 9.7
Parallel connection l In parallel connection the plus pole of the first bat-
In parallel connection all resistances (consumers) are tery is connected with the plus pole of the second
connected between feed and return line. battery and the minus pole of the first battery with
the minus pole of the second battery.
l All resistances (consumers) are supplied with the
same voltage.
l Plus and minus poles have the voltage of the single
battery applied.
l Each of the resistances (consumers) draws as
much current as required.
l The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.

Fig. 3 Parallel connection

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

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

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

Parallel connection of batteries

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

008 914 20 BOMAG 145

9.8 Ohm's law

9.8 Ohm's law 9.9 Electrical energy

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

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

146 BOMAG 008 914 20

Formula diagram 9.10
9.10 Formula diagram
Description:
l Select the desired value from the inner circle.
l Determine the formula variables in the quarter circle
l Calculate

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

Fig. 1 Formula diagram

Resistance, R Ohm 

Voltage, U Volt

Current, I Ampere

Power, P Watt

008 914 20 BOMAG 147

9.11 Metrology

9.11 Metrology Multimeter

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

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

Fig. 2 Diode test lamp

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

148 BOMAG 008 914 20

Metrology 9.11
Resistance and continuity measurement with mul- Voltage and voltage drop measurement with mul-
timeter timeter

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

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

008 914 20 BOMAG 149

9.11 Metrology

Current measurement with the multimeter Clip-on measuring instrument

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

Fig. 6 Measuring current

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

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

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

150 BOMAG 008 914 20

Metrology 9.11
Magnet tester Power measurement
The electric power of a module within a circuit can be
indirectly determined (calculated) by separate meas-
uring of current and voltage.
However, there are also pure power meters with 4
connections available. The power meter has a electro-
dynamic measuring mechanism. The current circuit
must be opened for measuring. Take care when per-
forming power measurements: Voltage or current path
may already be overloaded during the measurement,
even though the end stop in the meter has not yet
been reached.

Fig. 1 Magnet tester

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

Fig. 2

008 914 20 BOMAG 151

9.12 Diodes, relays, fuses

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

Diodes

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

Fig. 2 Marking of the cathode

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

Fig. 3 Diode circuitry

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

152 BOMAG 008 914 20

Diodes, relays, fuses 9.12
Light emitting diodes Relays

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

Fig. 2 Relay circuitry

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

008 914 20 BOMAG 153

9.12 Diodes, relays, fuses

85 = Ground supply for coil Fuses

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

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

Caution
!

Fuses must not be repaired or bridged.

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

154 BOMAG 008 914 20

Telemecanique switch 9.13
9.13 Telemecanique switch
Disassembly

Fig. 1 Disassembly
l
Lift up the interlock (5).

Fig. 3 Pulling out the front element

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

008 914 20 BOMAG 155

9.13 Telemecanique switch

Assembly

Fig. 4 Assembly
l Insert the front element (3) into the bore in the con-
trol panel.

Fig. 6 Assemble the switch block

l Clip on the switch block (4).

Fig. 5 Observe the marks.

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

i Note
Watch the marls on front element (Fig. 5) and fasten-
ing flange.
l
Tighten the screw (1) with a tightening torque of 0.6
Nm.

156 BOMAG 008 914 20

Plug connectors 9.14
9.14 Plug connectors
Duties and requirements
Electric plug connectors must provide a reliable con-
nection between different system components and
thus ensure the safe function of the systems under
any operating condition. There design ensures that
they will withstand the applied loads throughout the
lifetime of the machine.
Examples for these loads are:
l Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l Dampness
l Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
cuits in neighbouring lines. Electric plug connectors
must therefore have the following properties:
l
Low transition resistances of the conductive parts.
l
High insulation strength between conductive parts
with different voltage potentials.
l
Excellent leak tightness against water and mois-
ture.

008 914 20 BOMAG 157

9.15 Magnetic coil plug

Magnetic coil plug with LED and suppres-

9.15 Magnetic coil plug

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

Fig. 7 Magnetic coil plug without LED and with-

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

Fig. 8

Fig. 9 Switching symbol in circuit diagram

158 BOMAG 008 914 20

Magnetic coil plug 9.15
Assembly of magnetic coil plugs
These instructions are intended to explain the correct
installation of the magnetic coil plug. The objective of
the instructions is the correct installation of the plug
and to avoid malfunctions in the field caused by mois-
ture and any related corrosion damage.

Fig. 12
l
Fasten the screw with a suitable screwdriver.

Fig. 10 Solenoid valve plug with pointed cable

Fig. 13
l
Press the plug firmly on again.

Fig. 11
l Connect the plug with the coil connection and press
it firmly onto the connecting housing.

Fig. 14
l Retighten the screw.

008 914 20 BOMAG 159

9.16 Deutsch plug, series DT and DTM

9.16 Deutsch plug, series DT and

DTM

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

Fig. 15

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

Fig. 17 Crimp connections

Caution
!

Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
Fig. 16 Correctly installed plug without gap When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).

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

160 BOMAG 008 914 20

Deutsch plug, series DT and DTM 9.16
DT Series

Fig. 1 DT plug connection

Fig. 2 DT Series

Fig. 3 Sectional drawing

008 914 20 BOMAG 161

9.16 Deutsch plug, series DT and DTM

DT Series
Installing DT contacts

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

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

i Note
Use the same method when assembling the socket.

Disassembling DT contacts

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

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

162 BOMAG 008 914 20

Deutsch plug, series DT and DTM 9.16
DTM Series

Fig. 6 DTM plug connection

Fig. 7 DTM Series

Fig. 8 Sectional drawing

008 914 20 BOMAG 163

9.16 Deutsch plug, series DT and DTM

Installing DTM contacts

Fig. 9
l
Insert the contacts through the rubber grommet until they click into place.
l Insert the orange wedge, until it clicks into place.

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

i Note
Use the same method when assembling the socket.

Disassembling DTM contacts

Fig. 10
l Pull the orange wedge (interlock) out with long nose pliers.
l Slightly pull the lead and unlock the interlocking hook with a screw driver.
l Pull the contact out of the socket.

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

164 BOMAG 008 914 20

Plugs and terminals in spring clamping technology 9.17
9.17 Plugs and terminals in spring clamping technology

General

Fig. 1

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

Connecting terminal for quick repairs

Fig. 2 That's how it works

BOMAG part-no.: 057 565 72

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

That's how it works

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

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

008 914 20 BOMAG 165

9.17 Plugs and terminals in spring clamping technology

Series clamp

Fig. 3 That's how it works

That's how it works

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

Caution
!

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

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

Fig. 4 Test adapter

166 BOMAG 008 914 20

Plugs and terminals in spring clamping technology 9.17
X-COM System
The X-COM-SYSTEM, a synthesis of plug connector and series clamp, has grown up to a construction kit for
universal system wiring, ever since it was introduced in 1997. All the familiar series clamping functions have thus
become pluggable.

X-COM plug clamp

Fig. 5 That's how it works

That's how it works

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

Caution
!

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

Fig. 6 X-COM plug with measuring cable

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

008 914 20 BOMAG 167

9.17 Plugs and terminals in spring clamping technology

Measuring signals

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

168 BOMAG 008 914 20

Inductive proximity switches 9.18
9.18 Inductive proximity switches NPN circuitry

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

Working principle

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

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

Fig. 9 PNP circuitry

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

008 914 20 BOMAG 169

9.19 Angle sensors

Sensor with current output

Fig. 1 Angle sensor

The the function of the angle sensor (Fig. 1) is based
on the so-called "Hall-Effect". Named after the Ameri-
can physicist E.H. Hall.
The advantage of the Hall sensor lies in the fact that,
in contrast to the potentiometer, there is no dragging
Fig. 12 Circuit diagram, making contact contact and thus no wear by abrasion.
The circuit diagram (Fig. 12) shows a proximity switch The Hall sensor generates an electric voltage, the Hall
with normally open contact. voltage. The necessary electric and magnetic proc-
esses take place in a very confined space inside the
Brown = voltage supply
Hall-IC. Since a vast variety of electronic elements
Blue = ground supply work together in highly complicated circuitries inside
Black = switching output the Hall-IC, the Hall sensor needs an external power
supply, which is not possible through the vehicle
The initiator switches the relay (K05)
mains supply or the associated control unit.
The Hall effect is based on the phenomenon that elec-
trons are deflected to one side when they pass
through a magnetic field that acts from the outside. In
this case an excess of electrons is created on the side
used by the electrons, because the negative electrical
potential of the flowing electrons predominates. On
the opposite side the electrically positive potential of
the stationary atomic cores is predominant, after the
associated electrons were forced to the opposite side.
A semi-conductor is used as current conductor.

170 BOMAG 008 914 20

Angle sensors 9.19
Situation without external magnetic field

Fig. 2
I = Current in semi-conductor of Hall-IC
W = Semi-conductor as current conductor in Hall-IC
Current passes through the semi-conductor W in the Fig. 4 Connection diagram
Hall-IC. Since there is no other magnetic force, the The angle sensor has 3 electric connections (Fig. 4).
electrons pass evenly through the semi-conductor.
Ub, supply voltage (+ 8.5 Volt)
There is no measureable Hall voltage (UHall = 0 V).
Gnd, ground
Situation with external magnetic field
Out, output current 4-20 mA.
l at -35° = 4 mA output current
l
at 0° = 12 mA output current
l at +35° = 20 mA output current.

Fig. 3
Current passes through the semi-conductor W in the
Hall-IC. Since there is the effect of an external mag-
netic field, the electrons are deflected to the left. There
is an excess of electrons on the left, and a lack of elec-
trons on the right. Hall voltage (UHall > 0 V) can be
measured on the side surfaces.

008 914 20 BOMAG 171

9.19 Angle sensors

Sensor with voltage output

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

172 BOMAG 008 914 20

Acceleration transducer 9.20

Fig. 1 When this combination is set to oscillate, the seismic

BVC machines and machines with E-VIB meter are (sluggish) mass transfers a force to the piezo disc. Ac-
equipped with two piezo-electric acceleration trans- cording to NewtonsLawtheresultantforceisthepro-
ducers, which are mounted to the drum. ductofaccelerationandmass.'
During operation these transducers transmit the ac- A small wire connects the piezo element with the sen-
celeration signals to the measuring ESX. sor socket.
The function of the piezo electric acceleration trans- The piezo electric effect generates a charge on the
ducer is based on the self-charging effect of quartz electrodes, which is proportional to the force and thus
crystals under mechanical load (pressure, tension, also to the acceleration.
torsion) in vertical direction to the polar axes, which
was discovered in 1880 by J. and P. Curie.

Mode of action
The piezo electric acceleration transducer consists of
two basic components:
l
Piezo electric material
l Seismic mass
Once side of the piezo disc is connected with the so-
called seismic mass, the other one with a rigid carrier.

008 914 20 BOMAG 173

9.21 Potentiometer on the slewing motor, B62

9.21 Potentiometer on the slewing

motor, B62
The potentiometer is directly connected with the con-
trol shaft of the slewing motor via a small coupling.
This enables to control and approach the exciter posi-
tion.

Disassembling the potentiometer

Fig. 1
1 Seismic mass
2 Piezo electric material
3 Acceleration

Fig. 1
l
Unscrew the fastening screws and remove the pro-
tection hood (Fig. 1).

Fig. 2
l Remove the protective hood 1 (Fig. 2).

174 BOMAG 008 914 20

Potentiometer on the slewing motor, B62 9.21
Installing the potentiometer

Fig. 3
Fig. 1
l Cut the cable straps (Fig. 3).
l
Disconnect the plug connection.
!Caution
The potentiometer must only be assembled in ver-
tical position.
If the slewing motor is incorrectly positioned (Fig.
1) (horizontal), it needs to be turned accordingly,
l .... for this purpose connect the new potentiometer
to plug (electrically).
l Start the engine and run it at idle speed.

i Note
The slewing motor swivels to vertical position.
l
Shut down the engine again.
Fig. 4
l Unscrew the fastening screws. (Fig. 4)

Fig. 2

Fig. 5
i Note
(Fig. 2) shows the correct installation position.
l Pull out the potentiometer housing (Fig. 5) and re-
place.

008 914 20 BOMAG 175

9.21 Potentiometer on the slewing motor, B62

Checking the potentiometer installation

Fig. 3

Fig. 1
i Note
If necessary rotate the potentiometer shaft and insert l Start the engine, run it with idle speed and watch the
it carefully into the blue coupling. display (Fig. 1).
l Assemble the new potentiometer with loop ring (Fig.
3). !Caution
If the potentiometer has been installed correctly,
the effective amplitude will be a "0" (Fig. 1).

Fig. 4
l Tighten the fastening screws (Fig. 4) hand tight.
Fig. 2

! Caution
If the potentiometer had been mounted incorrectly
(offset by 180°) the effective amplitude will be at
"0,9"(Fig. 2).
In this case the potentiometer needs to be turned
by 180° (Fig. 3).

176 BOMAG 008 914 20

Potentiometer on the slewing motor, B62 9.21
Fine-tuning the potentiometer l Fasten with new cable straps.
l Assemble the protection hood.

Fig. 1
l Park the machine on a firm base (asphalt or con-
crete) (Fig. 1).

i Note
Soft ground is not suitable.

Danger
!

Secure the wheels with chocks.

l Start the engine and run it with high speed.
l Switch the vibration on .
l Release the brake.

i Note
Turn the potentiometer housing clockwise, the drum
will rotate slowly forward.
Turn the potentiometer housing anti-clockwise, the
drum will rotate slowly backward.
l Turn the potentiometer housing anti-clockwise or
clockwise (Fig. 1), until the drum stops turning.

Fig. 2
l Tighten the fastening screws. (Fig. 2)
l
Shut down the engine.

008 914 20 BOMAG 177

9.22 Batteries

9.22 Batteries Battery maintenance

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

Battery test in general

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

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

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

178 BOMAG 008 914 20

Batteries 9.22
Testing batteries without screw plugs
On closed batteries the acid density cannot be meas-
ured, we therefore recommend testing with the follow-
ing mobile tester:

Fig. 3 Battery and generator tester

The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) integrated ther-
mal printer.

i Note
Before testing clean the poles and ensure good con-
nection between clamps and poles.
The test program calculates the text messages "good"
or "replace" on the basis of the charge condition (de-
rived from the battery voltage) and the currently avail-
able starting power of the battery. A battery with 45%
starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
The starting power represents the ratio of detected
cold testing current to the entered cold testing current
of the battery.
The starting power can exceed 100%.

008 914 20 BOMAG 179

9.22 Batteries

Charge condition with hydrometer

Fig. 4 Charge condition

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

! Danger

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

low, the battery must no longer be charged.

180 BOMAG 008 914 20

Battery service 9.23
9.23 Battery service

! Danger

Danger of cauterisation ! Danger of explosion!

When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
For recharging remove the plugs from the battery Fig. 5
to avoid the accumulation of highly explosive gas-
es.
l Remove the battery (Fig. 5) and clean the battery
compartment.
l Clean the outside of the battery.
Environment
Dispose of the old battery environmentally.
l Clean battery poles and pole clamps and grease
them with pole grease (Vaseline).
l Check the fastening of the battery.
i Note
Maintenance free batteries also need care. Mainte- l On serviceable batteries check the acid level, if nec-
nance free only means that the fluid level does not essary top up to the filling mark with distilled water.
need to be checked. Each battery suffers under self-
discharge, which may, in not checked occasionally,
even cause damage to the battery as a result of ex-
haustive discharge.

The following therefore applies for the service life:

l
Switch off all consumers (e.g. ignition, light, inside
light, radio).
l
Check open-circuit voltage of the battery at regular
intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l
Recharge the battery immediately after an open-cir-
cuit voltage of 12.25 V or less is reached. Do not
perform quick charging.
The open-circuit voltage of the battery occurs approx.
10 hours after the last charging process or one hour
after the last discharge.
l
After each charging process allow the battery to rest
for one hour before taking it into service.
l
For resting periods of more than one month you
should always disconnect the battery. Do not forget
to perform regular open-circuit voltage measure-
ments.

Caution
!

Exhausted batteries (batteries with formation of

sulphate on the plates) are not covered under war-
ranty!
l Open the engine hood and remove the covering

008 914 20 BOMAG 181

9.24 Main battery fuse

9.24 Main battery fuse 9.25 Starting with jump wires

Fig. 6 Fig. 7
125A = (F00) Main fuse
125A = (F48) Fuse for glow plugs !Caution
A wrong connection will cause severe damage in
the electric system.
i Note
Battery with main fuse is located in the engine com- l
Bridge the machine only with a 12 Volt auxiliary bat-
partment tery.
l
When jump starting with an external battery connect
both plus poles first.
l
Then connect the ground cable first to the minus
pole of the current supplying auxiliary battery and
then to engine or chassis ground, as far away from
the battery as possible (Fig. 7).
l
Start as described under 'Starting the engine'.
l
Once the engine is running switch on a powerful
consumer (working light, etc.).

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

182 BOMAG 008 914 20

Overview of electric components 9.26
9.26 Overview of electric components

1) Wiring loom cabin

008 914 20 BOMAG 183

9.26 Overview of electric components

1) Wiring loom engine

184 BOMAG 008 914 20

Overview of electric components 9.26

22) Wiring loom, battery-fuses

23) Wiring loom ground, battery-frame
24) Wiring loom ground, engine-frame
25) Wiring loom ground, battery-battery
26) Wiring loom supply central electrics
27) Wiring loom starter

008 914 20 BOMAG 185

9.26 Overview of electric components

1) Wiring loom rear frame

186 BOMAG 008 914 20

Overview of electric components 9.26

1) Wiring loom, central electrics-engine control unit

2) Wiring loom transducer for vibration frequency
3) Wiring loom speed transducer
4) Wiring loom speed range selector

008 914 20 BOMAG 187

9.26 Overview of electric components

13) Wiring loom, tachograph-cabin

188 BOMAG 008 914 20

Overview of electric components 9.26

7) Wiring loom working lights

008 914 20 BOMAG 189

9.26 Overview of electric components

1) Wiring loom front lighting StVZO

2) Wiring loom rear lighting StVZO

190 BOMAG 008 914 20

Overview of electric components 9.26

11) Wiring loom, lighting on railing

008 914 20 BOMAG 191

9.26 Overview of electric components

1) Wiring loom auxiliary heating

192 BOMAG 008 914 20

Overview of electric components 9.26

1) Wiring loom heating fan, old design

2) Wiring loom air conditioning, old design

008 914 20 BOMAG 193

9.26 Overview of electric components

1) Wiring loom heating fan, new design

2) Wiring loom air conditioning, new design

194 BOMAG 008 914 20

Overview of electric components 9.26

1) Wiring loom acceleration transducer

5) Wiring (P16)

008 914 20 BOMAG 195

9.26 Overview of electric components

5) Wiring loom, battery - battery disconnecting switch

6) Wiring loom battery disconnecting switch - frame

196 BOMAG 008 914 20

Overview of electric components 9.26

Fig. 8 9 S03, push button, warning horn

1 S00, ignition switch 10 S64, Rotary switch for attachment plates floating
2 A81 LC-Display unit position
3 Vent for heating and ventilation, driver 11 S139, Rotary switch for attachment plates vibration
4 Vent for heating and ventilation, footwell frequency
5 Control panel, travel lever 12 S36, Rotary switch vibration attachment plates on/
off
6 S55, Travel lever
13 S35, Rotary switch for drum amplitude
7 S42, Rotary switch, end speed
14 not used
8 S01, Emergency Stop switch

008 914 20 BOMAG 197

9.27 Cabin

15 S127, Rotary momentary contact switch for engine 9.27 Cabin

speed
16 S37, Rotary switch for direction indicators left/right*
17 S14, rotary switch for hazard light system*
18 S15, Rotary switch for lighting (StVZO)*
19 S53, Rotary switch for working lights*
20 S139, Rotary switch for drum frequency
21 Steering wheel adjustment lever

Fig. 9

a = S38, toggle switch for flashing beacon

b = S20, toggle switch for front windscreen wiper/

washer
up = windscreen wiper moves to end
position and stops.
down = Switches on front windscreen wip-
ing.
Push button = Front windscreen is sprayed dur-
ing wiping.

c = S21, toggle switch for rear windscreen wiper/

washer
up = windscreen wiper moves to end
position and stops.
down = Switches on wiping of rear wind-
screen.
Push button = Rear windscreen is sprayed dur-
ing wiping.

d = S163, toggle switch for rear windscreen heat-

ing

198 BOMAG 008 914 20

Electronic control units 9.28
9.28 Electronic control units

Control units
Control units (ECU = electronic control unit or ECM =
electronic control module) are electronic modules
which are mainly installed in places where something
needs to be controlled or regulated. Control units are
used in almost any electronic sector in the automotive
industry, but also to control machines, plants and oth-
er technical processes.
Control units generally work according to the IPO-
principle. IPO stands for Input-Processing-Output.
Sensors are available for input. Sensors determine a
Fig. 10 physical characteristic like e.g. rotary speed, pres-
g = E29, Reading and dashboard light sure, temperature, etc. This value is compared with a
setpoint entered into or calculated in the control unit.
h = S45, Toggle switch for cabin lamp If the measured value does not match the stored val-
ue, the control unit regulates the physical process by
i = S158, Toggle switch for reading and dashboard means of actors, so that the measured actual values
light match the setpoint again. This means that the actors
j = E70, Cabin lamp correctively interfere with the ongoing process.

Fig. 1 Electronic control (ESX)

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

008 914 20 BOMAG 199

9.28 Electronic control units

Modules Signals
In the latest generation of machines BOMAG uses Analog signals
machine programmable modules. A module mainly
consists of a programmable microprocessor with ad- Process states are continuous (analog) when they
ditional circuitry for inputs and outputs. can be mapped by means of a real number, e.g. tem-
perature = 65.5 °C. The sensor converts a continuous
process status into an analog signal. If the control unit
needs the numerical value of the analog signal, an an-
alog-digital conversion is required.
Analog signals are needed to control, display or mon-
itor limit values. Checking the limit values of physical
quantities leads to the binary information: limit value
reached/not reached.

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

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

200 BOMAG 008 914 20

Electronic control units 9.28
CAN-bus, Controller Area Network
created by Bosch at the end of the eighties for auto-
mobile applications.

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

Fig. 3

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

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

Measuring on the CAN

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

008 914 20 BOMAG 201

9.29 Checking the voltage supply for the control unit

Power supply for a control unit, general

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

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

Fig. 4 Circuitry example

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

202 BOMAG 008 914 20

Checking the voltage supply for the control unit 9.29
Fault in current supply, general
Clear interruptions in the plus or minus supply are relatively easy to detect. However, the plus and minus sides
of control units are in most cases connected to the vehicle mains supply via several cables, so that several par-
allel current branches exist. Checking the power supply is therefore slightly more difficult than expected. Another
point is the fact that every current branch has several plug connections, which could corrode over the years.
Corroded points are transition resistances and thus cause undesired voltage drops. In case of undesired voltage
drops the control unit is supplied with a lower voltage. This can lead to faulty reactions or even failure of the
control unit.

Fig. 5 Circuitry example

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

008 914 20 BOMAG 203

9.29 Checking the voltage supply for the control unit

Measuring principle for line testing

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

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

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

Fig. 6 Pinbox for 68 pole ESX control

204 BOMAG 008 914 20

Checking the voltage supply for the control unit 9.29
General measuring setup to check a supply line (plus side)

Fig. 7 Measuring arrangement 12 Volt

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

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

008 914 20 BOMAG 205

9.29 Checking the voltage supply for the control unit

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

Fig. 8 Measuring arrangement 12 Volt

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

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

206 BOMAG 008 914 20

Checking the voltage supply for the control unit 9.29
Connection example to check the plus line between battery and plug pin 28

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

008 914 20 BOMAG 207

9.29 Checking the voltage supply for the control unit

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

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

208 BOMAG 008 914 20

Checking the voltage supply for the control unit 9.29
Test protocol for ESX
E lamp 12V / 21W in 12V vehicle network, to load the current branches.
E lamp 24V / 21W in 24V vehicle network, to load the current branches.
G01, battery
P multimeter, measuring range: DC

Plug pin Note Setpoints

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

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

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

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

008 914 20 BOMAG 209

9.30 Diagnostics concept

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

Fault description and questioning of the customer

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

Description of fault,
Questioning of customer

Visual inspection,
possible test drive

Interrogation of error log

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

Fig. 11

(1) Fault memorized in error log

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

210 BOMAG 008 914 20

Diagnostics concept 9.30
Line or component?

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

Sequence after the fault is found

Fault found

Replace component or
repair the connecting line

Delete the error log, test drive

Read out the error log again

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

Fig. 13

008 914 20 BOMAG 211

9.30 Diagnostics concept

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

Consideration, when the error log has not recorded a fault

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

212 BOMAG 008 914 20

10 582 502 15 dust protection / 582 502 16 gasket

008 914 20 BOMAG 213

10.1 Assembling the dust protection

1. Unscrew the fastening screws (Fig. 1).

Fig. 1
2. Lift the operating console up and out (Fig. 2).

Fig. 2
3. Pull the wiring loom carefully out of the dash-
board(Fig. 3).

Fig. 3
4. Attach the new gasket to the back of the operat-
ing console (Fig. 4).

i Note
Pull the adhesive strip off the gasket and stick on
the gasket.

Fig. 4

214 BOMAG 008 914 20

Assembling the dust protection 10.1
5. Pull the dust protection bag over the operating
console (Fig. 5), (Fig. 6) and (Fig. 7).

Fig. 5

Fig. 6

Fig. 7
6. Tighten the screws for the operating console
hand tight (Fig. 8).

i Note
Ensure the seal/gasket is fitted correctly.

Fig. 8

008 914 20 BOMAG 215

10.1 Assembling the dust protection

7. Disassemble the dashboard, for this purpose un-

screw the fastening screws (4X), take off spacers
and washers (Fig. 9).

Fig. 9
8. Lift the dashboard up (Fig. 10) and.....

Fig. 10
9. ... fold it back (Fig. 11).

Fig. 11
10. Wrap the dust protection bag around the wiring
looms and fasten it with cable straps (Fig. 12).

Fig. 12

216 BOMAG 008 914 20

Assembling the dust protection 10.1
11. Assemble the dashboard (Fig. 13).

Fig. 13
12. Fasten the dashboard with fastening screws (4X),
spacers and washers (Fig. 14).

Fig. 14
13. Tighten the fastening screws (Fig. 15).

i Note
Check the function of control switches.

Fig. 15

008 914 20 BOMAG 217

10.1 Assembling the dust protection

218 BOMAG 008 914 20

11 Engine electrics

008 914 20 BOMAG 219

11.1 EMR3 system components

11.1 EMR3 system components i Note

The Deutz part-number specified on the EMR-control
Engine control unit unit is the part number without software specific for
the engine. The correct part number can be found in
the spare parts catalogue.
! Caution
It is strictly prohibited to interchange control units Replacing the EMR or DCR components
from one production series or against another en- l
On TCD-engines with Common Rail technology the
gine serial number. The warranty will in this case system pressure is so high, that in case of leaks or
become null and void. repair all parts need to be replaced. When replacing
Sensors and actuators must not be connected to sensors or other electric components, the new parts
external power sources for testing, but must sole- must be calibrated with the EMR control unit. This
ly be operated in combination with the EMR3. Oth- calibration must be performed with SERDIA (Level
erwise components may be permanently IIIa). (see also SERDIA manual).
damaged. l
Any other EMR components (sensors etc) must un-
Disconnecting the control unit plug connectors der no circumstances be repaired, but must be re-
with the control unit switched on (i.e. with power placed if they are defective.
supply to terminal 15), is not permitted. Correct
procedure: Switch off the electric power supply
(normally with the ignition switch), wait until the
main relay has switched off (delayed by up to 15 s,
listen for clicking sound), disconnect the plugs
from the control unit.
The engine control unit is the central component of the
EMR3-system. It has the function to assure optimal
engine performance with the objectives
l good exhaust characteristic,
l low fuel consumption,
l smooth running of engine,
l long lifetime of engine,
l efficient service
. For this purpose the engine control unit runs a
number of calculations using the detected measuring
values and the parameters saved in the database,
which for the basis for all functions provided. The most
important functions include:
l
exact control of injection process (among others the
number, start and duration of injection processes),
l idle speed control,
l control of the exhaust gas recirculation quantity,
l
optimization of smooth running (by means of cor-
recting the injection quantity),
l engine monitoring,
l system diagnose.

Replacing the control unit

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

220 BOMAG 008 914 20

EMR3 system components 11.1

Fig. 16
The engine control unit EMR3-S (TCD 2012 and TCD
2013) (Fig. 16) has two connecting sockets on the
front side of the housing:
l
the socket D2.1 to connect the engine wiring loom,
l the socket D2.2 to connect the vehicle wiring loom.

Fig. 17
The engine control unit EMR3-E (TCD 2015) (Fig. 17)
has three connecting sockets on top of the housing:
l the socket D2.1 to connect the vehicle wiring loom,
l the socket D2.2 to connect the engine wiring loom
for sensors and actuators,
l the socket D2.3 to connect the engine wiring loom
for fuel metering unit and injection valves.

008 914 20 BOMAG 221

11.1 EMR3 system components

EMR3-system in connection with injec-

tion system and electronics

Fig. 1 19 Pressure relief valve

1 Fuel tank 20 Battery, terminal 31 and 30
2 Pre-filter 21 Connecting cable between control unit and engine
3 Fuel lift pump 22 Connecting line for engine wiring loom
4 Fuel filter 23 Engine wiring harness
5 High pressure fuel pump 24 Sensor, water in fuel
6 Fuel metering unit ZME
7 Control unit
8 High pressure accumulator, rail
9 Injector
10 Rail pressure sensor
11 Exhaust gas turbocharger
12 Engine transfer plug
13 Exhaust gas recirculation, option
14 Engine sensors
15 Diagnostics lamp
16 Ignition switch
17 Pedal
18 Diagnostics button

222 BOMAG 008 914 20

EMR3 system components 11.1
Sensors TCD 2012 / 2013 Sensors TCD 2015

Fig. 1 Fig. 1
1 Fuel metering unit ZME 1 Oil pressure sensor
2 Coolant temperature sensor 2 Fuel temperature sensor
3 Sensor for charge air temperature and charge air 3 Sensor for charge air temperature and charge air
pressure pressure
4 Connecting line for engine wiring loom 4 Engine control unit
5 Engine control unit 5 Coolant temperature sensor
6 Rotary speed sensor for crankshaft 6 Oil level sensor, option
7 Rail pressure sensor 7 Central plug
8 Oil level sensor, option 8 Rotary speed sensor for crankshaft
9 Oil pressure sensor 9 Rotary speed sensor for camshaft
10 Fuel pressure sensor 10 Connecting line for engine wiring loom
11 Rotary speed sensor for camshaft
12 Central plug

008 914 20 BOMAG 223

11.1 EMR3 system components

Shutting down the engine

The engine is shut down by disconnecting the elec-
tronics from terminal 15 by means of the ignition
switch The injectors are closed immediately, the rail
pressure is reduced in a controlled manner and the
counter status data are saved in the non-volatile
memory. During this period the system must not be
disconnected from terminal 30 (+Ubatt). Once this time
has expired the main relay will switch off and the con-
trol unit is de-energized.
The main relay has the function of releasing the vehi-
cle power supply for the EMR3-system.
l The engine control unit EMR3-S requires an exter-
nal main relay (K41, see circuit diagram).
l The engine control unit EMR3-E has an internal
electronic main relay.
The following applies for both control units: once ter-
minal 15 is no longer connected to battery (+) (i.e. af-
ter the ignition has been switched off), the main relay
is switched off after approx. 10 seconds.
The main relay disconnects the control unit from ter-
minal 30 battery (+), whereby is becomes de-ener-
gized.
The switching state of the main relay can be directly
observed on Pin72 of the EMR3-S and on Pin13 of the
EMR3-E.

224 BOMAG 008 914 20

Pin assignment of engine control EDC16 / EMR3 11.2
11.2 Pin assignment of engine control EDC16 / EMR3

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008 914 20 BOMAG 229

11.3 Rotary speed sensor for camshaft

11.3 Rotary speed sensor for cam-

shaft

Speed sensor, B114

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

Fig. 4
l
Unscrew the screw (Fig. 4).
Fig. 2 l
Remove the speed sensor
Disassembling the speed sensor
Installing the speed sensor

Fig. 5
l Clean the sealing faces on speed transducer and
timing gear cover.
l Assemble a new O-ring (Fig. 5) (arrow).
l
Cover the O-ring slightly with oil.

Fig. 3
l Remove the cable strap (Fig. 3).
l Disconnect the cable plug.

230 BOMAG 008 914 20

Crankshaft speed sensor 11.4
11.4 Crankshaft speed sensor

Speed sensor, B130

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

RPM-meter
The rotary speed is detected by the EMR control and
passed on to the LC-Display (A81)(Fig. 8) via the
CAN-bus connection.

Fig. 6
l
Insert the speed sensor (Fig. 6).
l
Tighten the screw.

i Note
Assemble the screw with screw retention agent.

Fig. 8 A81, multi-function LC-Display

x = Engine rpm-meter

Fig. 7
Fig. 9 Crankshaft speed sensor
l Plug in the cable plug (Fig. 7).
l Route the cable.
l Fasten the cable with cable straps.

008 914 20 BOMAG 231

11.5 Rail pressure sensor

Check the gap measurement 11.5 Rail pressure sensor

Pressure sensor, B93

l Pressure sensor
l Monitoring the injection pressure

Fig. 11
Fig. 10
1 Toothed disc on crankshaft
Disassembling the pressure sensor
2 Speed sensor
l
Check gap measurement with a feeler gauge c (Fig.
! Danger
10).
After shutting down the engine wait 30 seconds,
Nominal value: 0,6 ± 0,5mm before starting work in the fuel system.

i Note !Caution
The feeler gauge must fit with only little resistance Ensure strict cleanliness when working on the
through the gap between toothed disc and speed sen- fuel system.
sor (crankshaft).
Thoroughly clean the areas around the affected
components. Dry off moist locations with com-
pressed air.
Do not allow foreign particles to enter into the rail.
Ensure strict cleanliness. Particularly on the
thread and the sealing surface of the rail.
Follow the safety regulations and the country spe-
cific instructions concerning the handling of fuel.
Close any opened connection immediately with
new and clean plugs/caps.
Remove plugs/caps only just before assembly.
Do not touch the pin contacts of the rail pressure
sensor with bare hands to avoid electrostatic dis-
charge.

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

232 BOMAG 008 914 20

Rail pressure sensor 11.5
Installing the rail pressure sensor

Fig. 12
l Unlock and pull out the cable plug (Fig. 12).
Fig. 14
l
Unscrew the rail pressure sensor with a socket
wrench
Caution
!

Ensure strict cleanliness. Particularly on the

thread and the sealing surface of the rail.
l Apply a little bit of grease to the thread and the seal-
ing edge of the rail pressure sensor.
l Turn in the rail pressure sensor (2) (Fig. 14) and
tighten it.

i Note
Tightening torque: 40 + 5Nm
l Plug on the cable plug.

Fig. 13
l Visually examine the thread and the sealing edge
(arrows) (Fig. 13) of the rail pressure sensor.

008 914 20 BOMAG 233

11.6 Fuel pressure sensor

Pressure sensor, B145

l Pressure sensor
l Monitoring of input pressure
The fuel low pressure sensor is located after the fuel
filter and the pressure is normally between 5 and 7
bar.

Fig. 16
l Unscrew the locking ring (Fig. 16).
l
Pull out the cable plug.
l
Unscrew the fuel pressure sensor with a socket
Fig. 15
wrench.
Disassembling the pressure sensor Assembling the pressure sensor

! Caution
Ensure strict cleanliness when working on the
fuel system.
Thoroughly clean the areas around the affected
components. Dry off moist locations with com-
pressed air.
Follow the safety regulations and the country spe-
cific instructions concerning the handling of fuel.
Close any opened connection immediately with
new and clean plugs/caps.
Remove plugs/caps only just before assembly.

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

Fig. 17
l
Install and tighten the fuel pressure sensor with a
new seal ring (Fig. 17).

i Note
Tightening torque: 30 ± 5 Nm

234 BOMAG 008 914 20

Fuel control unit 11.7
11.7 Fuel control unit

Control unit, Y137

Fig. 18
l Push the cable plug onto the fuel level sensor (Fig.
18).
l
Screw in the locking ring, until it locks in place.

Fig. 19
i Note
Ensure matching of the contacts. Function
Here the fuel flowing into the pump elements is me-
Bleed the fuel system via the manual fuel pump on the
tered by a infinitely controllable solenoid valve (re-
fuel pre-filter.
ferred to as fuel control unit).
This valve is mounted on the control block FCU (Fuel
Control Unit) and adapts the fuel quantity delivered to
the Rail to the system requirements. The solenoid
valve is triggered by means of a pulse width modulat-
ed signal (PWM-signal). When the valve is triggered,
the piston is actuated by magnetic force. This opens a
flow cross-section, the size of which depends on the
position of the piston. This quantity regulation lowers
the power requirements of the high pressure pump, it
only delivers the amount of fuel required to generate
the mapped rail pressure.

008 914 20 BOMAG 235

11.7 Fuel control unit

Fig. 21
1 Max. flow capacity
2 no flow

Fig. 20
1 Plug with electric interface
2 Magnet housing
3 Bearing
4 Armature with plunger
5 Winding with coil body
6 Bowl
7 Residual gap disc
8 Magnetic core
9 O-ring
10Piston with control slots
11Spring
12Securing element

236 BOMAG 008 914 20

Injector 11.8
11.8 Injector

Injectors, Y147, Y148, Y149, Y166, (Y169

and Y170, 6 cylinders engine)

Fig. 22
Fig. 23
Function
The injectors are installed in the cylinder head. They 
have the same function as nozzle and nozzle holder 
in conventional injection systems. The injectors are
connected with the pressure accumulator (Rail) by
high pressure lines (Fig. 23).
A valve determines the start of injection and the end
of injection of the nozzle. The actuating forces to open
and close the valve are generated by an solenoid. The
injectors work with 50 to 70 V instead of the 12 V on-
board voltage, which opens the injectors instantane-
ously. The high voltage is generated by capacitors in
the control unit. The solenoid valves are then held in Fig. 24
position by cycled 12 V power.
The forces required to open and close the nozzle nee-
dle cannot be generated by a solenoid valve on its
own. The nozzle needle is therefore indirectly trig-
gered via an hydraulic power booster system in the in-
jector (Fig. 24).

008 914 20 BOMAG 237

11.9 Oil pressure sensor

11.9 Oil pressure sensor The warning buzzer (H07) is triggered by the travel
control (A34).

Pressure sensor, B88

Oil pressure monitoring
The operator is warned if
l the oil pressure falls short of the warning limit and/or
l
the power is reduced by the EMR after a pre-warn-
ing time, or
l the oil pressure falls short of the shut-down limit and
the engine is shut down after a pre-warning time.

Fig. 25 Oil pressure sensor

Engine oil pressure warning light

The inductive sensor is monitored by the EMR-control
(A48). In case of a fault a message is sent through the
CAN-bus connection to the LC-Display (A81) (Fig. 26)
and to the data collector (A80).

Fig. 26 A81, multi-function LC-Display

e red = flashes if the oil pressure is too low. The
warning buzzer sounds, codes 5100 and
5112 appear in the display.
If the engine is shut down by the EMR
control the codes 5101 and 5112 will be
displayed.

i Note
A detailed description of how to read out fault codes
can be found in the Service Training Electrics.

238 BOMAG 008 914 20

Oil pressure sensor 11.9
Disassembling the pressure sensor Installing the pressure sensor

!Caution
Ensure absolute cleanliness when working in the
lubrication oil system.
Thoroughly clean the area around the affected
component. Dry off wet locations with com-
pressed air.
Immediately close all connections and openings
with new and clean plugs/caps.
Only remove plugs/caps just before assembling.

Environment
Catch engine oil and dispose of environmentally.

Fig. 28
l
Insert the oil pressure sensor with a new seal ring
and tighten.

i Note
Tightening torque: 20Nm

Fig. 27
l Unlock and pull out the cable plug (Fig. 27).
l
Unscrew the coolant temperature sensor.

008 914 20 BOMAG 239

11.10 Sensor for charge air temperature and charge air pressure

11.10Sensor for charge air tempera- Disassembling the sensor

ture and charge air pressure

Sensor, B133
Combined charge air pressure / temperature sen-
sor

Fig. 30
l
Unscrew fastening screw 1 (Fig. 30).
l
Remove the cover plate.

Fig. 29
This sensor unites two functions in one housing. The
one function measures the charge air pressure in the
and adapts the injection quantity in dependence on
the measured pressure. On the other hand the EMR
now detects the temperature of the passing air flow.
This is used for the smoke limitation.

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

Charge air temperature monitoring

The operator is warned if
Fig. 31
l
the temperature exceeds the warning limit and/or
l
Unlock and pull out the cable plug (Fig. 31).
l
the power is reduced by the EMR 3 after a pre-
warning time, or l Remove the pressure/temperature sensor.
l
the temperature exceeds the shut-down limit and
the engine is shut down after a pre-warning time.

240 BOMAG 008 914 20

Sensor for charge air temperature and charge air pressure 11.10
Assembling the sensor

Fig. 32
Fig. 34
l
Assemble a new O-ring (Fig. 32).
l Attach the cover plate (Fig. 34).
l
Slightly cover the O-ring with grease.
l
Tighten the screw (1).

Fig. 33
l Carefully insert the pressure/temperature sensor
(Fig. 33).
l Plug in and lock the cable plug.

008 914 20 BOMAG 241

11.11 EMR coolant temperature sensor

11.11EMR coolant temperature sen- i Note

sor A detailed description of how to read out fault codes
can be found in the Service Training Electrics.
Temperature sensor, B113 The warning buzzer (H07) is triggered by the travel
control (A34).
The coolant temperature has an effect on the calculat-
ed injection quantity and the preheating behaviour of Coolant temperature gauge
the glow plugs.
c = upper display field, shows either the time
Coolant temperature monitoring or the coolant temperature.
The operator is warned if
l the temperature exceeds the warning limit and/or
l the power is reduced by the EMR after a pre-warn-
ing time, or
l the temperature exceeds the shut-down limit and
the engine is shut down after a pre-warning time.

Fig. 35 Coolant temperature sensor

Warning light engine overheating

The coolant temperature is detected by the EMR con-
trol (A48). In case of a fault a message is sent through
the CAN-bus connection to the LC-Display (A81) (Fig.
36) and to the data collector (A80).

Fig. 36 A81, multi-function LC-Display

f red = flashes if the engine is overheating The
warning buzzer sounds, codes 5100 and
5116 appear in the display.
If the engine is shut down by the EMR
control the codes 5101 and 5116 will be
displayed.

242 BOMAG 008 914 20

EMR coolant temperature sensor 11.11
Disassembling the temperature sensor Installing the temperature sensor

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

i Note
Follow the corresponding documentation in the oper-
ating instructions to drain and fill the cooling system.

Fig. 39
l Tighten the coolant temperature sensor (Fig. 39).

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

Fig. 37
l Unlock and pull out the cable plug (Fig. 37).

Fig. 40
l Push on the cable plug (Fig. 40).

Fig. 38
l Unscrew the coolant temperature sensor (Fig. 38).

i Note
Counter the adapter piece.

008 914 20 BOMAG 243

11.12 Glow plugs

11.12Glow plugs 11.13Sensor, water in fuel

R81 to R86 Sensor, B124

The engines are equipped with glow plugs for cold
starting as standard. Preheating the glow plugs in the
combustion chamber of the diesel engine ensures
perfect cold starting and post-heating of the glow
plugs has a positive effect on the emissions from the
still "cold running" diesel engine (e.g. avoidance of
white smoke, noise reduction).

Pre-heating control light

Pre- and after-heating is passed on via the CAN-bus
connection to the LC-Display (A81) (Fig. 41).

Fig. 43
1 Water separator sensor connection (B124)
2 Fuel pre-heating connection * (R79) 200 Watt
Fig. 41 A81, LC-Display
k yellow = lights when temperatures are low (pre- Warning light water in fuel
heating for starting). The sensor data are detected by the EMR control
Triggering of glow plugs (A48) and passed on to the LC-Display (A81)(Fig. 44)
and the data collector (A80) via the CAN-bus connec-
During cold starting the EMR-control (Pin24 ground, tion.
Pin 34 plus) switches, whereby the coil of relay (K14)
is excited. The switch contact of relay (K14) supplies
the glow plugs with battery current.

Fuse for glow plugs

Fig. 44 A81, multi-function LC-Display

m red = Lights when the water proportion in the
transparent section of the fuel filter
reaches the contacts. The warning buzz-
Fig. 42 er sounds, codes 5100 and 5119 appear
125A = (F48) Fuse for glow plugs in the display.

125A = (F00) Main fuse

* Option

244 BOMAG 008 914 20

Fuel pre-heating 11.14
i Note 11.14Fuel pre-heating
A detailed description of how to read out fault codes
can be found in the Service Training Electrics. Fuel pre-heating (option)
The warning buzzer (H07) is triggered by the travel
control (A34). The travel control receives the signal i Note
from the data collector (A80) via the CAN-bus connec-
The preheating system is not monitored by the engine
tion.
control unit.

Fig. 45
1 Water separator sensor connection (B124)
2 Fuel pre-heating connection (R79) 200 Watt (op-
tion)
In diesel engines the pre-heating of the fuel prevents
malfunctions caused by the formation of jelly (paraffin
separation) in the fuel under low temperatures.
The heater is activated when the ignition is switched
on, this should take place at least 5 minutes before
starting the engine.
The generated heat works directly under the filter ele-
ment and melts the wax crystals that have formed, so
that the fuel can flow through the filter element without
restriction. The 200W heating is supplied with 12V
D.C-current.

008 914 20 BOMAG 245

11.15 Rotary switch for engine speed

11.15Rotary switch for engine 11.16Data collector

speed The data collector (A80) is an electronic device which
records various machine signals and supplies these in
form of a CAN-message to the machine system, main-
ly the display module.

Fig. 1

Rotary switch for engine speed, S127

The switch position is detected by the LC-Display
(A81) and passed on to the EMR-control (A48) via the
CAN-bus connection.
Position left = Idle speed position Fig. 1

Position middle = „ECO“ -mode. The electric evaluation of the signals takes place in
The engine speed adapts auto- analog mode.
matically to the power require- In the data collector various signals are recorded,
ments. This enables economical processed and, with the help of a micro-processor,
operation. passed on to the collective display via a CAN bus con-
Position right = Full throttle position, operating po- nection.
sition for driving and vibration The superordinate control sends a machine specific
parameter string via CAN bus, which enables the cal-
ibration of data in the collective display.
! Caution
Always drive and vibrate with max. engine speed
or in ECO-mode! Control the travel speed with the Collective display
travel lever.
CAN-Bus

electronic
Control

Data collector

Digital signals Analog signals

246 BOMAG 008 914 20

Data collector 11.16
Type and number of inputs: Vacuum switch, B03
l 11 digital inputs.
l 2 analog 4-20 mA current inputs to ground i Note
l 1 analog measuring input for temperature sensor. The vacuum is not monitored by the engine control
unit.
l 2 analog inputs for fuel and water level gauge
l 1 CAN bus

Digital inputs
The 11 inputs are (HIGH- and LOW-active) inputs,
which may be differently equipped, depending on the
machine type.
One of these digital inputs serves for direct connection
of a signal output from a Sepa filter for water separa-
tion in the fuel filter.

Analog inputs
The 4-20 mA inputs work against reference ground.

Fig. 2

Air filter warning light

At a vacuum of > 50 mbar the vacuum switch will
switch to ground.
The switching state is detected by the data collector
and passed on to the multi-function LC-Display (A81)
(Fig. 3) via the CAN-bus connection.

Fig. 3 A81, multi-function LC-Display

g yellow = lights (with a 5 second delay) if the com-
bustion air filter cartridge is contaminat-
ed. The warning buzzer sounds and the
code 5026 appears in the display. The
engine is shut down after 2 seconds, the
code 5027 is displayed.

i Note
The warning buzzer (H07) is triggered by the travel
control (A34).

008 914 20 BOMAG 247

11.16 Data collector

Float switch, B55 Charge control light

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

Fig. 4

Coolant level warning light

In case of a too low coolant level the float switch will
switch to ground.
The switching state is detected by the data collector Fig. 6
and passed on to the multi-function LC-Display (A81)
1 Terminal B+
(Fig. 5) and the EMR-control via the CAN-bus connec-
tion. 2 Terminal W
3 Terminal D+
If the battery is not being charged, a ground signal is
applied to D+ terminal 3 (Fig. 6).
The switching state is detected by the data collector
and passed on to the multi-function LC-Display (A81)
(Fig. 7) via the CAN-bus connection.

Fig. 5 A81, multi-function LC-Display

h red = flashes (with a 5 second delay) if the
coolant level is too low. The warning
buzzer sounds and the code 5024 ap-
pears in the display. The engine is shut
down after 10 seconds, the code 5025 is
displayed. Fig. 7 A81, multi-function LC-Display
l yellow = Charge control lamp, lights if the battery
i Note is not being charged. 
The warning buzzer (H07) is triggered by the travel Check V-belt, if necessary repair the
control (A34). generator.

248 BOMAG 008 914 20

Data collector 11.16
Level sensor in diesel tank (R03) Differential pressure switch for hydraulic
oil filter, B21
i Note
The immersion pipe sensor is not monitored by the
engine control unit.

Fig. 1
l The differential pressure switches (Fig. 1) switch to
Fig. 8 ground at a pressure differential of  3.6 bar.
The fluid of the level to be measured carries a float, The switching state is detected by the data collector
which lowers or rises with the fluid level. Contact and passed on to the multi-function LC-Display (A81)
springs mounted on the float thereby slide along two (Fig. 2) and the EMR-control via the CAN-bus connec-
resistor wires arranged parallel to the movement of tion.
the float and generate a resistance value, which is
proportionate to the fluid filling level.
The switching state is detected by the data collector
and passed on to the multi-function LC-Display (A81)
(Fig. 9) via the CAN-bus connection.

Fig. 2 A81, multi-function LC-Display

i yellow = lights if the hydraulic oil filter is contami-
nated, the engine is shut down after 2
minutes. Warning buzzer sounds.
Check hydraulic system, replace hydrau-
Fig. 9 A81, multi-function LC-Display lic oil filter.
b = Fuel level gauge
i Note
The warning buzzer (H07) is triggered by the travel
control (A34). The travel control receives the signal
from the data collector via the CAN-bus connection.

008 914 20 BOMAG 249

11.17 Fault display

Fig. 1 Display

Caution
!

All detected faults are displayed

Fault codes 5000 - 5499 are diesel engine related.
A detailed reading out of fault codes for the diesel engine is only possible with Deutz-Serdia

i Note
A detailed description of how to read out fault codes can be found in the Service Training Electrics.

250 BOMAG 008 914 20

Diagnose with SERDIA 11.18
11.18Diagnose with SERDIA

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

EDC16
EMR3

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

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

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

008 914 20 BOMAG 251

11.18 Diagnose with SERDIA

Representation of measuring values

Fig. 2
There is a vast variety of measuring values available
for selection which can even be used if no EMR-fault
is present (start behaviour, engine sawing, lack of
power).

252 BOMAG 008 914 20

Diagnose with SERDIA 11.18
Representation of fault log

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

008 914 20 BOMAG 253

11.19 Diagnose with CAN-bus

11.19Diagnose with CAN-bus

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

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

254 BOMAG 008 914 20

Diagnostics interface 11.20
11.20Diagnostics interface

SerDia connection

Fig. 1 Control unit under driver's stand

008 914 20 BOMAG 255

11.20 Diagnostics interface

SerDia connection

Serdia
Connecting
Socket

Fig. 2 Serdia connection socket in electrics cabinet K = K-Line

M = CAN2 high

Fig. 3 Diagnostic link

A = Battery plus (+)
B = Battery minus (-)
F = CAN2 low
G = CAN1 low
H = CAN1 high

256 BOMAG 008 914 20

Diagnostics interface 11.20
SERDIA connection CAN-bus display connection
Operation of the display is described in a separate op-
eration manual.

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

BOMAG part-no.: 057 189 94

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

BOMAG part-no.: 079 900 19

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

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

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

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

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

11.21

263
264
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Deutz-Code / SPN / Fehlername ...............................Seite Deutz-Code / SPN / Fehlername............................... Seite Deutz-Code / SPN / Fehlername...............................Seite
166 / 654 / InjVlvCyl4B .................................................... 40 211 / 523613 / RailMeUn0 ...............................................52 255 / 523659 / FrmMngRapeOilVlv1 ............................... 64
167 / 655 / InjVlvCyl5A .................................................... 40 212 / 523613 / RailMeUn1 ...............................................52 256 / 523660 / FrmMngRapeOilVlv2 ............................... 65
168 / 655 / InjVlvCyl5B .................................................... 40 213 / 523613 / RailMeUn2 ...............................................53 257 / 523661 / FrmMngRapeOilVlv3 ............................... 65
169 / 656 / InjVlvCyl6A .................................................... 41 214 / 523613 / RailMeUn3 ...............................................53 258 / 523662 / FrmMngRapeOilVlv4 ............................... 65
170 / 656 / InjVlvCyl6B .................................................... 41 215 / 523613 / RailMeUn4 ...............................................53 259 / 523663 / FrmMngRapeOilVlv5 ............................... 66
171 / 657 / InjVlvCyl7A .................................................... 41 216 / 523613 / RailMeUn7 ...............................................54 260 / 523664 / FrmMngSTIN1RX.................................... 66
172 / 657 / InjVlvCyl7B .................................................... 42 218 / 523490 / SOPTst.....................................................54
173 / 658 / InjVlvCyl8A .................................................... 42 219 / 1079 / SSpMon1 .....................................................54
174 / 658 / InjVlvCyl8B .................................................... 42 221 / 1080 / SSpMon2 .....................................................55
175 / 523370 / InjVlvErrDet.............................................. 43 222 / 523601 / SSpMon3 .................................................55
176 / 523615 / MeUnCD_ADC ........................................ 43 223 / 677 / StrtCDHS .......................................................55
177 / 523615 / MeUnCDNoLoad ..................................... 43 224 / 677 / StrtCDLS........................................................56
178 / 523615 / MeUnCDSCBat........................................ 44 225 / 624 / SysLamp ........................................................56
179 / 523615 / MeUnCDSCGnd ...................................... 44 226 / 158 / T15CD............................................................56
182 / 2634 / MnRly1_SCB ............................................... 44 227 / 523550 / T50CD......................................................57
183 / 2634 / MnRly1_SCG............................................... 45 228 / 523550 / TPUMon...................................................57
184 / 523420 / Montr........................................................ 45 232 / 84 / VSSCD1...........................................................57
186 / 2634 / MRlyCD ....................................................... 45 235 / 523600 / WdCom ....................................................58
187 / 563 / MRlyCDMnRly2 ............................................. 46 236 / 523470 / PRVMonSysReac ....................................58

BOMAG
188 / 2634 / MRlyCDMnRly3 ........................................... 46 237 / 523006 / APPCDSwtnSel........................................58
189 / 523450 / MSSCD1.................................................. 46 238 / 523007 / FrmMng_TORxEngPress.........................59
190 / 523451 / MSSCD2.................................................. 47 239 / 523008 / MplCtl.......................................................59
191 / 523452 / MSSCD3.................................................. 47 240 / 98 / OLSCD.............................................................59
192 / 639 / NetMngCANAOff ........................................... 47 241 / 98 / OLSCDSysReacHi...........................................60
193 / 1231 / NetMngCANBOff ......................................... 48 242 / 107 / ADPSCDAna..................................................60
194 / 1235 / NetMngCANCOff ......................................... 48 243 / 98 / OLSCDSysReacLo ..........................................60
195 / 705 / OPLpCD ........................................................ 48 244 / 523009 / PrvMonWear ............................................61
196 / 100 / OPSCD.......................................................... 49 245 / 523010 / RailMeUn8 ...............................................61
197 / 100 / OPSCD1........................................................ 49 246 / 523650 / FlSys_FLPFMSysReac............................61
198 / 100 / OPSCDSysReacHi ........................................ 49 247 / 523651 / FlSys_FTSFMSysReac............................62
199 / 100 / OPSCDSysReacLo........................................ 50 248 / 523652 / FlSys_FlushStateEngineOff.....................62
200 / 1237 / OSwCD........................................................ 50 249 / 523653 / FlSys_RapeOilHeatEx .............................62
201 / 175 / OTSCD .......................................................... 50 250 / 523654 / FrmMngDieselLvl .....................................63
203 / 175 / OTSCDSysReac............................................ 51 251 / 523655 / FrmMngFuelTemp....................................63
208 / 523470 / PRVMon .................................................. 51 252 / 523656 / FrmMngLowPressureDiesel.....................63
209 / 157 / RailCD ........................................................... 51 253 / 523657 / FrmMngRapeOilIn....................................64
210 / 157 / RailCDOfsTst................................................. 52 254 / 523658 / FrmMngRapeOilLvl ..................................64

DEUTZ AG, TE-CE, Fi Seite 2 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

11 / 107 / AirFltSysReac 12 / 91 / APP1 14 / 91 / APPPwm

Error description AIR FILTER COND. Error description THROTTLE 1 Error description THROTTLE 1
Air filter differential pressure: the pressure difference of the intake Analog accelerator pedal sensor 1 or double accelerator pedal Digital accelerator pedal sensor (PWM): the signal received by
air between the filter inlet and outlet calculated by ECU is above sensor: the voltage measured by ECU is out of the target range ECU is defective or implausible or the pulse-duty factor is out of
the target range and the ECU activates a system reaction or the calculated pedal position is implausible compared with the the target range
Error codes position of the second pedal Error codes
EMR3 List of fault codes

DEUTZ-Errorcode: 11 Error codes DEUTZ-Errorcode: 14

BlinkCode (short-long-short): 1 - 3 - 6 DEUTZ-Errorcode: 12 BlinkCode (short-long-short): 2 - 2 - 2
SPN: 107 BlinkCode (short-long-short): 2 - 2 - 6 SPN: 91
possible FMI: SPN: 91 possible FMI:
0: data valid, but above normal working area possible FMI: 8: unusual frequency, pulse or period.
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 8: unusual frequency, pulse or period.
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
12. Errormode not identifiable 12. Errormode not identifiable 8: unusual frequency, pulse or period.
Errordetection 2: data stream is defective Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errordetection Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Pressure loss above target range with system reaction, air filter Possible reason for error Duty cycle outside target range, signal erroneous or implausible
clogged or defective, sensor not working, connection cable Voltage outside target range, signal implausible compared to (pedal 1), sensor defective, onnection cable demaged
demaged signal of redundant pedal (analog pedal 1), sensor defective, Take actions for error repair

BOMAG
Take actions for error repair connection cable demaged Check cabling, check accelator pedal sensor and if necessary
Check airfilter and if necessary clean or renew it, check cabling, Take actions for error repair replace it, check connection cable and if necessary repair or
check air filter and if necessary replace the filter component, Check cabling, check accelator pedal sensor and if necessary replace it
check sensor and if necessary replace it, check connection cable replace it, check connection cable and if necessary repair or other error properties
and if necessary repair or replace it replace it System reaction: Warning, switching to substitute value
other error properties other error properties correspond to Priority-Chain or Limp Home
System reaction: Warning or Warning and power reduction System reaction: Warning, switching to substitute value Behaviour error lamp: permanent light
Behaviour error lamp: permanent light correspond to Priority-Chain or Limp Home Selfhealing: yes
Selfhealing: yes Behaviour error lamp: permanent light Signal Priority: 4
Signal Priority: 2 Selfhealing: no Measurement @ errortime: actual value
Measurement @ errortime: actual value Signal Priority: 4
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 3 Rev. 2.1, 22.10.2008

11.21

265
266
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

15 / 91 / APPPwmPer 16 / 108 / APSCD 17 / 729 / ArHt1

Error description THROTTLE 1 Error description BAROMETRIC PRESS. Error description AIR HEATER RELAY
digital accelerator pedal sensor (PWM): the frequence of the Ambient air pressure sensor (in ECU): the voltage measured by Air heater relay: the current drain measured by ECU is out of the
signal received by ECU is out of the target range ECU is out of the target range or the calculated ambient air target range
Error codes pressure is implausible compared with the charge air pressure Error codes
DEUTZ-Errorcode: 15 Error codes DEUTZ-Errorcode: 17
BlinkCode (short-long-short): 2 - 2 - 2 DEUTZ-Errorcode: 16 BlinkCode (short-long-short): 2 - 6 - 3
SPN: 91 BlinkCode (short-long-short): 2 - 9 - 2 SPN: 729
possible FMI: SPN: 108 possible FMI:
8: unusual frequency, pulse or period. possible FMI: 3: Voltage to high or short circuit to +Ubatt
8: unusual frequency, pulse or period. 3: Voltage to high or short circuit to +Ubatt 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection 2: data stream is defective Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errordetection Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Pulse frequency outside target range (pedal 1), sensor defective, Possible reason for error Cable break or short circuit at EDC output, relay defective,
connection cable demaged Ambient air pressure sensor defective, ECU defective connection cable demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling, check accelator pedal sensor and if necessary Change ECU Check cabling, if sensor not working, check relay and if

BOMAG
replace it, check connection cable and if necessary repair or other error properties necessary replace it, check connection cable and if necessary
replace it System reaction: Warning, substitute value (0,85bar) repair or replace it
other error properties Behaviour error lamp: permanent light other error properties
System reaction: Warning, switching to substitute value Selfhealing: yes System reaction: Warning, shutoff output
correspond to Priority-Chain or Limp Home Signal Priority: 4 Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Measurement @ errortime: default value Selfhealing: yes
Selfhealing: yes Signal Priority: 2
Signal Priority: 4 Measurement @ errortime: shut off value
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 4 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300

008 914 20
Diagnosis- and Errorcodes

18 / 730 / ArHt2 19 / 676 / ArHtCD_NoLd 20 / 676 / ArHtCD_RlyErr

Error description AIR HEATER VALVE Error description AIR HEATER Error description AIR HEATER
Air heater magnet valve: the current drain measured by ECU is Air heater relay: the ECU detects no switching operation at the Air heater relay: the ECU detects an implausible signal at the
out of the target range input of a readback process input of a readback process
Error codes Error codes Error codes
DEUTZ-Errorcode: 18 DEUTZ-Errorcode: 19 DEUTZ-Errorcode: 20
EMR3 List of fault codes

BlinkCode (short-long-short): 2 - 6 - 3 BlinkCode (short-long-short): 2 - 6 - 3 BlinkCode (short-long-short): 2 - 6 - 3

SPN: 730 SPN: 676 SPN: 676
possible FMI: possible FMI: possible FMI:
3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable 5: current to low or broken wire
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
5: current to low or broken wire 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Cable break or short circuit, valve defective, connection cable Relay energized, but no feedback on sense line, relay defective Relay not energized, but working voltage on sense line, relay
demaged or wrong wired, preheat component defective, connection cable defective (can not disconnect or switch off), preheat component
Take actions for error repair demaged defective, connection cable demaged
Check valve and if necessary replace it, check connection cable Take actions for error repair Take actions for error repair

BOMAG
and if necessary repair or replace it Check cabling of preheat component, if relay not working,check Check cabling of preheat component, if relay not working,check
other error properties relay and if necessary replace it, check preheat component and if relay and if necessary replace it, check preheat component and if
System reaction: necessary replace it, check connection cable and if necessary necessary replace it, check connection cable and if necessary
Behaviour error lamp: permanent light repair or replace it repair or replace it
Selfhealing: yes other error properties other error properties
Signal Priority: 2 System reaction: Warning System reaction: Warning
Measurement @ errortime: shut off value Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: no Selfhealing: no
Signal Priority: 3 Signal Priority: 3
Measurement @ errortime: setpoint for output status Measurement @ errortime: setpoint for output status

DEUTZ AG, TE-CE, Fi Seite 5 Rev. 2.1, 22.10.2008

11.21

267
268
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

22 / 168 / BattCD 23 / 168 / BattCDSysReac 24 / 523561 / BIPCyl1

Error description BATTERY VOLTAGE Error description BATTERY VOLTAGE Error description INJECT. PERIOD ZYL.1
Battery voltage: the voltage measured by ECU is out of the target Battery voltage: the voltage measured by ECU is out of the target Begin of injection of cylinder 1: the ECU can not identify the
range range; the ECU activates a system reaction magnet valve or the injection pump with the measured value of
Error codes Error codes current drain at the begin of the injection
DEUTZ-Errorcode: 22 DEUTZ-Errorcode: 23 Error codes
BlinkCode (short-long-short): 3 - 1 - 8 BlinkCode (short-long-short): 3 - 1 - 8 DEUTZ-Errorcode: 24
SPN: 168 SPN: 168 BlinkCode (short-long-short): 5 - 3 - 1
possible FMI: possible FMI: SPN: 523561
0: data valid, but above normal working area 2: data stream is defective possible FMI:
1: data valid, but below normal working area 2: data stream is defective 2: data stream is defective
12. Errormode not identifiable 12. Errormode not identifiable 2: data stream is defective
12. Errormode not identifiable 12. Errormode not identifiable 2: data stream is defective
Errordetection Errordetection 2: data stream is defective
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errordetection
Possible reason for error Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
Voltage below target range, battery defective, too high power Above target range with system reaction, too high power supply Possible reason for error
supply voltage, too high contact resistance, wiring demaged, voltage, parametering inaccurate, ECU defective Value outside target range or missing (cylinder 1), magnet valve
energie system overloaded, parametering inaccurate, ECU Take actions for error repair or injection pump defective
defective Check dataset of calibration of working voltage for application, Take actions for error repair

BOMAG
Take actions for error repair check LIMA? Check voltage of generator, check the parameters Check magnetic valve or injection pump and if
Check LIMA?, ECU, cabling, contact resistance, safety fuses, too and if necessary correct them, replace ECU necessary change them
high load in energy system, check battery and if necessary other error properties other error properties
replace it, check battery pole and if necessary clean it, check System reaction: Warning System reaction: No function at the moment/ Allocation check
connection cable and if necessary repair or replace it, check volta Behaviour error lamp: permanent light cylinder!
other error properties Selfhealing: yes Behaviour error lamp: permanent light
System reaction: Warning, substitute value, dependent upon Signal Priority: 4 Selfhealing: yes
supply voltage (12V, 24V) Measurement @ errortime: actual value Signal Priority: 3
Behaviour error lamp: permanent light Measurement @ errortime: actual value
Selfhealing: yes
Signal Priority: 3
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 6 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300

008 914 20
Diagnosis- and Errorcodes

25 / 523562 / BIPCyl2 26 / 523563 / BIPCyl3 27 / 523564 / BIPCyl4

Error description INJECT. PERIOD ZYL.2 Error description INJECT. PERIOD ZYL.3 Error description INJECT. PERIOD ZYL.4
Begin of injection of cylinder 2: the ECU can not identify the Begin of injection of cylinder 3: the ECU can not identify the Begin of injection of cylinder 4: the ECU can not identify the
magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of
current drain at the begin of the injection current drain at the begin of the injection current drain at the begin of the injection
Error codes Error codes Error codes
EMR3 List of fault codes

DEUTZ-Errorcode: 25 DEUTZ-Errorcode: 26 DEUTZ-Errorcode: 27

BlinkCode (short-long-short): 5 - 3 - 2 BlinkCode (short-long-short): 5 - 3 - 3 BlinkCode (short-long-short): 5 - 3 - 4
SPN: 523562 SPN: 523563 SPN: 523564
possible FMI: possible FMI: possible FMI:
2: data stream is defective 2: data stream is defective 2: data stream is defective
2: data stream is defective 2: data stream is defective 2: data stream is defective
2: data stream is defective 2: data stream is defective 2: data stream is defective
2: data stream is defective 2: data stream is defective 2: data stream is defective
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Value outside target range or missing (cylinder 2), magnet valve Value outside target range or missing (cylinder 3), magnet valve Value outside target range or missing (cylinder 4), magnet valve
or injection pump defective or injection pump defective or injection pump defective
Take actions for error repair Take actions for error repair Take actions for error repair

BOMAG
Check magnetic valve or injection pump and if Check magnetic valve or injection pump and if d
necessary change them necessary change them other error properties
other error properties other error properties System reaction: No function at the moment/ Allocation check
System reaction: No function at the moment/ Allocation check System reaction: No function at the moment/ Allocation check cylinder!
cylinder! cylinder! Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Selfhealing: yes
Selfhealing: yes Selfhealing: yes Signal Priority: 3
Signal Priority: 3 Signal Priority: 3 Measurement @ errortime: actual value
Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 7 Rev. 2.1, 22.10.2008

11.21

269
270
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

28 / 523565 / BIPCyl5 29 / 523566 / BIPCyl6 30 / 523567 / BIPCyl7

Error description INJECT. PERIOD ZYL.5 Error description INJECT. PERIOD ZYL.6 Error description INJECT. PERIOD ZYL.7
Begin of injection of cylinder 5: the ECU can not identify the Begin of injection of cylinder 6: the ECU can not identify the Begin of injection of cylinder 7: the ECU can not identify the
magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of
current drain at the begin of the injection current drain at the begin of the injection current drain at the begin of the injection
Error codes Error codes Error codes
DEUTZ-Errorcode: 28 DEUTZ-Errorcode: 29 DEUTZ-Errorcode: 30
BlinkCode (short-long-short): 5 - 3 - 5 BlinkCode (short-long-short): 5 - 3 - 6 BlinkCode (short-long-short): 5 - 3 - 7
SPN: 523565 SPN: 523566 SPN: 523567
possible FMI: possible FMI: possible FMI:
2: data stream is defective 2: data stream is defective 2: data stream is defective
2: data stream is defective 2: data stream is defective 2: data stream is defective
2: data stream is defective 2: data stream is defective 2: data stream is defective
2: data stream is defective 2: data stream is defective 2: data stream is defective
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Value outside target range or missing (cylinder 5), magnet valve Value outside target range or missing (cylinder 6), magnet valve Value outside target range or missing (cylinder 7), magnet valve
or injection pump defective or injection pump defective or injection pump defective
Take actions for error repair Take actions for error repair Take actions for error repair

BOMAG
Check magnetic valve or injection pump and if Check magnetic valve or injection pump and if Check magnetic valve or injection pump and if
necessary change them necessary change them necessary change them
other error properties other error properties other error properties
System reaction: No function at the moment/ Allocation check System reaction: No function at the moment/ Allocation check System reaction: No function at the moment/ Allocation check
cylinder! cylinder! cylinder!
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 3 Signal Priority: 3 Signal Priority: 3
Measurement @ errortime: actual value Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 8 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

31 / 523568 / BIPCyl8 32 / 102 / BPSCD 33 / 102 / BPSCDSysReac

Error description INJECT. PERIOD ZYL.8 Error description CHARGE AIR PRESS. Error description CHARGE AIR PRESS.
Begin of injection of cylinder 8: the ECU can not identify the Charge air pressure sensor: the measured voltage of sensor by Charge air pressure: the charge air pressure calculated by ECU
magnet valve or the injection pump with the measured value of ECU is out of the target range; the calculated charge air pressure is above the target range; the ECU activates a system reaction
current drain at the begin of the injection is implausible or the received value via CAN is defective Error codes
Error codes Error codes DEUTZ-Errorcode: 33
EMR3 List of fault codes

DEUTZ-Errorcode: 31 DEUTZ-Errorcode: 32 BlinkCode (short-long-short): 2 - 2 - 3

BlinkCode (short-long-short): 5 - 3 - 8 BlinkCode (short-long-short): 2 - 2 - 3 SPN: 102
SPN: 523568 SPN: 102 possible FMI:
possible FMI: possible FMI: 2: data stream is defective
2: data stream is defective 3: Voltage to high or short circuit to +Ubatt 2: data stream is defective
2: data stream is defective 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
2: data stream is defective 2: data stream is defective 12. Errormode not identifiable
2: data stream is defective 2: data stream is defective Errordetection
Errordetection Errordetection Errorlamp shows permanent light
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. oder
Possible reason for error Possible reason for error blinking. Entry in errormemory.
Value outside target range or missing (cylinder 8), magnet valve Cable break or short circuit, sensor defective, onnection cable Possible reason for error
or injection pump defective demaged Outside target range with system reaction, air system demaged,
Take actions for error repair Take actions for error repair sensor defective, onnection cable demaged

BOMAG
Check magnetic valve or injection pump and if Check cabling, if LDF6T sensor not working, check sensor and if Take actions for error repair
necessary change them necessary replace it, check connection cable and if necessary Check air system, inspect air system and if necessary repair it,
other error properties repair or replace it check sensor and if necessary replace it, check connection cable
System reaction: No function at the moment/ Allocation check other error properties and if necessary repair or replace it
cylinder! System reaction: Warning, substitute value other error properties
Behaviour error lamp: permanent light Behaviour error lamp: permanent light System reaction: Advice: BPSCD_stSysReacReq
Selfhealing: yes Selfhealing: yes Behaviour error lamp: permanent light
Signal Priority: 3 Signal Priority: 4 oder
Measurement @ errortime: actual value Measurement @ errortime: default value blinking
Selfhealing: yes
Signal Priority: 4
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 9 Rev. 2.1, 22.10.2008

11.21

271
272
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

37 / 111 / CLSCDSysReac 38 / 1323 / CmbChbMisfire1 39 / 1324 / CmbChbMisfire2

Error description ENG COOLANT LEVEL Error description MISFIRE CYL. 1 Error description MISFIRE CYL. 2
Coolant level: the coolant level calculated by ECU is underneath Misfire at cylinder 1: the number of the misfire detected by ECU Misfire at cylinder 2: the number of the misfire detected by ECU
the allowed minimum is out of the allowed limit value is out of the allowed limit value
Error codes Error codes Error codes
DEUTZ-Errorcode: 37 DEUTZ-Errorcode: 38 DEUTZ-Errorcode: 39
BlinkCode (short-long-short): 2 - 3 - 5 BlinkCode (short-long-short): 2 - 4 - 1 BlinkCode (short-long-short): 2 - 4 - 1
SPN: 111 SPN: 1323 SPN: 1324
possible FMI: possible FMI: possible FMI:
1: data valid, but below normal working area 12: Defective component 12: Defective component
1: data valid, but below normal working area 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
oder Possible reason for error Possible reason for error
blinking. Entry in errormemory. Misfire detected (cylinder 1), magnet valve or injection pump Misfire detected (cylinder 2), magnet valve or injection pump
Possible reason for error defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged
Outside target range with system reaction, cooling system Take actions for error repair Take actions for error repair
untight, sensor defective, onnection cable demaged Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace

BOMAG
Take actions for error repair them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor
Check coolant level, check cabling, inspect cooling system and if engineering and if necessary repair it engineering and if necessary repair it
necessary repair it, check sensor and if necessary replace it, other error properties other error properties
check connection cable and if necessary repair or replace it System reaction: System reaction:
other error properties Behaviour error lamp: permanent light Behaviour error lamp: permanent light
System reaction: Advice: CLSCD_stSysReacReq Selfhealing: no Selfhealing: no
Behaviour error lamp: permanent light Signal Priority: 0 Signal Priority: 0
oder Measurement @ errortime: actual value Measurement @ errortime: actual value
blinking
Selfhealing: no
Signal Priority: 3
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 10 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

40 / 1325 / CmbChbMisfire3 41 / 1326 / CmbChbMisfire4 42 / 1327 / CmbChbMisfire5

Error description MISFIRE CYL. 3 Error description MISFIRE CYL. 4 Error description MISFIRE CYL. 5
Misfire at cylinder 3: the number of the misfire detected by ECU Misfire at cylinder 4: the number of the misfire detected by ECU Misfire at cylinder 5: the number of the misfire detected by ECU
is out of the allowed limit value is out of the allowed limit value is out of the allowed limit value
Error codes Error codes Error codes
DEUTZ-Errorcode: 40 DEUTZ-Errorcode: 41 DEUTZ-Errorcode: 42
EMR3 List of fault codes

BlinkCode (short-long-short): 2 - 4 - 1 BlinkCode (short-long-short): 2 - 4 - 1 BlinkCode (short-long-short): 2 - 4 - 1

SPN: 1325 SPN: 1326 SPN: 1327
possible FMI: possible FMI: possible FMI:
12: Defective component 12: Defective component 12: Defective component
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Misfire detected (cylinder 3), magnet valve or injection pump Misfire detected (cylinder 4), magnet valve or injection pump Misfire detected (cylinder 5), magnet valve or injection pump
defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace

BOMAG
them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor
engineering and if necessary repair it engineering and if necessary repair it engineering and if necessary repair it
other error properties other error properties other error properties
System reaction: System reaction: System reaction:
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: no Selfhealing: no Selfhealing: no
Signal Priority: 0 Signal Priority: 0 Signal Priority: 0
Measurement @ errortime: actual value Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 11 Rev. 2.1, 22.10.2008

11.21

273
274
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

123 / 523608 / FrmMngTOTSC1DR 124 / 523609 / FrmMngTOTSC1PE 125 / 898 / FrmMngTOTSC1TE

Error description CAN ERROR TSC1-DR Error description CAN ERROR TSC1-PE Error description CAN ERROR TSC1-TE
CAN message TSC1-DR (Torque/Speed Control #1 from CAN message TSC1-PE (Torque/Speed Control #1 from Power CAN message TSC1-TE (Torque/Speed Control #1 from Traction
Driveline to Retarder): the message can not be received by ECU Take Off to Engine): the message can not be received by ECU Control to Engine): the message can not be received by ECU
Error codes Error codes Error codes
DEUTZ-Errorcode: 123 DEUTZ-Errorcode: 124 DEUTZ-Errorcode: 125
BlinkCode (short-long-short): 1 - 1 - 9 BlinkCode (short-long-short): 1 - 1 - 8 BlinkCode (short-long-short): 1 - 1 - 8
SPN: 523608 SPN: 523609 SPN: 898
possible FMI: possible FMI: possible FMI:
12: Defective component 12: Defective component 12: Defective component
12: Defective component 12: Defective component 12: Defective component
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Missing message "TSC1-DR", CAN bus wrong cabled, wiring is Missing message "TSC1-PE", CAN bus wrong cabled, wiring is Missing message "TSC1-TE", CAN bus wrong cabled, wiring is
demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately,
parametering inaccurate parametering inaccurate parametering inaccurate
Take actions for error repair Take actions for error repair Take actions for error repair

BOMAG
Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check CAN Bus cabling (Bus sheduling, polarity, short circuit,
power interrupt), test protocol of receiver, check CAN functional power interrupt), test protocol of receiver, check CAN functional power interrupt), test protocol of receiver, check CAN functional
range range range
other error properties other error properties other error properties
System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values
according to priority chain. according to priority chain. according to priority chain.
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: no Selfhealing: no Selfhealing: no
Signal Priority: 1 Signal Priority: 1 Signal Priority: 1
Measurement @ errortime: default value Measurement @ errortime: default value Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 28 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

126 / 520 / FrmMngTOTSC1TR 127 / 523610 / FrmMngTOTSC1VE 128 / 523611 / FrmMngTOTSC1VR

Error description CAN ERROR TSC1-TR Error description CAN ERROR TSC1-VE Error description CAN ERROR TSC1-VR
CAN message TSC1-TR (Torque/Speed Control #1 from Traction CAN message TSC1-VE (Torque/Speed Control #1 from Vehicle CAN message TSC1-VR (Torque/Speed Control #1 from Vehicle
Control to Retarder): the message can not be received by ECU Control to Engine): the message can not be received by ECU Control to Retarder): the message can not be received by ECU
Error codes Error codes Error codes
DEUTZ-Errorcode: 126 DEUTZ-Errorcode: 127 DEUTZ-Errorcode: 128
EMR3 List of fault codes

BlinkCode (short-long-short): 1 - 1 - 9 BlinkCode (short-long-short): 1 - 1 - 8 BlinkCode (short-long-short): 1 - 1 - 9

SPN: 520 SPN: 523610 SPN: 523611
possible FMI: possible FMI: possible FMI:
12: Defective component 12: Defective component 12: Defective component
12: Defective component 12: Defective component 12: Defective component
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Missing message "TSC1-TR", CAN bus wrong cabled, wiring is Missing message "TSC1-VE", CAN bus wrong cabled, wiring is Missing message "TSC1-VR", CAN bus wrong cabled, wiring is
demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately,
parametering inaccurate parametering inaccurate parametering inaccurate
Take actions for error repair Take actions for error repair Take actions for error repair

BOMAG
Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check CAN Bus cabling (Bus sheduling, polarity, short circuit,
power interrupt), test protocol of receiver, check CAN functional power interrupt), test protocol of receiver, check CAN functional power interrupt), test protocol of receiver, check CAN functional
range range range
other error properties other error properties other error properties
System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values
according to priority chain. according to priority chain. according to priority chain.
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: no Selfhealing: no Selfhealing: no
Signal Priority: 1 Signal Priority: 1 Signal Priority: 1
Measurement @ errortime: default value Measurement @ errortime: default value Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 29 Rev. 2.1, 22.10.2008

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291
292
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

131 / 523500 / FrmMngTxTO 133 / 174 / FTSCD 134 / 174 / FTSCDSysReac

Error description CAN MESS. TIMEOUT Error description FUEL TEMP. SENSOR Error description FUEL TEMP. SENSOR
CAN message: the ECU detects a timeout for one or more Fuel temperature sensor: the voltage measured by ECU is out of Fuel temperature: the fuel temperature calculated by ECU is
posted message the target range above the target range; the ECU activates a system reaction
Error codes Error codes Error codes
DEUTZ-Errorcode: 131 DEUTZ-Errorcode: 133 DEUTZ-Errorcode: 134
BlinkCode (short-long-short): 2 - 7 - 1 BlinkCode (short-long-short): 2 - 2 - 7 BlinkCode (short-long-short): 2 - 3 - 7
SPN: 523500 SPN: 174 SPN: 174
possible FMI: possible FMI: possible FMI:
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 0: data valid, but above normal working area
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 0: data valid, but above normal working area
12: Defective component 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light
Possible reason for error Possible reason for error oder
Timeout for sent messages Fuel temp. sensor: cable break or short circuit, sendor defective, blinking. Entry in errormemory.
Take actions for error repair connection cable demaged Possible reason for error
other error properties Take actions for error repair Above target range with system reaction, interruption of fuel loop
System reaction: Check cabling, if sensor not working, check sensor and if (for example, rail pressure relief valve defective), sensor

BOMAG
Behaviour error lamp: permanent light necessary replace it, check connection cable and if necessary defective, connection cable demaged
Selfhealing: yes repair or replace it Take actions for error repair
Signal Priority: 1 other error properties Check fuel system and if necessary repair it, check sensor and if
Measurement @ errortime: - System reaction: Warning, substitute value necessary replace it, check connection cable and if necessary
Behaviour error lamp: permanent light repair or replace it
Selfhealing: yes other error properties
Signal Priority: 4 System reaction: Advice: FTSCD_stSysReacReq
Measurement @ errortime: default value Behaviour error lamp: permanent light
oder
blinking
Selfhealing: yes
Signal Priority: 4
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 30 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

136 / 523618 / GOTSCD 137 / 523619 / GOTSCDSysReac 138 / 29 / HdThrt

Error description CUSTOMER TEMPSENS 1 Error description Error description THROTTLE 2
Customer specific temperature sensor 1: the voltage of sensor Customer specific temperature 1: the temperature calculated by Hand throttle pedal sensor: the voltage measured by ECU is out
measured by ECU is out of the target range or the received value ECU is above the target range; the ECU activates a system of the target range or the calculated pedal position is implausible
of temperature via CAN is defective reaction compared with the position of accelerator pedal 1
Error codes Error codes Error codes
EMR3 List of fault codes

DEUTZ-Errorcode: 136 DEUTZ-Errorcode: 137 DEUTZ-Errorcode: 138

BlinkCode (short-long-short): 1 - 3 - 3 BlinkCode (short-long-short): 1 - 3 - 3 BlinkCode (short-long-short): 1 - 2 - 6
SPN: 523618 SPN: 523619 SPN: 29
possible FMI: possible FMI: possible FMI:
3: Voltage to high or short circuit to +Ubatt 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 2: data stream is defective 4: Voltage to low or short circuit to -Ubatt
2: data stream is defective 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 2: data stream is defective
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error oder Possible reason for error
Cable break or short circuit (sensor 1), sensor defective, blinking. Entry in errormemory. Cable break or short circuit, signal implausible compared to
connection cable demaged, CAN bus wrong cabled, wiring Possible reason for error signal of idle sensor, transmitter defective, connection cable
demaged, receiver (sender of the message) work inaccurately, Outside target range with system reaction (temperature 1), demaged

BOMAG
parametering inaccurate dependant on the application Take actions for error repair
Take actions for error repair Take actions for error repair Check cabling, check sensor and if necessary replace it, check
Customer specific bugfixing, check sensor and if necessary Customer specific bugfixing, denpendant on application connection cable and if necessary repair or replace it
replace it, check connection cable and if necessary repair or other error properties other error properties
replace it, Check CAN Bus cabling (Bus sheduling, polarity, short System reaction: Advice: GOTSCD_stSysReacReq System reaction: Warning, changing to substitute values
circuit, power interrupt), test protocol of receiver, check CAN fun Behaviour error lamp: permanent light according to priority chain or limp home
other error properties oder Behaviour error lamp: permanent light
System reaction: Warning, substitute value (customer specific) blinking Selfhealing: no
Behaviour error lamp: permanent light Selfhealing: yes Signal Priority: 4
Selfhealing: yes Signal Priority: 3 Measurement @ errortime: actual value
Signal Priority: 2 Measurement @ errortime: actual value
Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 31 Rev. 2.1, 22.10.2008

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293
294
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

139 / 1638 / HOTSCD 140 / 1638 / HOTSCDSysReac 141 / 523617 / HWEMonCom

Error description CUSTOMER TEMPSENS 2 Error description CUSTOMER TEMPSENS 2 Error description INTERNAL COMM. ERROR
Customer specific temperature sensor 2: the voltage of sensor Customer specific temperature 2: the temperature calculated by Internal hardware monitoring: the ECU detects a communication
measured by ECU is out of the target range or the received value ECU is above the target range; the ECU activates a system distrubance
of temperature via CAN is defective reaction Error codes
Error codes Error codes DEUTZ-Errorcode: 141
DEUTZ-Errorcode: 139 DEUTZ-Errorcode: 140 BlinkCode (short-long-short): 5 - 5 - 5
BlinkCode (short-long-short): 3 - 1 - 4 BlinkCode (short-long-short): 3 - 1 - 4 SPN: 523617
SPN: 1638 SPN: 1638 possible FMI:
possible FMI: possible FMI: 12: Defective component
3: Voltage to high or short circuit to +Ubatt 2: data stream is defective 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 2: data stream is defective 12. Errormode not identifiable
12: Defective component 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable Errordetection
Errordetection Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light Possible reason for error
Possible reason for error oder Communication with chip CJ 940 disturbed, ECU defective
Cable break or short circuit (sensor 2), sensor defective, blinking. Entry in errormemory. Take actions for error repair
connection cable demaged, CAN bus wrong cabled, wiring Possible reason for error If cannot delete the error, change ECU
demaged, receiver (sender of the message) work inaccurately, Outside target range with system reaction (temperature 2), other error properties

BOMAG
parametering inaccurate dependant on the application System reaction: Warning
Take actions for error repair Take actions for error repair Behaviour error lamp: permanent light
Customer specific bugfixing, check sensor and if necessary Customer specific bugfixing, denpendant on application Selfhealing: no
replace it, check connection cable and if necessary repair or other error properties Signal Priority: 4
replace it, Check CAN Bus cabling (Bus sheduling, polarity, short System reaction: Advice: HOTSCD_stSysReacReq Measurement @ errortime: -
circuit, power interrupt), test protocol of receiver, check CAN fun Behaviour error lamp: permanent light
other error properties oder
System reaction: Warning, substitute value (customer specific) blinking
Behaviour error lamp: permanent light Selfhealing: yes
Selfhealing: yes Signal Priority: 3
Signal Priority: 2 Measurement @ errortime: actual value
Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 32 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

142 / 630 / HWEMonEEPROM 143 / 523612 / HWEMonRcyLocked 144 / 523612 / HWEMonRcySuppressed

Error description EEPROM MEM. ACCESS Error description INT. RECOVERY Error description INT. RECOVERY
Internal hardware monitoring: the ECU finds an error during the Internal hardware monitoring: the CPU of the ECU is reset and Internal hardware monitoring: the CPU of the ECU is reset and
access to ist EEPROM memory or works with an alternative the cause is logged internally; no item will be created in error the cause is logged internally; no item will be created in error
value memory memory
Error codes Error codes Error codes
EMR3 List of fault codes

DEUTZ-Errorcode: 142 DEUTZ-Errorcode: 143 DEUTZ-Errorcode: 144

BlinkCode (short-long-short): 2 - 8 - 1 BlinkCode (short-long-short): 5 - 5 - 5 BlinkCode (short-long-short): 5 - 5 - 5
SPN: 630 SPN: 523612 SPN: 523612
possible FMI: possible FMI: possible FMI:
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12: Defective component 12. Errormode not identifiable 12. Errormode not identifiable
12: Defective component 12. Errormode not identifiable 12. Errormode not identifiable
12: Defective component 14: Special Instructions 14: Special Instructions
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Error during EEPROM memory access or EEPROM works with A recovery occurred which is stored as protected A recovery occurred which is not stored
substitute value, programming error, ECU defective Take actions for error repair Take actions for error repair
Take actions for error repair Recoverey occured which is stored as protected Recoverey occured which is stored as protected

BOMAG
If not programmed, EEPROM is defect --> ECU is defect, With parameter HWEMon_numRexxxxxxx the recovery nummer With parameter HWEMon_numRexxxxxxx the recovery nummer
reprogram ECU and if necessary replace it and the subsequent position can be identified. See especially and the subsequent position can be identified. See especially
other error properties SW-Doku _rcy_auto.pdf SW-Doku _rcy_auto.pdf
System reaction: Warning other error properties other error properties
Behaviour error lamp: permanent light System reaction: Recovery of ECU System reaction: Warning, shown at error path
Selfhealing: no Behaviour error lamp: blinking Behaviour error lamp: blinking
Signal Priority: 4 Selfhealing: no Selfhealing: no
Measurement @ errortime: - Signal Priority: 5 Signal Priority: 5
Measurement @ errortime: - Measurement @ errortime: -

DEUTZ AG, TE-CE, Fi Seite 33 Rev. 2.1, 22.10.2008

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295
296
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

145 / 523612 / HWEMonRcyVisible 146 / 523612 / HWEMonUMaxSupply 147 / 523612 / HWEMonUMinSupply

Error description INT. RECOVERY Error description INT. RECOVERY Error description INT. RECOVERY
Internal hardware monitoring: the CPU of the ECU is reset and Internal hardware monitoring: the ECU detects an excess of the Internal hardware monitoring: the ECU detects an undershooting
an item will be created in error memory target range for the power supply of ist communication module of the target range for the power supply of ist communication
Error codes Error codes module
DEUTZ-Errorcode: 145 DEUTZ-Errorcode: 146 Error codes
BlinkCode (short-long-short): 5 - 5 - 5 BlinkCode (short-long-short): 5 - 5 - 5 DEUTZ-Errorcode: 147
SPN: 523612 SPN: 523612 BlinkCode (short-long-short): 5 - 5 - 5
possible FMI: possible FMI: SPN: 523612
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt possible FMI:
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
14: Special Instructions 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection 12. Errormode not identifiable
Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errordetection
Possible reason for error Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
A recovery occurred which is visible in the error memory Overvoltage at CJ940, power supply voltage too high, ECU Possible reason for error
Take actions for error repair defective Undervoltage at CJ940, power supply voltage too low, ECU
Recoverey occured which is stored as protected Take actions for error repair defective
With parameter HWEMon_numRexxxxxxx the recovery nummer Check working voltage and if necessary correct it, Check ECU Take actions for error repair

BOMAG
and the subsequent position can be identified. See especially and if necessary replace it Check working voltage and if necessary correct it, Check ECU
SW-Doku _rcy_auto.pdf other error properties and if necessary replace it
other error properties System reaction: Power stage shut off other error properties
System reaction: Recovery of ECU Behaviour error lamp: permanent light System reaction: Power stage shut off
Behaviour error lamp: blinking Selfhealing: no Behaviour error lamp: permanent light
Selfhealing: no Signal Priority: 4 Selfhealing: no
Signal Priority: 5 Measurement @ errortime: - Signal Priority: 4
Measurement @ errortime: - Measurement @ errortime: -

DEUTZ AG, TE-CE, Fi Seite 34 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

149 / 105 / IATSCD 150 / 105 / IATSCDSysReac 153 / 523350 / InjVlvBnk1A

Error description CHARGE AIR TEMP. Error description CHARGE AIR TEMP. Error description INJECTOR BANK A
Charge air temperature sensor: the voltage of sensor measured Charge air temperature: die charge air temperature calculated by Injector cylinder bank 1: the current drain measured by ECU is
by ECU is out of the target range or the received value of ECU is above the target range; the ECU activates a system above the target range
temperature via CAN is defective reaction Error codes
Error codes Error codes DEUTZ-Errorcode: 153
EMR3 List of fault codes

DEUTZ-Errorcode: 149 DEUTZ-Errorcode: 150 BlinkCode (short-long-short): 1 - 5 - 1

BlinkCode (short-long-short): 1 - 2 - 8 BlinkCode (short-long-short): 2 - 3 - 3 SPN: 523350
SPN: 105 SPN: 105 possible FMI:
possible FMI: possible FMI: 3: Voltage to high or short circuit to +Ubatt
3: Voltage to high or short circuit to +Ubatt 0: data valid, but above normal working area 4: Voltage to low or short circuit to -Ubatt
4: Voltage to low or short circuit to -Ubatt 0: data valid, but above normal working area 13: out of calibrated range
2: data stream is defective 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable Errordetection
Errordetection Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light Possible reason for error
Possible reason for error oder Short circuit (cylinder bank 1), injector defective, connection
Cable break or short circuit, sensor defective, connection cable blinking. Entry in errormemory. cable demaged
demaged, CAN bus wrong cabled, wiring demaged, receiver Possible reason for error Take actions for error repair
(sender of the message) work inaccurately, parametering Above target range with system reaction, air system demaged, Check cabling, check injectors and if necessary replace them,

BOMAG
inaccurate sensor defective, connection cable demaged check connection cable and if necessary repair or replace it
Take actions for error repair Take actions for error repair other error properties
Check cabling, LDF6T-sensor not working, check sensor and if Check construction of LDF6T , check suction parts, check air System reaction: Warning, cylinder shut off
necessary replace it, check connection cable and if necessary system and if necessary repair it, check sensor and if necessary Behaviour error lamp: permanent light
repair or replace it, Check CAN Bus cabling (Bus sheduling, replace it, check connection cable and if necessary repair or Selfhealing: yes
polarity, short circuit, power interrupt), test protocol of receiver, c replace it Signal Priority: 4
other error properties other error properties Measurement @ errortime: actual value
System reaction: Warning, substitute value System reaction: Advice: IATSCD_stSysReacReq
Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes oder
Signal Priority: 4 blinking
Measurement @ errortime: default value Selfhealing: yes
Signal Priority: 4
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 35 Rev. 2.1, 22.10.2008

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297
298
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

154 / 523351 / InjVlvBnk1B 155 / 523352 / InjVlvBnk2A 156 / 523353 / InjVlvBnk2B

Error description INJECTOR BANK A Error description INJECTOR BANK B Error description INJECTOR BANK B
Injector cylinder bank 1: the current drain measured by ECU is Injector cylinder bank 2: the current drain measured by ECU is Injector cylinder bank 2: the current drain measured by ECU is
underneath the target range above the target range underneath the target range
Error codes Error codes Error codes
DEUTZ-Errorcode: 154 DEUTZ-Errorcode: 155 DEUTZ-Errorcode: 156
BlinkCode (short-long-short): 1 - 5 - 1 BlinkCode (short-long-short): 1 - 5 - 2 BlinkCode (short-long-short): 1 - 5 - 2
SPN: 523351 SPN: 523352 SPN: 523353
possible FMI: possible FMI: possible FMI:
13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range
13: out of calibrated range 4: Voltage to low or short circuit to -Ubatt 13: out of calibrated range
5: current to low or broken wire 13: out of calibrated range 5: current to low or broken wire
13: out of calibrated range 12. Errormode not identifiable 13: out of calibrated range
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Cable break (cylinder bank 1), injector defective, connection Short circuit (cylinder bank 2), injector defective, connection Cable break (cylinder bank 2), injector defective, connection
cable demaged cable demaged cable demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them,

BOMAG
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it
other error properties other error properties other error properties
System reaction: Warning, cylinder shut off System reaction: Warning, cylinder shut off System reaction: Warning, cylinder shut off
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 4 Signal Priority: 4 Signal Priority: 4
Measurement @ errortime: actual value Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 36 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

157 / 523354 / InjVlvChipA 158 / 523355 / InjVlvChipB 159 / 651 / InjVlvCyl1A

Error description PWR. INJ. BANK B Error description PWR. INJ. BANK B Error description INJECTOR 1
Internal hardware monitoring: the ECU detects an error of ist Internal hardware monitoring: the ECU detects a disturbance in Injector 1: the current drain measured by ECU is above the target
injector high current output its injector high current output range
Error codes Error codes Error codes
DEUTZ-Errorcode: 157 DEUTZ-Errorcode: 158 DEUTZ-Errorcode: 159
EMR3 List of fault codes

BlinkCode (short-long-short): 1 - 5 - 3 BlinkCode (short-long-short): 1 - 5 - 3 BlinkCode (short-long-short): 1 - 5 - 4

SPN: 523354 SPN: 523355 SPN: 651
possible FMI: possible FMI: possible FMI:
3: Voltage to high or short circuit to +Ubatt 12: Defective component 3: Voltage to high or short circuit to +Ubatt
2: data stream is defective 12: Defective component 13: out of calibrated range
14: Special Instructions 12: Defective component 4: Voltage to low or short circuit to -Ubatt
12: Defective component 12: Defective component 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows blinking. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
High power stage Injector A, ECU defective High power stage Injector B, ECU defective Short circuit (cylinder 1), injector defective, connection cable
Take actions for error repair Take actions for error repair demaged
If error is not removable, change ECU If error is not removable, change ECU Take actions for error repair
other error properties other error properties Check cabling, check injectors and if necessary replace them,

BOMAG
System reaction: Warninig, outputs shut off System reaction: Warninig, outputs shut off check connection cable and if necessary repair or replace it
Behaviour error lamp: blinking Behaviour error lamp: blinking other error properties
Selfhealing: no Selfhealing: no System reaction: Warning, fuel injection failed, shut off wenn the
Signal Priority: 5 Signal Priority: 5 number of active cylinders below minimum
Measurement @ errortime: actual value Measurement @ errortime: actual value Behaviour error lamp: permanent light
Selfhealing: yes
Signal Priority: 4
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 37 Rev. 2.1, 22.10.2008

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299
300
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

160 / 651 / InjVlvCyl1B 161 / 652 / InjVlvCyl2A 162 / 652 / InjVlvCyl2B

Error description INJECTOR 1 Error description INJECTOR 2 Error description INJECTOR 2
Injector 1: the current drain measured by ECU is underneath the Injector 2: the current drain measured by ECU is above the target Injector 2: the current drain measured by ECU is underneath the
target range range target range
Error codes Error codes Error codes
DEUTZ-Errorcode: 160 DEUTZ-Errorcode: 161 DEUTZ-Errorcode: 162
BlinkCode (short-long-short): 1 - 5 - 4 BlinkCode (short-long-short): 1 - 5 - 5 BlinkCode (short-long-short): 1 - 5 - 5
SPN: 651 SPN: 652 SPN: 652
possible FMI: possible FMI: possible FMI:
13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range
13: out of calibrated range 13: out of calibrated range 13: out of calibrated range
5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire
13: out of calibrated range 12. Errormode not identifiable 13: out of calibrated range
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Cable break (cylinder 1), injector defective, connection cable Short circuit (cylinder 2), injector defective, connection cable Cable break (cylinder 2), injector defective, connection cable
demaged demaged demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them,

BOMAG
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it
other error properties other error properties other error properties
System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the
number of active cylinders below minimum number of active cylinders below minimum number of active cylinders below minimum
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 3 Signal Priority: 4 Signal Priority: 3
Measurement @ errortime: actual value Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 38 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

163 / 653 / InjVlvCyl3A 164 / 653 / InjVlvCyl3B 165 / 654 / InjVlvCyl4A

Error description INJECTOR 3 Error description INJECTOR 3 Error description INJECTOR 4
Injector 3: the current drain measured by ECU is above the target Injector 3: the current drain measured by ECU is underneath the Injector 4: the current drain measured by ECU is above the target
range target range range
Error codes Error codes Error codes
DEUTZ-Errorcode: 163 DEUTZ-Errorcode: 164 DEUTZ-Errorcode: 165
EMR3 List of fault codes

BlinkCode (short-long-short): 1 - 5 - 6 BlinkCode (short-long-short): 1 - 5 - 6 BlinkCode (short-long-short): 1 - 6 - 1

SPN: 653 SPN: 653 SPN: 654
possible FMI: possible FMI: possible FMI:
3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt
13: out of calibrated range 13: out of calibrated range 13: out of calibrated range
4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 13: out of calibrated range 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Short circuit (cylinder 3), injector defective, connection cable Cable break (cylinder 3), injector defective, connection cable Short circuit (cylinder 4), injector defective, connection cable
demaged demaged demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them,

BOMAG
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it
other error properties other error properties other error properties
System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the
number of active cylinders below minimum number of active cylinders below minimum number of active cylinders below minimum
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 4 Signal Priority: 3 Signal Priority: 4
Measurement @ errortime: actual value Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 39 Rev. 2.1, 22.10.2008

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301
302
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

166 / 654 / InjVlvCyl4B 167 / 655 / InjVlvCyl5A 168 / 655 / InjVlvCyl5B

Error description INJECTOR 4 Error description INJECTOR 5 Error description INJECTOR 5
Injector 4: the current drain measured by ECU is underneath the Injector 5: the current drain measured by ECU is above the target Injector 5: the current drain measured by ECU is underneath the
target range range target range
Error codes Error codes Error codes
DEUTZ-Errorcode: 166 DEUTZ-Errorcode: 167 DEUTZ-Errorcode: 168
BlinkCode (short-long-short): 1 - 6 - 1 BlinkCode (short-long-short): 1 - 6 - 2 BlinkCode (short-long-short): 1 - 6 - 2
SPN: 654 SPN: 655 SPN: 655
possible FMI: possible FMI: possible FMI:
13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range
13: out of calibrated range 13: out of calibrated range 13: out of calibrated range
5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire
13: out of calibrated range 12. Errormode not identifiable 13: out of calibrated range
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Cable break (cylinder 4), injector defective, connection cable Short circuit (cylinder 5), injector defective, connection cable Cable break (cylinder 5), injector defective, connection cable
demaged demaged demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them,

BOMAG
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it
other error properties other error properties other error properties
System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the
number of active cylinders below minimum number of active cylinders below minimum number of active cylinders below minimum
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 3 Signal Priority: 4 Signal Priority: 3
Measurement @ errortime: actual value Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 40 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

169 / 656 / InjVlvCyl6A 170 / 656 / InjVlvCyl6B 171 / 657 / InjVlvCyl7A

Error description INJECTOR 6 Error description INJECTOR 6 Error description INJECTOR 7
Injector 6: the current drain measured by ECU is above the target Injector 6: the current drain measured by ECU is underneath the Injector 7: the current drain measured by ECU is above the target
range target range range
Error codes Error codes Error codes
DEUTZ-Errorcode: 169 DEUTZ-Errorcode: 170 DEUTZ-Errorcode: 171
EMR3 List of fault codes

BlinkCode (short-long-short): 1 - 6 - 3 BlinkCode (short-long-short): 1 - 6 - 3 BlinkCode (short-long-short): 1 - 6 - 4

SPN: 656 SPN: 656 SPN: 657
possible FMI: possible FMI: possible FMI:
3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt
13: out of calibrated range 13: out of calibrated range 13: out of calibrated range
4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 13: out of calibrated range 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Short circuit (cylinder 6), injector defective, connection cable Cable break (cylinder 6), injector defective, connection cable Short circuit (cylinder 7), injector defective, connection cable
demaged demaged demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them,

BOMAG
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it
other error properties other error properties other error properties
System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the
number of active cylinders below minimum number of active cylinders below minimum number of active cylinders below minimum
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 4 Signal Priority: 3 Signal Priority: 4
Measurement @ errortime: actual value Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 41 Rev. 2.1, 22.10.2008

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303
304
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

172 / 657 / InjVlvCyl7B 173 / 658 / InjVlvCyl8A 174 / 658 / InjVlvCyl8B

Error description INJECTOR 7 Error description INJECTOR 8 Error description INJECTOR 8
Injector 7: the current drain measured by ECU is underneath the Injector 8: the current drain measured by ECU is above the target Injector 8: the current drain measured by ECU is underneath the
target range range target range
Error codes Error codes Error codes
DEUTZ-Errorcode: 172 DEUTZ-Errorcode: 173 DEUTZ-Errorcode: 174
BlinkCode (short-long-short): 1 - 6 - 4 BlinkCode (short-long-short): 1 - 6 - 5 BlinkCode (short-long-short): 1 - 6 - 5
SPN: 657 SPN: 658 SPN: 658
possible FMI: possible FMI: possible FMI:
13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range
13: out of calibrated range 13: out of calibrated range 13: out of calibrated range
5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire
13: out of calibrated range 12. Errormode not identifiable 13: out of calibrated range
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Cable break (cylinder 7), injector defective, connection cable Short circuit (cylinder 8), injector defective, connection cable Cable break (cylinder 8), injector defective, connection cable
demaged demaged demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them,

BOMAG
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it
other error properties other error properties other error properties
System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the
number of active cylinders below minimum number of active cylinders below minimum number of active cylinders below minimum
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 3 Signal Priority: 4 Signal Priority: 3
Measurement @ errortime: actual value Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 42 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

175 / 523370 / InjVlvErrDet 176 / 523615 / MeUnCD_ADC 177 / 523615 / MeUnCDNoLoad

Error description RAIL PRESS. MON. DISABLED Error description METERING UNIT Error description METERING UNIT
Rail pressure monitoring: the monitoring of the rail pressure will Fuel volume flow rate: the fuel volume rate calculated by ECU at Valve at outlet of the fuel metering unit: the ECU detects no load
be deactivated by ECU because of the activation of the function outlet of the fuel metering unit is out of the target range or temperature excess of the ECU component for power supply
"compression test" by user Error codes of the valve
Error codes DEUTZ-Errorcode: 176 Error codes
EMR3 List of fault codes

DEUTZ-Errorcode: 175 BlinkCode (short-long-short): 1 - 3 - 5 DEUTZ-Errorcode: 177

BlinkCode (short-long-short): 5 - 5 - 5 SPN: 523615 BlinkCode (short-long-short): 1 - 3 - 5
SPN: 523370 possible FMI: SPN: 523615
possible FMI: 3: Voltage to high or short circuit to +Ubatt possible FMI:
14: Special Instructions 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 5: current to low or broken wire
12. Errormode not identifiable Errordetection 12: Defective component
Errordetection Errorlamp shows permanent light. Entry in errormemory. Errordetection
Errorlamp shows . Entry in errormemory. Possible reason for error Errorlamp shows permanent light, 15s before shut off. Entry in
Possible reason for error Flow rate outside target range errormemory.
Compression test active: rail-pressure monitoring is going to be Take actions for error repair Possible reason for error
disabled other error properties wiring error or ECU output is switched off because of
Take actions for error repair System reaction: overtemperature, fuel metering unit defective, connection cable

BOMAG
not correct Behaviour error lamp: permanent light demaged
other error properties Selfhealing: no Take actions for error repair
System reaction: Rail pressure monitoring disabled Signal Priority: 4 Check cabling , if necessary check FCU, check fuel metering unit
Behaviour error lamp: Measurement @ errortime: actual value and if necessary replace it, check connection cable and if
Selfhealing: - necessary repair or replace it
Signal Priority: 1 other error properties
Measurement @ errortime: System reaction: Warning, max.extraction of FCU --> open rail
pressure relief valve --> shut the engine off in about 5 minutes
Behaviour error lamp: permanent light, 15s before shut off
Selfhealing: no
Signal Priority: 4
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 43 Rev. 2.1, 22.10.2008

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306
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

178 / 523615 / MeUnCDSCBat 179 / 523615 / MeUnCDSCGnd 182 / 2634 / MnRly1_SCB

Error description METERING UNIT Error description METERING UNIT Error description MAIN RELAY
Valve at outlet of the fuel metering unit: the current drain Valve at outlet of the fuel metering unit: the current drain Main relay 1: the current drains measured by ECU is above the
measured by ECU is above the target range measured by ECU is above the target range target range
Error codes Error codes Error codes
DEUTZ-Errorcode: 178 DEUTZ-Errorcode: 179 DEUTZ-Errorcode: 182
BlinkCode (short-long-short): 1 - 3 - 5 BlinkCode (short-long-short): 1 - 3 - 5 BlinkCode (short-long-short): 1 - 3 - 7
SPN: 523615 SPN: 523615 SPN: 2634
possible FMI: possible FMI: possible FMI:
12: Defective component 12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12: Defective component 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light. Entry in errormemory.
errormemory. errormemory. Possible reason for error
Possible reason for error Possible reason for error Short circuit to Ubatt (relay 1), relay defective, connection cable
Short circuit to Ubatt, fuel metering unit defective, connection Short circuit to ground, fuel metering unit defective, connection demaged
cable demaged cable demaged Take actions for error repair
Take actions for error repair Take actions for error repair Check cabling, check ECU, check relay and if necessary replace

BOMAG
Check cabling , if necessary check FCU, check fuel metering unit Check cabling , if necessary check FCU, check fuel metering unit it, check connection cable and if necessary repair or replace it
and if necessary replace it, check connection cable and if and if necessary replace it, check connection cable and if other error properties
necessary repair or replace it necessary repair or replace it System reaction: Warning, shutoff the outputs MPROP
other error properties other error properties Behaviour error lamp: permanent light
System reaction: Warning, rail pressure relief valve will open System reaction: Warning, rail pressure relief valve will open Selfhealing: no
Behaviour error lamp: permanent light, 15s before shut off Behaviour error lamp: permanent light, 15s before shut off Signal Priority: 3
Selfhealing: no Selfhealing: no Measurement @ errortime: actual value
Signal Priority: 4 Signal Priority: 4
Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 44 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

183 / 2634 / MnRly1_SCG 184 / 523420 / Montr 186 / 2634 / MRlyCD

Error description MAIN RELAY Error description WATCHDOG COUNTER Error description MAIN RELAY
Main relay 1: the current drains measured by ECU is above the Internal hardware monitoring: the ECU detects an disturbance in Main relay: during the switching off, main relay does not switch
target range ist monitoring module (Wachtdog) on within an allowed time
Error codes Error codes Error codes
DEUTZ-Errorcode: 183 DEUTZ-Errorcode: 184 DEUTZ-Errorcode: 186
EMR3 List of fault codes

BlinkCode (short-long-short): 1 - 3 - 8 BlinkCode (short-long-short): 1 - 3 - 9 BlinkCode (short-long-short): 2 - 6 - 1

SPN: 2634 SPN: 523420 SPN: 2634
possible FMI: possible FMI: possible FMI:
12. Errormode not identifiable 12. Errormode not identifiable 7: Mechanical system not OK
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 12: Defective component
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 14: Special Instructions 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Short circuit to ground (relay 1), relay defective, connection cable Watchdog counter exceeds maximum, ECU defective EDC16: main relay not open in allowed time or main relay open
demaged Take actions for error repair too early; EDC7: main relay not open in allowed time or short
Take actions for error repair If error is not removable, change ECU circuit of main relay to ground; EDC16: main relay defective,
Check cabling, check ECU, check relay and if necessary replace other error properties connection cable demaged; generally: rapid shut-off of the ECU

BOMAG
it, check connection cable and if necessary repair or replace it System reaction: Recovery of ECU (witho
other error properties Behaviour error lamp: blinking Take actions for error repair
System reaction: Warning, shutoff the outputs MPROP Selfhealing: no EDC16: check external main relay, check cabling
Behaviour error lamp: permanent light Signal Priority: 5 EDC7: if error is not removable, change ECU, EDC16: Check
Selfhealing: no Measurement @ errortime: - main relay and if necessary replace it, check connection cable
Signal Priority: 3 and if necessary repair or replace it; both: if error is not
Measurement @ errortime: actual value removable, change ECU
other error properties
System reaction: Warning
Behaviour error lamp: permanent light
Selfhealing: no
Signal Priority: 3
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 45 Rev. 2.1, 22.10.2008

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308
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

187 / 563 / MRlyCDMnRly2 188 / 2634 / MRlyCDMnRly3 189 / 523450 / MSSCD1

Error description MAIN RELAY 2 Error description MAIN RELAY Error description MULTISTATE SWITCH 1
Main relay 2 (in ECU): during the switching off, main relay does Main relay 3 (in ECU): during the switching off, main relay does Multi state switch 1: the voltage measured by ECU is out of the
not switch on within an allowed time not switch on within an allowed time target range or the swith setting is not plausible
Error codes Error codes Error codes
DEUTZ-Errorcode: 187 DEUTZ-Errorcode: 188 DEUTZ-Errorcode: 189
BlinkCode (short-long-short): 2 - 6 - 1 BlinkCode (short-long-short): 2 - 6 - 1 BlinkCode (short-long-short): 1 - 4 - 3
SPN: 563 SPN: 2634 SPN: 523450
possible FMI: possible FMI: possible FMI:
7: Mechanical system not OK 7: Mechanical system not OK 3: Voltage to high or short circuit to +Ubatt
12: Defective component 12: Defective component 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 2: data stream is defective
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
rapid shut-off of the ECU (without waiting till the end of the Short circuit to ground or emergency shut-off (relay 3 internal), Cable break or short circuit, input voltage outside target range
afterrun), ECU defective rapid shut-off of the ECU (without waiting till the end of the (switch 1), switch defective, connection cable demaged
Take actions for error repair afterrun), ECU defective Take actions for error repair
If error not removable, change ECU Take actions for error repair Check cabling and sensor, check switch and if necessary replace

BOMAG
other error properties Check cabling, check ECU, if error not removable, change ECU it, check connection cable and if necessary repair or replace it
System reaction: other error properties other error properties
Behaviour error lamp: permanent light System reaction: Warning, shutoff the outputs MPROP (see System reaction: Warning, substitute value
Selfhealing: no BOSCH-Electricity operating plan) Behaviour error lamp: permanent light
Signal Priority: 3 Behaviour error lamp: permanent light Selfhealing: yes
Measurement @ errortime: actual value Selfhealing: no Signal Priority: 2
Signal Priority: 3 Measurement @ errortime: default value
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 46 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

190 / 523451 / MSSCD2 191 / 523452 / MSSCD3 192 / 639 / NetMngCANAOff

Error description MULTISTATE SWITCH 2 Error description MULTISTATE SWITCH 3 Error description CAN A BUS OFF
Multi state switch 2: the voltage measured by ECU is out of the Multi state switch 3: the voltage measured by ECU is out of the CAN bus A: the ECU is not allowed to send messages, because
target range or the swith setting is not plausible target range or the swith setting is not plausible the status "BusOff" is detected
Error codes Error codes Error codes
DEUTZ-Errorcode: 190 DEUTZ-Errorcode: 191 DEUTZ-Errorcode: 192
EMR3 List of fault codes

BlinkCode (short-long-short): 1 - 4 - 3 BlinkCode (short-long-short): 1 - 4 - 3 BlinkCode (short-long-short): 2 - 7 - 1

SPN: 523451 SPN: 523452 SPN: 639
possible FMI: possible FMI: possible FMI:
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 14: Special Instructions
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
2: data stream is defective 2: data stream is defective 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Cable break or short circuit, input voltage outside target range Cable break or short circuit, input voltage outside target range Cable break or short circuit, off-state (CAN bus A), CAN bus
(switch 2), switch defective, connection cable demaged (switch 3), switch defective, connection cable demaged deactivated, connection cable demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling and sensor, check switch and if necessary replace Check cabling and sensor, check switch and if necessary replace Check cabling of CAN bus and if necessary repair it, check

BOMAG
it, check connection cable and if necessary repair or replace it it, check connection cable and if necessary repair or replace it connection cable and if necessary repair or replace it
other error properties other error properties other error properties
System reaction: Warning, substitute value System reaction: Warning, substitute value System reaction:
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 2 Signal Priority: 2 Signal Priority: 2
Measurement @ errortime: default value Measurement @ errortime: default value Measurement @ errortime:

DEUTZ AG, TE-CE, Fi Seite 47 Rev. 2.1, 22.10.2008

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310
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

193 / 1231 / NetMngCANBOff 194 / 1235 / NetMngCANCOff 195 / 705 / OPLpCD

Error description CAN B BUS OFF Error description CAN C BUS OFF Error description OIL PRESS LAMP
CAN bus B: the ECU is not allowed to send messages, because CAN bus C: the ECU is not allowed to send messages, because Warning lamp for oil level: the current drain measured by ECU is
the status "BusOff" is detected the status "BusOff" is detected out of the target range or the maximum temperature of the ECU
Error codes Error codes component for power supply of the lamp is exceeded
DEUTZ-Errorcode: 193 DEUTZ-Errorcode: 194 Error codes
BlinkCode (short-long-short): 2 - 7 - 1 BlinkCode (short-long-short): 2 - 7 - 1 DEUTZ-Errorcode: 195
SPN: 1231 SPN: 1235 BlinkCode (short-long-short): 1 - 3 - 5
possible FMI: possible FMI: SPN: 705
14: Special Instructions 14: Special Instructions possible FMI:
12. Errormode not identifiable 12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 12. Errormode not identifiable 5: current to low or broken wire
Errordetection Errordetection 2: data stream is defective
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errordetection
Possible reason for error Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
Cable break or short circuit, off-state (CAN bus B), CAN bus Cable break or short circuit, off-state (CAN bus C), CAN bus Possible reason for error
deactivated, connection cable demaged deactivated, connection cable demaged Cable break or short circuit, lamp defective, connection cable
Take actions for error repair Take actions for error repair demaged
Check cabling of CAN bus and if necessary repair it, check Check cabling of CAN bus and if necessary repair it, check Take actions for error repair

BOMAG
connection cable and if necessary repair or replace it connection cable and if necessary repair or replace it Check cabling and load, check lamp and if necessary replace it,
other error properties other error properties check connection cable and if necessary repair or replace it
System reaction: System reaction: other error properties
Behaviour error lamp: permanent light Behaviour error lamp: permanent light System reaction: Warning, shutoff output
Selfhealing: yes Selfhealing: yes Behaviour error lamp: permanent light
Signal Priority: 2 Signal Priority: 2 Selfhealing: no
Measurement @ errortime: Measurement @ errortime: Signal Priority: 1
Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 48 Rev. 2.1, 22.10.2008

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EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

196 / 100 / OPSCD 197 / 100 / OPSCD1 198 / 100 / OPSCDSysReacHi

Error description ENG OIL PRESS. Error description ENG OIL PRESS. Error description ENG OIL PRESS.
Oil pressure sensor: the voltage of sensor measured by ECU is Oil pressure: the oil pressure calculated by ECU is implausibly Oil pressure: the oil pressure calculated by ECU is above the
out of the target range or the received value of oil pressure via low target range; the ECU activates a system reaction
CAN is implausible (Oil pressure is above the target range with Error codes Error codes
higher oil temperature at the same time) DEUTZ-Errorcode: 197 DEUTZ-Errorcode: 198
EMR3 List of fault codes

Error codes BlinkCode (short-long-short): 2 - 3 - 1 BlinkCode (short-long-short): 2 - 3 - 1

DEUTZ-Errorcode: 196 SPN: 100 SPN: 100
BlinkCode (short-long-short): 2 - 2 - 4 possible FMI: possible FMI:
SPN: 100 12. Errormode not identifiable 0: data valid, but above normal working area
possible FMI: 12. Errormode not identifiable 0: data valid, but above normal working area
3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 1: data valid, but below normal working area 12. Errormode not identifiable
2: data stream is defective Errordetection Errordetection
0: data valid, but above normal working area Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light
Errordetection Possible reason for error oder
Errorlamp shows permanent light. Entry in errormemory. Oil pressure implausible low, sensor defective, connection cable blinking. Entry in errormemory.
Possible reason for error demaged Possible reason for error
Cable break or short circuit, sensor defective, connection cable Take actions for error repair Above target range, oil volume too large, sensor defective, oil
demaged, CAN bus wrong cabled, wiring demaged, receiver Check cabling, if sensor not working, check sensor and if pump defective, connection cable demaged

BOMAG
(sender of the message) work inaccurately, parametering necessary replace it, check connection cable and if necessary Take actions for error repair
inaccurate repair or replace it Check oil level and if necessary correct it, check oil pump and if
Take actions for error repair other error properties necessary replace it, check sensor and if necessary replace it,
Check cabling, if sensor not working, check sensor and if System reaction: Warning, substitute value check connection cable and if necessary repair or replace it
necessary replace it, check connection cable and if necessary Behaviour error lamp: permanent light other error properties
repair or replace it, Check CAN Bus cabling (Bus sheduling, Selfhealing: yes System reaction: Advice: OPSCD_stSysReacReqHi
polarity, short circuit, power interrupt), test protocol of receiver, Signal Priority: 2 Behaviour error lamp: permanent light
chec Measurement @ errortime: actual value oder
other error properties blinking
System reaction: Warning, substitute value Selfhealing: yes
Behaviour error lamp: permanent light Signal Priority: 4
Selfhealing: yes Measurement @ errortime: actual value
Signal Priority: 4
Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 49 Rev. 2.1, 22.10.2008

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312
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

199 / 100 / OPSCDSysReacLo 200 / 1237 / OSwCD 201 / 175 / OTSCD

Error description ENG OIL PRESS. Error description OVERRIDE SWITCH Error description OIL TEMP. SENSOR
Oil pressure: the oil pressure calculated by ECU is underneath Bridgeover switch: the ECU receives a permanent signal Oil temperature sensor: the voltage of sensor measured by ECU
the target range; the ECU activates a system reaction Error codes is out of the target range; the oil temperature calculated by ECU
Error codes DEUTZ-Errorcode: 200 is implausible compared with coolant temperature or the received
DEUTZ-Errorcode: 199 BlinkCode (short-long-short): 1 - 4 - 5 value via CAN is defective
BlinkCode (short-long-short): 2 - 3 - 1 SPN: 1237 Error codes
SPN: 100 possible FMI: DEUTZ-Errorcode: 201
possible FMI: 12. Errormode not identifiable BlinkCode (short-long-short): 1 - 4 - 4
1: data valid, but below normal working area 12. Errormode not identifiable SPN: 175
1: data valid, but below normal working area 12. Errormode not identifiable possible FMI:
12. Errormode not identifiable 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable Errordetection 4: Voltage to low or short circuit to -Ubatt
Errordetection Errorlamp shows permanent light. Entry in errormemory. 2: data stream is defective
Errorlamp shows permanent light Possible reason for error 2: data stream is defective
oder Switch is blocked, taster locked, connection cable demaged Errordetection
blinking. Entry in errormemory. Take actions for error repair Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Check cabling, if sensor not working, check switch and if Possible reason for error
Below target range, oil volume too small, sensor defective, oil necessary replace it, check connection cable and if necessary Cable break or short circuit, sensor defective, connection cable
pump defective, connection cable demaged repair or replace it demaged

BOMAG
Take actions for error repair other error properties Take actions for error repair
Check oil level and if necessary correct it, check oil pump and if System reaction: Warning Check cabling, if sensor not working, check switch and if
necessary replace it, check sensor and if necessary replace it, Behaviour error lamp: permanent light necessary replace it, check connection cable and if necessary
check connection cable and if necessary repair or replace it Selfhealing: yes repair or replace it
other error properties Signal Priority: 2 other error properties
System reaction: Advice: OPSCD_stSysReacReqLo Measurement @ errortime: actual value System reaction: Warning, substitute value
Behaviour error lamp: permanent light Behaviour error lamp: permanent light
oder Selfhealing: yes
blinking Signal Priority: 4
Selfhealing: yes Measurement @ errortime: default value
Signal Priority: 4
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 50 Rev. 2.1, 22.10.2008

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EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300

008 914 20
Diagnosis- and Errorcodes

203 / 175 / OTSCDSysReac 208 / 523470 / PRVMon 209 / 157 / RailCD

Error description OIL TEMP. SENSOR Error description RAIL PRESS. LIM. VALVE Error description RAIL PRESS. SENSOR
Oil temperature: the oil temperature calculated by ECU is above Rail pressure relief valve: is open, will be forced to open, the Rail pressure sensor: the voltage of sensor measured by ECU is
the target range; the ECU activates a system reaction forced-open failed out of the target range
Error codes Error codes Error codes
DEUTZ-Errorcode: 203 DEUTZ-Errorcode: 208 DEUTZ-Errorcode: 209
EMR3 List of fault codes

BlinkCode (short-long-short): 1 - 4 - 4 BlinkCode (short-long-short): 1 - 4 - 6 BlinkCode (short-long-short): 1 - 4 - 7

SPN: 175 SPN: 523470 SPN: 157
possible FMI: possible FMI: possible FMI:
0: data valid, but above normal working area 14: Special Instructions 3: Voltage to high or short circuit to +Ubatt
0: data valid, but above normal working area 2: data stream is defective 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 12: Defective component 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light, 15s before shut off. Entry in
oder errormemory. errormemory.
blinking. Entry in errormemory. Possible reason for error Possible reason for error
Possible reason for error Rail pressure relief valve open or forced open abortive Cable break or short circuit, sensor defective, connection cable
Above target range with system reaction, oil volume too small, oil (interpretation of the rail pressure gradient), operating voltage too demaged
loop disturbed, sensor defective, connection cable demaged low, rail pressure sensor defective, fuel metering unit defective, Take actions for error repair

BOMAG
Take actions for error repair rail pressure relief valve defective, air in fuel system Check cabling, check rail pressure sensor and if necessary
Check cycle cooling system and compressor, check oil level and Take actions for error repair replace it, check connection cable and if necessary repair or
if necessary correct it, check sensor and if necessary replace it, Check working voltage and if necessary correct it, check rail- replace it
check oil loop and if necessary repair it, check connection cable pressure sensor and if necessary replace it, check FCU and if other error properties
and if necessary repair or replace it necessary replace it, check rail pressure relief valve and if System reaction: Warning, max.extraction of FCU --> open rail
other error properties necessary replace it, bleed the fuel-system pressure relief valve --> shut the engine off in about 5 minutes
System reaction: Advice: OTSCD_stSysReacReq other error properties Behaviour error lamp: permanent light, 15s before shut off
Behaviour error lamp: permanent light System reaction: Warning, shut the engine off in about 5 minutes Selfhealing: no
oder Behaviour error lamp: permanent light, 15s before shut off Signal Priority: 4
blinking Selfhealing: no Measurement @ errortime: default value
Selfhealing: yes Signal Priority: 4
Signal Priority: 4 Measurement @ errortime: actual value
Measurement @ errortime: actual value

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314
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

210 / 157 / RailCDOfsTst 211 / 523613 / RailMeUn0 212 / 523613 / RailMeUn1

Error description RAIL PRESS. SENSOR Error description RAIL PRESSURE Error description RAIL PRESSURE
Rail pressure sensor: the change of the voltage measured by Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is
ECU during the engine start or the after-run is out of the target above the target range which is dependant on the engine speed above the target range which is dependant on the volume flow
range Error codes rate
Error codes DEUTZ-Errorcode: 211 Error codes
DEUTZ-Errorcode: 210 BlinkCode (short-long-short): 1 - 3 - 4 DEUTZ-Errorcode: 212
BlinkCode (short-long-short): 1 - 4 - 7 SPN: 523613 BlinkCode (short-long-short): 1 - 3 - 4
SPN: 157 possible FMI: SPN: 523613
possible FMI: 0: data valid, but above normal working area possible FMI:
0: data valid, but above normal working area 12. Errormode not identifiable 0: data valid, but above normal working area
1: data valid, but below normal working area 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable Errordetection 12. Errormode not identifiable
Errordetection Errorlamp shows permanent light Errordetection
Errorlamp shows permanent light. Entry in errormemory. oder Errorlamp shows permanent light
Possible reason for error blinking. Entry in errormemory. oder
Deviation of signal during start or after-run above target range, Possible reason for error blinking. Entry in errormemory.
sensor defective 1) Leakage in high pressure system (external) , Possible reason for error
Take actions for error repair 2) Leakage at rail pressure relief valve (internal), 1) Leakage in high pressure system (external) ,

BOMAG
Replace sensor 3) Needle clampt in open position, 2) Leakage at rail pressure relief valve (internal),
other error properties 4) Abrasion at injector, 3) Needle clampt in open position,
System reaction: Warning 5) Abrasion at high pressure pump, 4) Abrasion at injector,
Behaviour error lamp: permanent light 6) Too low primary pressure on low pressure side, sensor d 5) Abrasion at high pressure pump,
Selfhealing: yes Take actions for error repair 6) Too low primary pressure on low pressure side, sensor d
Signal Priority: 2 (A) Check for leakage Take actions for error repair
Measurement @ errortime: actual value (B) Chek fuel-primary pressure (A) Check for leakage
(C) Change components, check sensor and if necessary replace (B) Chek fuel-primary pressure
it, check fuel system and if necessary repair it (C) Change components, check sensor and if necessary replace
other error properties it, check fuel system and if necessary repair it
System reaction: Warning or Warning and power reduction other error properties
Behaviour error lamp: permanent light System reaction: Warning or Warning and power reduction
oder Behaviour error lamp: permanent light
blinking oder
Selfhealing: yes blinking
Signal Priority: 4 Selfhealing: yes
Measurement @ errortime: actual value Signal Priority: 4
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 52 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

213 / 523613 / RailMeUn2 214 / 523613 / RailMeUn3 215 / 523613 / RailMeUn4

Error description RAIL PRESSURE Error description RAIL PRESSURE Error description RAIL PRESSURE
Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is
underneath the target range which is dependant on the engine underneath the target range which is dependant on the volume above the absolute target range
speed flow rate Error codes
Error codes Error codes DEUTZ-Errorcode: 215
EMR3 List of fault codes

DEUTZ-Errorcode: 213 DEUTZ-Errorcode: 214 BlinkCode (short-long-short): 1 - 3 - 4

BlinkCode (short-long-short): 1 - 3 - 4 BlinkCode (short-long-short): 1 - 3 - 4 SPN: 523613
SPN: 523613 SPN: 523613 possible FMI:
possible FMI: possible FMI: 0: data valid, but above normal working area
0: data valid, but above normal working area 1: data valid, but below normal working area 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable Errordetection
Errordetection Errordetection Errorlamp shows permanent light
Errorlamp shows permanent light Errorlamp shows permanent light oder
oder oder blinking. Entry in errormemory.
blinking. Entry in errormemory. blinking. Entry in errormemory. Possible reason for error
Possible reason for error Possible reason for error 1) No power supply in FCU,
1) No power supply in FCU, 1) Leakage in high pressure system (external) , 2) ZME clamped in open position,

BOMAG
2) ZME clamped in open position, 2) Leakage at rail pressure relief valve (internal), 3) Too high pressure nach Nullförderdrossel (FCU),
3) Too high pressure nach Nullförderdrossel (FCU), 3) Needle clampt in open position, 4) Nullförderdrossel clogged,
4) Nullförderdrossel clogged, 4) Abrasion at injector, 5) Too high primary pressure on low pressure side, sensor
5) Too high primary pressure on low pressure side, sensor 5) Abrasion at high pressure pump, defective, fuel system disturbed
defective, fuel system disturbed 6) Too low primary pressure on low pressure side, sensor d Take actions for error repair
Take actions for error repair Take actions for error repair (A) Check return-pressure FCU
(A) Check return-pressure FCU (A) Check for leakage (B) Check flow-pressure
(B) Check flow-pressure (B) Chek fuel-primary pressure (C) Change FCU, check sensor and if necessary replace it, check
(C) Change FCU, check sensor and if necessary replace it, check (C) Change components, check sensor and if necessary replace fuel system and if necessary repair it
fuel system and if necessary repair it it, check fuel system and if necessary repair it other error properties
other error properties other error properties System reaction: Warning or Warning and power reduction
System reaction: Warning or Warning and power reduction System reaction: Warning or Warning and power reduction Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Behaviour error lamp: permanent light oder
oder oder blinking
blinking blinking Selfhealing: yes
Selfhealing: yes Selfhealing: yes Signal Priority: 4
Signal Priority: 4 Signal Priority: 4 Measurement @ errortime: actual value
Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 53 Rev. 2.1, 22.10.2008

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315
316
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

216 / 523613 / RailMeUn7 218 / 523490 / SOPTst 219 / 1079 / SSpMon1

Error description RAIL PRESSURE Error description REDUNDANT SHUT OFF DET. Error description 5V SUPPLY 1 FAIL.
Rail pressure: the fuel pressure in rail calculated by ECU is Internal hardware monitoring: the ECU finds an disturbance in the Internal hardware monitoring: the ECU detects a deviation of the
implausible compared with the setpoint setting of the fuel redundant switch off path through a test during the ramp up target range of the power supply voltage of sensor 1
metering unit phase Error codes
Error codes Error codes DEUTZ-Errorcode: 219
DEUTZ-Errorcode: 216 DEUTZ-Errorcode: 218 BlinkCode (short-long-short): 2 - 8 - 2
BlinkCode (short-long-short): 1 - 3 - 4 BlinkCode (short-long-short): 1 - 4 - 9 SPN: 1079
SPN: 523613 SPN: 523490 possible FMI:
possible FMI: possible FMI: 3: Voltage to high or short circuit to +Ubatt
2: data stream is defective 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 12: Defective component 12. Errormode not identifiable
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt Errordetection
Errordetection Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
oder Possible reason for error 5V sensor supply voltage 1 outside target range, operating
blinking. Entry in errormemory. Test of redundant shut-off paths voltage too high or to low, connection cable demaged, ECU
Possible reason for error Take actions for error repair defective
1) Leakage in high pressure system (external) , Could be triggered by over/undervoltage or external Watchdog Take actions for error repair

BOMAG
2) Leakage at rail pressure relief valve (internal), other error properties If error not removable, change ECU, check cabling of external
3) Needle clampt in open position, System reaction: Test will only be executed with ECU components, check working voltage and if necessary correct it,
4) Abrasion at injector, Initialisation. Warning, dependent upon application. check connection cable and if necessary repair or replace it
5) Abrasion at high pressure pump, Behaviour error lamp: permanent light other error properties
6) Too low primary pressure on low pressure side, sensor d Selfhealing: no System reaction: Warning
Take actions for error repair Signal Priority: 4 Behaviour error lamp: permanent light
(A) Check for leakage Measurement @ errortime: - Selfhealing: yes
(B) Chek fuel-primary pressure Signal Priority: 3
(C) Change components, check sensor and if necessary replace Measurement @ errortime: actual value
it, check fuel system and if necessary repair it
other error properties
System reaction: Warning or Warning and power reduction
Behaviour error lamp: permanent light
oder
blinking
Selfhealing: yes
Signal Priority: 4
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 54 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

221 / 1080 / SSpMon2 222 / 523601 / SSpMon3 223 / 677 / StrtCDHS

Error description 5V SUPPLY 2 FAIL. Error description 5V SUPPLY 3 FAIL. Error description START RELAY
Internal hardware monitoring: the ECU detects a deviation of the Internal hardware monitoring: the ECU detects a deviation of the Start relay (high side power stage): the current drain measured
target range of the power supply voltage of sensor 2 target range of the power supply voltage of sensor 3 by ECU is above the target range
Error codes Error codes Error codes
DEUTZ-Errorcode: 221 DEUTZ-Errorcode: 222 DEUTZ-Errorcode: 223
EMR3 List of fault codes

BlinkCode (short-long-short): 2 - 8 - 2 BlinkCode (short-long-short): 2 - 8 - 2 BlinkCode (short-long-short): 5 - 1 - 2

SPN: 1080 SPN: 523601 SPN: 677
possible FMI: possible FMI: possible FMI:
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
5V sensor supply voltage 2 outside target range, operating Wrong voltage of internal 5V reference source 3, operating Start relay (high side): short circuit, relay defective, conncection
voltage too high or to low, connection cable demaged, ECU voltage too high or too low, connection cable demaged, ECU cable defective
defective defective Take actions for error repair
Take actions for error repair Take actions for error repair Check cabling and start relay and if necessary replace it, check

BOMAG
If error not removable, change ECU, check cabling of external If error not removable, change ECU, check cabling of external connection cable and if necessary repair or replace it
components, check working voltage and if necessary correct it, components, check working voltage and if necessary correct it, other error properties
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it System reaction: Warning, shutoff output
other error properties other error properties Behaviour error lamp: permanent light
System reaction: Warning System reaction: Warning Selfhealing: no
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Signal Priority: 1
Selfhealing: yes Selfhealing: yes Measurement @ errortime: default value
Signal Priority: 3 Signal Priority: 3
Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 55 Rev. 2.1, 22.10.2008

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317
318
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

224 / 677 / StrtCDLS 225 / 624 / SysLamp 226 / 158 / T15CD

Error description START RELAY Error description DIAGNOSTIC LAMP Error description TERMINAL 15
start relay (low side power stage): the current drain measured by Error lamp (diagnositic lamp): the current drain measured by Terminal 15: ECU receives no signal
ECU is out of the target range ECU is out of the target range or the maximum permissble Error codes
Error codes temperature of the ECU component for power supply of the lamp DEUTZ-Errorcode: 226
DEUTZ-Errorcode: 224 is exceeded BlinkCode (short-long-short): 5 - 1 - 4
BlinkCode (short-long-short): 5 - 1 - 2 Error codes SPN: 158
SPN: 677 DEUTZ-Errorcode: 225 possible FMI:
possible FMI: BlinkCode (short-long-short): 5 - 1 - 3 12. Errormode not identifiable
3: Voltage to high or short circuit to +Ubatt SPN: 624 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt possible FMI: 12: Defective component
5: current to low or broken wire 3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt Errordetection
Errordetection 5: current to low or broken wire Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. 2: data stream is defective Possible reason for error
Possible reason for error Errordetection Ignition ON not detected, ignition switch defective, connection
Start relay (low side): cable break or short circuit, disabled by Errorlamp shows -. Entry in errormemory. cable demaged
ECU, relay defective, connection cable demaged Possible reason for error Take actions for error repair
Take actions for error repair Cable break or short circuit, disabled by ECU, lamp defective, Check cabling, if sensor not working, check ignition switch and if
Check cabling and start relay and if necessary replace it, check connection cable demaged necessary replace it, check connection cable and if necessary

BOMAG
connection cable and if necessary repair or replace it Take actions for error repair repair or replace it
other error properties Check cabling and load, check lamp and if necessary replace it, other error properties
System reaction: Warning, shutoff output check connection cable and if necessary repair or replace it System reaction: Warning, engine can not start
Behaviour error lamp: permanent light other error properties Behaviour error lamp: permanent light
Selfhealing: no System reaction: only error memory item Selfhealing: no
Signal Priority: 1 Behaviour error lamp: - Signal Priority: 2
Measurement @ errortime: default value Selfhealing: no Measurement @ errortime: actual value
Signal Priority: 2
Measurement @ errortime: setpoint Diagnosticlamp

DEUTZ AG, TE-CE, Fi Seite 56 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

227 / 523550 / T50CD 228 / 523550 / TPUMon 232 / 84 / VSSCD1

Error description TERMINAL 50 Error description TERMINAL 50 Error description VEHICLE SPEED
Terminal 50: ECU receives a permanent signal Internal hardware monitoring: ECU detects a deviation between Vehicle speed: over the maximum, signal invalid or implausible
Error codes the signal of time module and the system time compared with the injection quantity and the engine speed, offset
DEUTZ-Errorcode: 227 Error codes factors unlearned
BlinkCode (short-long-short): 5 - 1 - 5 DEUTZ-Errorcode: 228 Error codes
EMR3 List of fault codes

SPN: 523550 BlinkCode (short-long-short): 5 - 5 - 5 DEUTZ-Errorcode: 232

possible FMI: SPN: 523550 BlinkCode (short-long-short): 5 - 2 - 1
12: Defective component possible FMI: SPN: 84
12. Errormode not identifiable 12. Errormode not identifiable possible FMI:
12. Errormode not identifiable 12. Errormode not identifiable 0: data valid, but above normal working area
12. Errormode not identifiable 12. Errormode not identifiable 12: Defective component
Errordetection 2: data stream is defective 8: unusual frequency, pulse or period.
Errorlamp shows permanent light. Entry in errormemory. Errordetection 14: Special Instructions
Possible reason for error Errorlamp shows blinking. Entry in errormemory. Errordetection
Engine start switch stuck, start switch clamped, connection cable Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
demaged Time processing unit (TPU) defective, ECU defective Possible reason for error
Take actions for error repair Take actions for error repair Speed above target range, signal invalid or implausible compared
Check cabling, if sensor not working, check start switch and if If error not removable, change ECU to injection volume and engine speed, distance factor not
necessary replace it, check connection cable and if necessary other error properties learned, sensor defective, connection cable demaged

BOMAG
repair or replace it System reaction: Recovery of ECU Take actions for error repair
other error properties Behaviour error lamp: blinking Check cabling, if sensor not working, check sensor and if
System reaction: Warning Selfhealing: no necessary replace it, check connection cable and if necessary
Behaviour error lamp: permanent light Signal Priority: 5 repair or replace it
Selfhealing: no Measurement @ errortime: - other error properties
Signal Priority: 1 System reaction: Warning
Measurement @ errortime: actual value Behaviour error lamp: permanent light
Selfhealing: yes
Signal Priority: 3
Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 57 Rev. 2.1, 22.10.2008

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319
320
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

Diagnosis- and Errorcodes

235 / 523600 / WdCom 236 / 523470 / PRVMonSysReac 237 / 523006 / APPCDSwtnSel

Error description SERIAL INTERFACE DEF. Error description RAIL PRESS. LIM. VALVE Error description CONTR. MODE SWITCH
Internal hardware monitoring: the ECU detects a disturbance in Rail pressure relief valve: is open, will be forced to open, the Controller mode switch: the signal received by ECU is defective
internal communication forced-open failed; the ECU activates a system reaction or implausible.
Error codes Error codes Error codes
DEUTZ-Errorcode: 235 DEUTZ-Errorcode: 236 DEUTZ-Errorcode: 237
BlinkCode (short-long-short): 5 - 5 - 5 BlinkCode (short-long-short): 1 - 4 - 6 BlinkCode (short-long-short): 2 - 4 - 2
SPN: 523600 SPN: 523470 SPN: 523006
possible FMI: possible FMI: possible FMI:
12. Errormode not identifiable 12: Defective component 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12: Defective component 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 12. Errormode not identifiable 2: data stream is defective
12: Defective component 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error errormemory. Possible reason for error
Communication disturbed, ECU defective Possible reason for error Cable break, signal implausible, switch defective, connection
Take actions for error repair Rail pressure relief valve open or forced open abortive cable demaged
If error not to removable, change ECU (interpretation of the rail pressure gradient), power supply voltage Take actions for error repair
other error properties too low, rail pressure sensor defective, fuel metering unit Check switch and if necessary replace it, check connection cable

BOMAG
System reaction: Recovery of ECU defective, rail pressure relief valve defective, air in fuel system and if necessary repair or replace it
Behaviour error lamp: blinking Take actions for error repair other error properties
Selfhealing: no Check working voltage and if necessary correct it, check rail- System reaction:
Signal Priority: 5 pressure sensor and if necessary replace it, check FCU and if Behaviour error lamp: permanent light
Measurement @ errortime: - necessary replace it, check rail pressure relief valve and if Selfhealing: yes
necessary replace it, bleed the fuel-system Signal Priority: 2
other error properties Measurement @ errortime: actual value
System reaction: Warning, shut the engine off in about 5 minutes
Behaviour error lamp: permanent light, 15s before shut off
Selfhealing: no
Signal Priority: 4
Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 58 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

238 / 523007 / FrmMng_TORxEngPress 239 / 523008 / MplCtl 240 / 98 / OLSCD

Error description CAN ERROR RxEngPress. Error description MANIPULATION CONTROL Error description OIL LEVEL SWITCH
Error codes Data monitoring: the torque curve does not match the Oil level sensor: the voltage of sensor measured by ECU is out of
DEUTZ-Errorcode: 238 specification the target range or the received value of oil level via CAN is
BlinkCode (short-long-short): 2 - 1 - 5 Error codes defective or the signal value is implausible
SPN: 523007 DEUTZ-Errorcode: 239 Error codes
EMR3 List of fault codes

possible FMI: BlinkCode (short-long-short): 4 - 2 - 4 DEUTZ-Errorcode: 240

12: Defective component SPN: 523008 BlinkCode (short-long-short): 2 - 1 - 1
12. Errormode not identifiable possible FMI: SPN: 98
12. Errormode not identifiable 1: data valid, but below normal working area possible FMI:
12. Errormode not identifiable 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
Errordetection 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
Errorlamp shows permanent light. Entry in errormemory. 12. Errormode not identifiable 2: data stream is defective
Possible reason for error Errordetection 2: data stream is defective
Take actions for error repair Errorlamp shows . Entry in errormemory. Errordetection
other error properties Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
System reaction: Manipulation of Topcurve detected, data manipulation, too slow Possible reason for error
Behaviour error lamp: permanent light changed curve Voltage outside target range, CAN signal error, signal
Selfhealing: yes Take actions for error repair implausible, sensor defective, connection cable demaged, CAN
Signal Priority: 1 other error properties bus wrong cabled, wiring demaged, receiver (sender of the

BOMAG
Measurement @ errortime: default value System reaction: message) work inaccurately, parametering inaccurate
Behaviour error lamp: Take actions for error repair
Selfhealing: - Check cabling, if sensor not working, check sensor and if
Signal Priority: 3 necessary replace it, check connection cable and if necessary
Measurement @ errortime: repair or replace it, Check CAN Bus cabling (Bus sheduling,
polarity, short circuit, power interrupt), test protocol of receiver,
chec
other error properties
System reaction: Warning, substitute value
Behaviour error lamp: permanent light
Selfhealing: yes
Signal Priority: 3
Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 59 Rev. 2.1, 22.10.2008

11.21

321
322
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

241 / 98 / OLSCDSysReacHi 242 / 107 / ADPSCDAna 243 / 98 / OLSCDSysReacLo

Error description OIL LEVEL SWITCH Error description AIR FILTER COND. Error description OIL LEVEL SWITCH
Oil level: the oil level calculated by ECU is above the target Air filter differential pressure sensor: the voltage of sensor Oil level: the oil level calculated by ECU is underneath the target
range; the ECU activates a system reaction measured by ECU is out of the target range range; the ECU activates a system reaction
Error codes Error codes Error codes
DEUTZ-Errorcode: 241 DEUTZ-Errorcode: 242 DEUTZ-Errorcode: 243
BlinkCode (short-long-short): 2 - 5 - 1 BlinkCode (short-long-short): 1 - 3 - 6 BlinkCode (short-long-short): 2 - 5 - 2
SPN: 98 SPN: 107 SPN: 98
possible FMI: possible FMI: possible FMI:
0: data valid, but above normal working area 3: Voltage to high or short circuit to +Ubatt 1: data valid, but below normal working area
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Oil level too high with system reaction, oil volume too large, Voltage outside target range, sensor defective, connection cable Oil level too low with system reaction, oil volume too small,
sensor defective, connection cable demaged, CAN data error demaged sensor defective, connection cable demaged, CAN data error
Take actions for error repair Take actions for error repair Take actions for error repair
Check oil level and if necessary correct it, check sensor and if Check cable harness, check sensor and if necessary replace it, Check oil level and if necessary correct it, check sensor and if

BOMAG
necessary replace it, check connection cable and if necessary check connection cable and if necessary repair or replace it necessary replace it, check connection cable and if necessary
repair or replace it other error properties repair or replace it
other error properties System reaction: Warning, substitute value other error properties
System reaction: Advice: OLSCD_stSysReacReq Behaviour error lamp: permanent light System reaction: Advice: OLSCD_stSysReacReq
Behaviour error lamp: permanent light Selfhealing: yes Behaviour error lamp: permanent light
Selfhealing: yes Signal Priority: 3 Selfhealing: yes
Signal Priority: 4 Measurement @ errortime: default value Signal Priority: 4
Measurement @ errortime: actual value Measurement @ errortime: actual value

DEUTZ AG, TE-CE, Fi Seite 60 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

244 / 523009 / PrvMonWear 245 / 523010 / RailMeUn8 246 / 523650 / FlSys_FLPFMSysReac

Error description REPL. RAIL PRESS. VALVE Error description LEAKAGE DETECTION Error description
Rail pressure relief valve: is open more frequently or for a longer Wenn the engine is in idle running, the metering unit compares its Low fuel pressure Diesel: the low fuel pressure calculated by
time than what the technical specification allows output and rail pressure with the default value (Parameter) and ECU is underneath the target range; the ECU activates a system
Error codes calculates a correction factor-it calibrates itself then reaction
DEUTZ-Errorcode: 244 Error codes Error codes
EMR3 List of fault codes

BlinkCode (short-long-short): 2 - 5 - 3 DEUTZ-Errorcode: 245 DEUTZ-Errorcode: 246

SPN: 523009 BlinkCode (short-long-short): 2 - 5 - 4 BlinkCode (short-long-short): 5 - 4 - 1
possible FMI: SPN: 523010 SPN: 523650
9: Abnormal update rated possible FMI: possible FMI:
10: Abnormal rate of change 0: data valid, but above normal working area 2: data stream is defective
14: Special Instructions 12. Errormode not identifiable 2: data stream is defective
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection 12. Errormode not identifiable 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. Errordetection Errordetection
Possible reason for error Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Rail pressure relief valve open more frequently than the technical Possible reason for error Possible reason for error
specification allowed, rail pressure relief valve open longer than Take actions for error repair Diesel fuel pressure below target range with system reaction,
the technical specification allowed, rail pressure relief valve other error properties interruption in cycling process of low fuel pressure (for example,
defective System reaction: fuel pump defective), sensor defective, connection cable

BOMAG
Take actions for error repair Behaviour error lamp: permanent light demaged
Change rail pressure relief valve and remove the error through Selfhealing: no Take actions for error repair
Serdia command Signal Priority: 3 Check Diesel low fuel pressure loop system, Check electrical fuel
other error properties Measurement @ errortime: actual value pump, inspect fuel system and if necessary repair it, check
System reaction: permanent error message, unerasable by sensor and if necessary replace it, check connection cable and if
"Clear EM" necessary repair or replace it
Behaviour error lamp: permanent light other error properties
Selfhealing: no System reaction: Warning
Signal Priority: 3 Behaviour error lamp: permanent light
Measurement @ errortime: actual value Selfhealing: yes
Signal Priority: 4
Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 61 Rev. 2.1, 22.10.2008

11.21

323
324
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

247 / 523651 / FlSys_FTSFMSysReac 248 / 523652 / FlSys_FlushStateEngineOff 249 / 523653 / FlSys_RapeOilHeatEx

Error description Error description Error description RAPEOILSYSTEM
Rape Oil Fuel temperature: the fuel temperature calculated by Engine shut off without flushing or flushing was not already Awaited temperatur rise with opened heat exchanger valve did
ECU is above the target range; the ECU activates a system completed. ECU stores every shutoff with uncompleted or not occur. Error in fuel heating system.
reaction missing flushing process Error codes
Error codes Error codes DEUTZ-Errorcode: 249
DEUTZ-Errorcode: 247 DEUTZ-Errorcode: 248 BlinkCode (short-long-short): 5 - 4 - 4
BlinkCode (short-long-short): 5 - 4 - 2 BlinkCode (short-long-short): 5 - 4 - 3 SPN: 523653
SPN: 523651 SPN: 523652 possible FMI:
possible FMI: possible FMI: 2: data stream is defective
2: data stream is defective 2: data stream is defective 12. Errormode not identifiable
2: data stream is defective 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable Errordetection
Errordetection Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Possible reason for error Possible reason for error Fuel heating system (heat exchanger) not working correctly
Rape oil fuel temperature above target range with system Engine shut off without flushing of the fuel system in Diesel Take actions for error repair
reaction, interruption of rape oil fuel loop (for example, heat operation mode, Shutoff before flushing in Diesel operation mode Check Heat exchanger and heat exchanger valve, check cooling
exchanger not working properly), sensor defective, connection was finished system going to the heat exchanger, check rape oil system going

BOMAG
cable demaged Take actions for error repair to the heat exchanger
Take actions for error repair Awaiting complete flushing of the fuel system everytime before other error properties
Check rape oil fuel system as well as heat exchanger and heat engine shut off System reaction: Warning
exchanger valve, if necessary repair it, check sensor and if other error properties Behaviour error lamp: permanent light
necessary replace it, check connection cable and if necessary System reaction: Warning Selfhealing: yes
repair or replace it Behaviour error lamp: permanent light Signal Priority: 3
other error properties Selfhealing: yes Measurement @ errortime: -
System reaction: Warning and switchover to Diesel operation Signal Priority: 3
mode Measurement @ errortime: -
Behaviour error lamp: permanent light
Selfhealing: yes
Signal Priority: 3
Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 62 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

250 / 523654 / FrmMngDieselLvl 251 / 523655 / FrmMngFuelTemp 252 / 523656 / FrmMngLowPressureDiesel

Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM
Status DieselLvl (Diesel tank level): the voltage of the sensor Status FuelTemp (Fuel Temperature): the voltage of the sensor Status LowPressureDiesel (Low fuel pressure diesel): the voltage
measured by ECU is out of the target range measured by ECU is out of the target range of the sensor measured by ECU is out of the target range
Error codes Error codes Error codes
DEUTZ-Errorcode: 250 DEUTZ-Errorcode: 251 DEUTZ-Errorcode: 252
EMR3 List of fault codes

BlinkCode (short-long-short): 5 - 4 - 5 BlinkCode (short-long-short): 5 - 4 - 6 BlinkCode (short-long-short): 5 - 4 - 7

SPN: 523654 SPN: 523655 SPN: 523656
possible FMI: possible FMI: possible FMI:
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Cable break or short circuit, sensor defective, connection cable Cable break or short circuit, lamp defective, connection cable Cable break or short circuit, lamp defective, connection cable
demaged demaged demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling, if sensor not working, check sensor and if Check cabling, if sensor not working, check sensor and if Check cabling, if sensor not working, check sensor and if

BOMAG
necessary replace it, check connection cable and if necessary necessary replace it, check connection cable and if necessary necessary replace it, check connection cable and if necessary
repair or replace it repair or replace it repair or replace it
other error properties other error properties other error properties
System reaction: Warning, substitute value System reaction: Warning, substitute value System reaction: Warning, substitute value
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 3 Signal Priority: 3 Signal Priority: 3
Measurement @ errortime: default value Measurement @ errortime: default value Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 63 Rev. 2.1, 22.10.2008

11.21

325
326
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

253 / 523657 / FrmMngRapeOilIn 254 / 523658 / FrmMngRapeOilLvl 255 / 523659 / FrmMngRapeOilVlv1

Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM
CAN messageRapeOilln (Rape oil input): the message can not Status RapeOilLvl (Rape oil tank level): the voltage of the sensor Status RapeOilVlv1 (Valve 1): the current drain measured by
be received by ECU measured by ECU is out of the target range ECU is out of the target range or the maximum permissible
Error codes Error codes temperature of the ECU component is exceeded
DEUTZ-Errorcode: 253 DEUTZ-Errorcode: 254 Error codes
BlinkCode (short-long-short): 5 - 6 - 1 BlinkCode (short-long-short): 5 - 6 - 2 DEUTZ-Errorcode: 255
SPN: 523657 SPN: 523658 BlinkCode (short-long-short): 5 - 6 - 3
possible FMI: possible FMI: SPN: 523659
12: Defective component 3: Voltage to high or short circuit to +Ubatt possible FMI:
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
12: Defective component 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12: Defective component
Errordetection Errordetection 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errordetection
Possible reason for error Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
CAN bus wrong cabled, wiring is demaged, receiver (sender of Cable break or short circuit, lamp defective, connection cable Possible reason for error
the message) work inaccurately, parametering inaccurate demaged Cable break or short circuit, valve defective, connection cable
Take actions for error repair Take actions for error repair demaged
Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check cabling, if sensor not working, check sensor and if Take actions for error repair

BOMAG
power interrupt), test protocol of receiver, check CAN functional necessary replace it, check connection cable and if necessary Check cabling, if valve not working, check valve and if necessary
range repair or replace it replace it, check connection cable and if necessary repair or
other error properties other error properties replace it
System reaction: Warning, substitute values System reaction: Warning, substitute value other error properties
Behaviour error lamp: permanent light Behaviour error lamp: permanent light System reaction: Warning and switchover to Diesel operation
Selfhealing: yes Selfhealing: yes mode
Signal Priority: 3 Signal Priority: 3 Behaviour error lamp: permanent light
Measurement @ errortime: default value Measurement @ errortime: default value Selfhealing: yes
Signal Priority: 3
Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 64 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213

008 914 20
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

256 / 523660 / FrmMngRapeOilVlv2 257 / 523661 / FrmMngRapeOilVlv3 258 / 523662 / FrmMngRapeOilVlv4

Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM
Status RapeOilVlv2 (Valve 2): the current drain measured by Status RapeOilVlv3 (Valve 3): the current drain measured by Status RapeOilVlv4 (Valve 4): the current drain measured by
ECU is out of the target range or the maximum permissible ECU is out of the target range or the maximum permissible ECU is out of the target range or the maximum permissible
temperature of the ECU component is exceeded temperature of the ECU component is exceeded temperature of the ECU component is exceeded
Error codes Error codes Error codes
EMR3 List of fault codes

DEUTZ-Errorcode: 256 DEUTZ-Errorcode: 257 DEUTZ-Errorcode: 258

BlinkCode (short-long-short): 5 - 6 - 4 BlinkCode (short-long-short): 5 - 6 - 5 BlinkCode (short-long-short): 5 - 6 - 6
SPN: 523660 SPN: 523661 SPN: 523662
possible FMI: possible FMI: possible FMI:
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
12: Defective component 12: Defective component 12: Defective component
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Cable break or short circuit, valve defective, connection cable Cable break or short circuit, valve defective, connection cable Cable break or short circuit, valve defective, connection cable
demaged demaged demaged
Take actions for error repair Take actions for error repair Take actions for error repair

BOMAG
Check cabling, if valve not working, check valve and if necessary Check cabling, if valve not working, check valve and if necessary Check cabling, if valve not working, check valve and if necessary
replace it, check connection cable and if necessary repair or replace it, check connection cable and if necessary repair or replace it, check connection cable and if necessary repair or
replace it replace it replace it
other error properties other error properties other error properties
System reaction: Warning and switchover to Diesel operation System reaction: Warning and switchover to Diesel operation System reaction: Warning
mode mode Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Selfhealing: yes
Selfhealing: yes Selfhealing: yes Signal Priority: 3
Signal Priority: 3 Signal Priority: 3 Measurement @ errortime: default value
Measurement @ errortime: default value Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 65 Rev. 2.1, 22.10.2008

11.21

327
328
referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
11.21

259 / 523663 / FrmMngRapeOilVlv5 260 / 523664 / FrmMngSTIN1RX

Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM
Status RapeOilVlv5 (Valve 5): the current drain measured by CAN message STIN1 (State Inputs 1): the message can not be
ECU is out of the target range or the maximum permissible received by ECU
temperature of the ECU component is exceeded Error codes
Error codes DEUTZ-Errorcode: 260
DEUTZ-Errorcode: 259 BlinkCode (short-long-short): 5 - 6 - 8
BlinkCode (short-long-short): 5 - 6 - 7 SPN: 523664
SPN: 523663 possible FMI:
possible FMI: 12: Defective component
12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12: Defective component
12: Defective component 12. Errormode not identifiable
12. Errormode not identifiable Errordetection
Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Possible reason for error CAN bus wrong cabled, wiring is demaged, receiver (sender of
Cable break or short circuit, valve defective, connection cable the message) work inaccurately, parametering inaccurate
demaged Take actions for error repair
Take actions for error repair Check CAN Bus cabling (Bus sheduling, polarity, short circuit,

BOMAG
Check cabling, if valve not working, check valve and if necessary power interrupt), test protocol of receiver, check CAN functional
replace it, check connection cable and if necessary repair or range
replace it other error properties
other error properties System reaction: Warning, substitute values
System reaction: Warning Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Selfhealing: yes
Selfhealing: yes Signal Priority: 3
Signal Priority: 3 Measurement @ errortime: default value
Measurement @ errortime: default value

DEUTZ AG, TE-CE, Fi Seite 66 Rev. 2.1, 22.10.2008

008 914 20
EMR3 List of fault codes
Generator 11.22
11.22Generator Three-phase generator
The AC-generator first of all produces AC-voltage /
General
AC-current.
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve- Why does AC-current need to be rectified?
hicle with electric current at a steady voltage already There are a few components for which can either be
at idling speed. operated with alternating current or direct current, be-
cause they work independently from the current flow
Terminal designations
direction.
l B61, L = charge control This includes :
l B+, B = battery plus, also with the designation "30" l
Incandescent lamps
l
B- = battery minus, also with the designation "31" l
Fluorescent lamps
l D+ = dynamo plus corresponds with terminal "61" l Glow lamps
and "L" l Electric heating elements.
l D- = dynamo minus (this designation is only found There are also a few components that could be oper-
on D.C. generators or A.C. generators with regula- ated either with alternating current, direct current or
tor removed) three-phase current, if the components were designed
accordingly.
l DF = dynamo field (this designation is only found on
D.C. generators or A.C. generators with regulator This includes :
removed). Note: The designation DF is also found l
Electric motors
on older alternators with externally arranged regula- l
Relays.
tor on the connection of the exciting coil to the reg-
ulator or on the regulator itself Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
l
DF1 = dynamo field 1 es work with alternating or three-phase current.
l
DF2 = dynamo field 2 This includes :
l
IG = "15" ignition switch l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.

Design and function

Fig. 7
1 Fan
2 Holding plate
3 Stator core
4 Stator winding
5 Brush

008 914 20 BOMAG 329

11.22 Generator

6 Brush holder
7 Rectifier
8 Bearing cover
9 Rotor winding
10Rotor
11V-belt pulley

Fig. 10 3-phase current

Fig. 8 Rotor with claw poles The wiring diagram (Fig. 10) shows the 3 windings in
Y-connection and the 6 associated rectifier diodes (D1
In the generator the armature windings are located in-
to D6).
side the stationary stator (Fig. 9), whereas the exciter
winding is arranged on the internally revolving rotor The diodes D1, D2, D3 are also referred to as minus
(Fig. 8). diodes, because they have B- as common connection
(minus plate). The other diodes are the plus diodes.
The rectifier diodes have the effect that the negative
half-wave is suppressed and only the positive section
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.

Fig. 9 Stator
The three stator windings (Fig. 9) are electrically offset
to each other by 120°. The excitation of the magnetic
field requires direct current, which is fed to the rotor
via two carbon brushes and slip rings.

330 BOMAG 008 914 20

Generator 11.22
Charge control light Any other behaviour would indicate a defect on the
The charge control light has two duties: generator (rectifier, carbon brushes, regulator) or a
defect on the lamp, presumed the on-board battery is
l Indication of the correct generator function not discharged.
l External excitation of the generator during the start- A far more important function of the lamp is the transi-
ing phase tion and provision of field current. At standstill there is
no magnetic field in the de-energized generator. Since
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak
field can build up.
The current flows from the ignition switch via the
charge control light through the generator winding
against ground (terminal 31) and is limited to approx.
300 mA by the light bulb (4 W) (without the lamp the
current flow would be 2 to 5 A). While the rotor is ro-
tating current is induced into the stator winding,
whereby a small part (2–5 A, depending on speed)
flows through the charge regulator into the field wind-
ing of the rotor and the major part flows to the output
terminals (B+), where it can be tapped as useful cur-
rent. If the charge control light is defective or no bat-
Fig. 11 plus controlled charging regulator tery is available or the battery is discharged, external
(Fig. 11) shows the current flow with the ignition excitation is no longer possible at standstill and no
switched on, engine stopped. voltage will be generated, even when the generator is
running.
With used, older generators a weak permanent mag-
netic field may have developed over the lifetime,
which does even exist when no voltage is applied.
This type of machines can even start without charge
control light and produce current during operation.
However, this is an unintended effect and you should
not presume that a generator without charge control
light or external excitation can be started up.

Fig. 12 plus controlled charging regulator

(Fig. 12) shows the current flow with the ignition
switched on, engine running.
1 Battery
2 Charge controller
3 Ignition switch
4 Charge control light
5 Rectifier
6 Rotor
7 Sliprings / carbon brush
8 Auxiliary rectifier
Normally the charge control light lights with the engine
stopped and the ignition switched on and goes out at
low engine speed, but at the latest after a single,
short-term increase in engine speed from idle speed,
because there is no longer a voltage difference on the
lamp.

008 914 20 BOMAG 331

11.22 Generator

Charge controller
The charge controller has the following functions
l To regulate the voltage generated by the generator
l To protect against overloads caused by too high
output current
l Protection against reverse current
If the output voltage or the output current of the gen-
erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.

Electronic charge regulator

Fig. 14 plus controlled regulator

Fig. 13
In AC-generators the electrically generated exciter
field of the generator rotor is influenced by an at-
tached electronic charge regulator. Together with the Fig. 15 minus controlled regulator
holder for the carbon brushes this regulator forms a
unit, which transfers the field current to the sliprings of
the rotor.
The regulator compares the rectified actual current of
the generator with the a stable reference voltage in
the regulator and matches the strength of the exciter
field (field current) by increasing or reducing the cur-
rent flow (PWM, switching controller) in such a way,
that the actual voltage of the generator remains con-
stant, irrespective of load and speed. The generator
voltage is thereby regulated, the generator current,
however, is not measured, but limited by the construc-
tion dependent internal resistance of the stator coils or
thermal monitoring.

332 BOMAG 008 914 20

Generator 11.22
Checking the generator Checking the pre-exciter circuit, D+ generator
First one must check whether the generator is actually The most common reason for a 3-phase alternator not
defective. charging is a too low pre-excitation current. The pre-
excitation current through connection D+ depends on
l This can be easily found out by checking whether
the connected consumer (resistance), e.g. charge
the charge control light in the dashboard lights up. If
control light or relay of a MD+ engine control.
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula- The pre-excitation current should be approx. 250 mA
tor, the wiring or the V-belt. at 12 Volt. This corresponds with a 3 Watt light bulb or
l When the engine is at rest, the charge control light an equivalent combination of light bulb + resistance or
must light up. If not, the lamp may probably be de- an LED + resistance.
fective. Defects on generator or wiring are obviously The total resistance of the disconnected dead supply
also possible. line D+ max. should not exceed 48 Ohm.
The following points allow to contain faults in the volt- In case of faults like
age supply within certain limits. l charge control light stays on
l Cable connections on the generator OK? l no voltage increase, e.g. from 12 V to 14 V
l V-belt OK?
one should check that the correct resistance is as-
l Generator ground (engine ground) OK?
sured.
l Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
replaced or the following trouble shooting procedure
must be performed.

Fig. 16 Connections on the three-phase alternator (exemplary de-

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
l Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 16). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.

008 914 20 BOMAG 333

11.22 Generator

Checking the rotor

Measuring the charge current
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact. i Note
The rotor coils can only be measured in disassembled
l The generator ground connection must be OK.
state.
l During the measurement switch on as many con-
sumers as possible.
1 Attach the clip-on ammeter around the B+ line.
2 Gradually increase the engine speed.
3 The generator current must be at least as high as
the total current of all switched on consumers.

Fig. 17
l Measure the resistance between the sliprings.
l If the resistance does not comply with the factory
specification, replace the rotor.
l Use the resistance range of the continuity tester to
check the continuity between slipring and core.
l Replace the rotor if no infinite value is indicated.

i Note
Factory specification for resistance: 2.8 to 5 OHM.

334 BOMAG 008 914 20

Generator 11.22
Checking the stator Checking the bearings

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

Fig. 19
l Check whether the bearing rotates without obstruc-
tion.
l Replace the bearing if it does not rotate properly.
Fig. 18
l Use the resistance range of the continuity tester to
measure the resistance between the individual lines
of the stator winding.
l If the measuring value does not comply with the fac-
tory specification, replace the stator.
l Use the resistance range of the continuity tester to
check the continuity between the individual stator
windings and the core.
l Replace the stator if no infinite value is indicated.

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

008 914 20 BOMAG 335

11.22 Generator

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

Fig. 21
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
Fig. 20 l The generator ground connection must be OK.
The generator test assesses the regulator voltage and l
The battery should be in good condition – the idle
the ripple factor of the generator voltage. voltage of the battery should be at least 12.6 Volt.
l
All plug-and-socket connectors must be free of cor- l
If possible switch off all consumers.
rosion and intermittent contact. l
Perform the measurement at raised engine speed.
l
The generator ground connection must be OK. l
The voltage (B+) should adjust itself at 13 to 14 Volt.
l
The battery should be in good condition – the idle
voltage of the battery should be at least 12.6 Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.

336 BOMAG 008 914 20

Generator 11.22
Checking the regulator in disassembled state
On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator. Fig. 23
E.g minus controlled regulator
i Note One connects the regulator (Fig. 23) with D+ and D- to
When testing the regulator one should be aware that the power source, as shown in the illustration, and the
there are 2 different types of regulators: lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
l If the carbon brush is not connected to ground the will first become brighter, because the regulator al-
regulator is a so-called minus controlled regulator. lows all lamp current (= exciter current) to flow at volt-
The exciter winding is positioned between D+ and age values up to 14.4V. Once the regulator voltage is
DF, the regulator therefore regulates the exciter reached, the regulator switches the lamp current off.
winding on the ground side. The other carbon brush When returning the voltage back below the control
is connected with the cathodes of the exciter di- voltage, the regulator will switch the lamp back on.
odes, terminal D+. This leaves one further terminal,
With this test the major difficulty is the problem to re-
this is DF.
move the regulator an identify terminals D+, DF and
D+ (vehicle wiring system) D-.
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)

Fig. 24

Fig. 25
Fig. 22
The illustrations (Fig. 24) and (Fig. 25) show two dif-
l If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).

008 914 20 BOMAG 337

11.23 Replacing the voltage regulator

Replacing carbon brushes 11.23Replacing the voltage regula-

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

Fig. 1
l Loosen the hexagon nuts M5 (Fig. 1).
l Take off hexagon nuts and washers.
l Remove the plastic cover.

i Note
Optional:
Unscrew the hexagon nut M5 from terminal W, take
off washer and flat plug connector.

Fig. 2
l Check whether washers are present. Take off the
washers (3x) (Fig. 2), to prevent these from falling
into the generator.

338 BOMAG 008 914 20

Replacing the voltage regulator 11.23

Fig. 3
l Slacken the screws M3 (A) (Fig. 3). Fig. 2
l Loosen the hexagon nuts M5 (B). l Check whether the rubber seal is present on the
brush holder (Fig. 2).
l Remove screw and hexagon nuts.
l Take off the voltage regulator.

Assembling the voltage regulator

Fig. 3
l
Attach the voltage regulator (Fig. 3).
l Tighten the screw M3 (A).- Tightening torque 0.7-
1.0 Nm.
Fig. 1 l
Tighten the screw M5 (B).- Tightening torque 3.5-
l
Check for correct fit of sealing ring on protective 4.5 Nm.
cover (Fig. 1).

Fig. 4
l Install the washers (Fig. 4).

008 914 20 BOMAG 339

11.24 Electric starter

11.24Electric starter
General
Combustion engines need to be started by means of
a special device, because they are not able to start by
themselves. Considerable resistances caused by
compression and friction must thereby be overcome.
The starter converts the electric energy stored in the
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
capacity is available.
Duties of the starter:
Fig. 5 l to accelerate the combustion engine to start speed
with lowest possible current consumption.
l Assemble the cover (Fig. 5).
l establish the gear connection between starter and
l Install the washers. combustion engine.
l Fasten the protective cover with the hexagon nuts.- l to maintain this connection.
Tightening torque for hexagon nut M5 2.1-3.1 Nm. l to switch on the starter current.
After starting the engine:
i Note l
to return the starter pinion to initial position.
Optional: l
to switch off the starter current.
Assemble flat plug connector, washer and hexagon
nut M5 to connection W.
Tightening torque for hexagon nut 2.7-3.8 Nm.

340 BOMAG 008 914 20

Electric starter 11.24
Directly acting electric starter 5 Ignition switch
This shows the design of this starter. It consists of a 6 Actuating lever
starter motor and a magnetic switch. 7 Ring gear
8 Pinion
9 Freewheeling clutch
10(Battery

Pinion meshes with the ring gear

Fig. 6
1 Magnetic switch
2 Armature
3 Actuating lever
4 Freewheeling clutch Fig. 8 Magnetic switch closed
5 Resetting spring When the pinion (3) meshes with the flywheel mount-
6 Brush ed ring gear (4) and the magnetic switch (2) is closed,
7 Exciting winding a strong current flows from the battery (7) directly into
8 Armature the exciting winding (6) and the armature winding, but
not into the pick-up winding.
9 Collector
This causes the armature (5) to rotate with high speed
Ignition switch in position "START" and drives the pinion, which in turn drives the ring gear
(4) with a speed of 200 to 300 rpm.
1 Pick-up winding
2 Magnetic switch
3 Pinion
4 Ring gear
5 Armature
6 Exciting winding
7 Battery

Fig. 7 Magnetic switch open

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

008 914 20 BOMAG 341

11.24 Electric starter

Engine running 4 Resetting spring

5 Magnetic switch
6 Ignition switch
7 Pinion
8 Ring gear
9 Battery

Fig. 9
Once the engine is running and drives the pinion (1)
via the ring gear (2), the freewheeling clutch (3) will
open and prevent the armature (4) from being driven
by the engine.
1 Pinion
2 (Ring gear
3 Freewheeling clutch
4 Armature

Ignition switch released

Fig. 10
When releasing the ignition switch (6) it will return
from position "START" to "ON" and interrupt the start-
er current circuit. Current will now flow from the bat-
tery (9) through the contact plate in the pick-up
winding (3) and the holding winding (2). Since both
coils generate opposed magnetic fields, the magnetic
field will collapse and the resetting spring (4) takes the
armature (1) back to its initial position.
This opens the current circuit on the contact plate and
the pinion (7) is pulled back from the ring gear (8) and
stops.
1 Armature
2 Holding winding
3 Pick-up winding

342 BOMAG 008 914 20

Electric starter 11.24
Magnetic switch Freewheeling clutch

Fig. 1 Direct acting electric motor Fig. 1 Freewheeling clutch

The freewheeling clutch is designed in such a way,
that the flow of force is automatically interrupted if the
pinion (5) of the clutch rotates faster than the free-
wheeling ring (1) at higher engine speeds.
This makes sure that the armature will only drive the
ring gear, but can never be driven by the engine.
1 Freewheeling ring
2 Roller
3 Roller spring
4 Splined shaft
5 Pinion
6 Pinion

Fig. 2 Geared motor

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

008 914 20 BOMAG 343

11.24 Electric starter

Trouble shooting "Starter" Testing and measuring the starter

i Note i Note
The most frequent fault is definitely a fully discharged The highest current flows when the starter is blocked!
battery. (Short circuit current in starter). This is the case when
the pinion is engaged and the starter has the duty to
If the starter rotates too slowly, either the brushes
accelerate the flywheel to starting speed.
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric Function control with the starter installed
contacts or a soiled ground connection causing ex- l
Initiate the starting process and measure the volt-
tremely high voltage losses in the overall starter sys-
age on the pickup solenoid switch (50a). At least
tem are the cause of problems. 10.8 Volt should be applied.
If the starter only emits a clicking sound,- either l
When operating the starter switch the magnetic
the magnetic switch is defect / soiled (dismantle and switch must engage in the flywheel ring gear (no-
clean))- the main contacts on the magnetic switch are ticeable clicking sound) and release the starting
worn off / soiled (scrape off carefully with a file and current to the starter. On most magnetic switches
clean)- the starter motor is defective / soiled (remove the voltage can be measured with the multimeter. If
armature and clean), cover cleaned, moveable parts this does not happen even though voltage is ap-
with grease. plied, replace the magnetic switch.
Frequently a jammed return mechanism is the reason
for a starter failure.
Occasionally worn contacts are found on the magnetic
return switch
Defects on the actual starter motor including pinion
and carbon brushes are very rare.
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system
can only work when many conditions are fulfilled at
the same time.
l Immobilizer deactivated?
l Ignition switch OK?
l Travel lever in correct position?
l Emergency stop not actuated?
l Battery sufficiently charged?
l Battery poles OK?
l Main battery fuse OK?
l Main battery switch closed?
l Main starter cable (terminal 30) OK?
l Starter control cable (terminal 50) OK, voltage
drop?
l Ground cable OK?
l Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l the experience of the specialist
l the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.

344 BOMAG 008 914 20

Electric starter 11.24
Testing and measuring the starter Continuity test for the magnetic switch

Function control with the starter removed

Caution
!

Fasten the starter to make sure that it will not

come loose during the test.

Fig. 4
l
Use a continuity tester to check for continuity be-
tween terminal (1) and terminal (29 while holding
the pin depressed.
l Replace the magnetic switch if no continuity is de-
tected.
Fig. 2
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).

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

Checking the magnetic switch

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

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

008 914 20 BOMAG 345

11.24 Electric starter

Removing and assembling the starter Assembling the starter

Removing the starter

Fig. 5
l Switch the main battery switch to position "0" (Fig.
5).
Fig. 7
l Insert the starter.
l Tighten the screws (arrows) (Fig. 7), tightening
torque 60 Nm.
l Connect the cables (terminal 30 and 50).

Caution
!

Please comply with the following tightening tor-

ques when tightening the cable connections, in
order to avoid damage to the starter terminals or
other components.
Terminal 30, 24±4 Nm
Terminal 50, 1 - 1,3 Nm
To tightly tightened nuts can cause damage to
starter components (e.g. cracks in the cover of the
magnetic switch). Moisture entering into the start-
Fig. 6 er can cause short circuit - or even cable fire.
l
Disconnect the cable connections (terminal 30 and Insufficiently tightened nuts can cause cable con-
50). nections to come loose and thus short circuit - or
even cable fire.
l
Unscrew the screws (arrows) (Fig. 6).
l
Take off the starter.

346 BOMAG 008 914 20

12 Electronic modules

008 914 20 BOMAG 347

348 BOMAG 008 914 20
12.1 Machine related electrics

008 914 20 BOMAG 349

12.1 Machine related electrics

350 BOMAG 008 914 20

Machine related electrics 12.1

Service Training
Electrics
Single Drum Rollers – 4

P/N 008 097 03 Version 3.39

Version/Status: V3.39 / 22.01.10 Page 1 of 88

Author: Seis,MASH,LOEW / TE/TES
Dateiname:

008 914 20 BOMAG 351

12.1 Machine related electrics

Service Training WZ-4 from Version DH

Table of contents

1 Confirmation of changes................................................................................................6
1.1 Document ..............................................................................................................................6

1.2 Software ................................................................................................................................7

2 Displayed monitoring activities with fault reactions ...................................................9

3 Known faults .................................................................................................................10
4 The diagnostics system ...............................................................................................11
4.1 Display functions................................................................................................................11

4.2 General facts and operation..............................................................................................12

4.2.1 Calling up service mode ...................................................................................................12
4.2.2 Entering input codes.........................................................................................................12
4.3 Fault log display and delete ...........................................................................................14
4.3.1 Showing stored faults .......................................................................................................14
4.3.2 Delete all stored faults......................................................................................................14
4.4 Delete engine control fault log..........................................................................................15
4.4.1 Deleting logged engine faults ...........................................................................................15
4.4.2 Deleting active engine faults ............................................................................................15

5 Settings and queries.....................................................................................................16

5.1 Adjusting the machine type ..............................................................................................16
5.1.1 Procedure for initial commissioning of a control ...............................................................17
5.1.2 Procedure for changing a machine type...........................................................................17
5.2 Driving against the closed brake ......................................................................................18

5.3 Teaching the travel direction sensor................................................................................18

5.4 Automatic detection of surge currents in travel system................................................18

5.4.1 Procedure.........................................................................................................................19
5.4.2 Procedure with software version 1.07 and 1.08................................................................20
5.5 Adjustment of the steering unit ........................................................................................21
5.5.1 Procedure.........................................................................................................................21
5.6 Teaching the steering end stops (electric) ......................................................................21
5.6.1 Procedure.........................................................................................................................21
5.7 Automatic surge current detection for electric steering valves....................................24
5.7.1 Procedure.........................................................................................................................24
5.7.2 Reading out actual surge current values ..........................................................................25
5.8 "Trimming" the speed measurement ...............................................................................25
5.8.1 Procedure.........................................................................................................................25
5.8.2 Explanation ......................................................................................................................25
5.9 Calibrating the speed detection (calibration of wheel diameter) ..................................26
5.9.1 Procedure.........................................................................................................................26
5.9.2 Explanation ......................................................................................................................26
5.10 Activating/deactivating the vibration control ..................................................................27

Version/Status: V3.39 / 22.01.10 Page 2 of 88

Author: Seis,MASH,LOEW / TE/TES
Dateiname:

352 BOMAG 008 914 20

Machine related electrics 12.1

Service Training WZ-4 from Version DH

5.10.1 Procedure.........................................................................................................................27
5.11 Activating/deactivating the attachment plates................................................................27
5.11.1 Procedure.........................................................................................................................27
5.12 Activating/deactivating the reversing lock for attachment plates ................................28
5.12.1 Procedure.........................................................................................................................28
5.13 Setting the vibration motor type .......................................................................................29
5.13.1 Table of vibration motor types ..........................................................................................29
5.13.2 Table of pulse numbers....................................................................................................30
5.14 Activate / deactivate engine shut-down by SEPA filter monitoring ..............................31
5.14.1 Procedure.........................................................................................................................31

6 Other explanations .......................................................................................................32

6.1 Extended machine functions ............................................................................................32
6.1.1 Hydraulic oil filter monitoring ............................................................................................32
6.1.2 Changing the arm rests and seat contact logic ................................................................32
6.1.3 Change of the vibration logic: Limitation of the lower speed in vibration operation...........32
6.1.4 Change to the attachment plate functions ........................................................................33

7 Replacement of components .......................................................................................34

7.1 How to proceed when replacing components? ..............................................................34

7.2 Replacement of an ESX-control........................................................................................34

7.3 Replacement of a travel pump / axle drive motor / drum drive motor ..........................34

7.4 Replacement of a steering valve.......................................................................................34

7.5 Replacement of a steering angle sensor .........................................................................34

7.6 Component replacement without adjustment procedure ..............................................35

8 Description of the signals on the ESX-control...........................................................36

9 Description of signals on the data collector ..............................................................41
10 Description of signals on the travel lever...................................................................43
11 Descriptions of signals on the LC - Display ...............................................................45
12 Description of Signals on DIOS-Module .....................................................................46
13 Fault codes of the ESX control ....................................................................................47
13.1 Overview..............................................................................................................................47

13.2 Description of fault reactions............................................................................................48

13.3 Note codes ..........................................................................................................................49

13.4 Detailed description of fault codes and their possible causes .....................................50
13.4.1 General ............................................................................................................................50
13.4.2 brake ................................................................................................................................51
13.4.3 Travel lever ......................................................................................................................51
13.4.4 Travel speed range selector switch ..................................................................................53
13.4.5 Travel system...................................................................................................................53
13.4.6 Steering............................................................................................................................57
13.4.7 Driver's seat arm rest sensor............................................................................................59

Version/Status: V3.39 / 22.01.10 Page 3 of 88

Author: Seis,MASH,LOEW / TE/TES
Dateiname:

008 914 20 BOMAG 353

12.1 Machine related electrics

Service Training WZ-4 from Version DH

13.4.8 Vibration ...........................................................................................................................60

13.4.9 Attachment plates ............................................................................................................63
13.4.10 Diesel engine ...................................................................................................................64
13.4.11 Diesel engine EMR...........................................................................................................64
13.4.12 Miscellaneous ..................................................................................................................66
13.4.13 Machine type....................................................................................................................67
13.4.14 Optional functions ............................................................................................................67

14 Input Codes for ESX Control........................................................................................68

14.1 Fault log...............................................................................................................................68

14.2 Value displays.....................................................................................................................68

14.2.1 General ............................................................................................................................68
14.2.2 brake ................................................................................................................................68
14.2.3 Travel lever / driving .........................................................................................................69
14.2.4 Travel speed range selector switch ..................................................................................69
14.2.5 Travel pump: Travel direction forward ..............................................................................70
14.2.6 Travel pump: Travel direction reverse ..............................................................................70
14.2.7 Travel motor front (drum) .................................................................................................71
14.2.8 Travel motor rear (wheel axle)..........................................................................................71
14.2.9 Shut-down of drives..........................................................................................................71
14.2.10 Adaptation values for speed regulation ............................................................................72
14.2.11 Travel pressure sensor.....................................................................................................72
14.2.12 Inclination sensor .............................................................................................................72
14.2.13 Travel condition values.....................................................................................................72
14.2.14 Calibrating the wheel diameter .........................................................................................73
14.2.15 Speed limitation................................................................................................................73
14.2.16 Arm rest contact ...............................................................................................................73
14.2.17 Adoption values traction control .......................................................................................74
14.2.18 Steering: Steering valve ...................................................................................................74
14.2.19 Steering: Angle sensor in articulated joint ........................................................................74
14.2.20 Steering: Steering wheel ..................................................................................................75
14.2.21 Vibration ...........................................................................................................................75
14.2.22 Vibration (up to version 3.24 ) ..........................................................................................75
14.2.23 Vibration control; Vario and low amplitude circular exciter (from version 3.25 ) ...............76
14.2.24 Vibration control; high amplitude circular exciter (from version 3.25 ) ..............................76
14.2.25 Attachment plates, option (only BW213 BVC) ..................................................................77
14.2.26 Engine ..............................................................................................................................78
14.2.27 Hydraulics ........................................................................................................................78
14.3 Test settings .......................................................................................................................79
14.3.1 brake ................................................................................................................................79
14.3.2 Disable electric supply to wheel and drum drive motors (switch off).................................79
14.4 Settings / Teach / Emergency functions ..........................................................................80
14.4.1 Changing the machine code.............................................................................................80
14.4.2 Automatic detection of surge currents in travel system ....................................................80
14.4.3 Speed detection, trimming of measuring values...............................................................80
14.4.4 Speed detection, teaching of distance pulses ..................................................................80
14.4.5 Detection of wheel rotation ...............................................................................................81
14.4.6 Engine shutdown by SEPA filter monitoring .....................................................................81
14.4.7 Steering: Automatic detection of surge currents on steering valve...................................82
14.4.8 Steering: Determining the steering stops .........................................................................82
14.4.9 Steering: Emergency function ..........................................................................................82
14.4.10 Steering: Other functions..................................................................................................82
14.4.11 Setting the vibration motor type........................................................................................82
14.4.12 Vibration: Travel speed dependent vibration lock.............................................................83
14.4.13 Vibration: Enable frequency setting..................................................................................83
14.4.14 Attachment plates (only circular exciter): Activating/deactivating the attachment plates
option ...............................................................................................................................83
14.4.15 Plates: Preventing reversing with plates lowered .............................................................83

15 History............................................................................................................................84

Version/Status: V3.39 / 22.01.10 Page 4 of 88

Author: Seis,MASH,LOEW / TE/TES
Dateiname:

354 BOMAG 008 914 20

Machine related electrics 12.1

Service Training WZ-4 from Version DH

15.1 Changing the arm rests and seat contact logic ..............................................................84

15.2 Changing the vibration logic -> limitation of lower speed in vibration operation.......84

16 Terminology in connection with ESX..........................................................................85

Version/Status: V3.39 / 22.01.10 Page 5 of 88

Author: Seis,MASH,LOEW / TE/TES
Dateiname:

008 914 20 BOMAG 355

12.1 Machine related electrics

Service Training WZ-4 from Version DH

1 Confirmation of changes

1.1 Document

No. Date Description of changes resp.

2.01 23.04.2004 Creation of version 1.00 Werner
2.02 06.05.2004 Revision, teach functions Fondel
2.03 11.05.2004 Revision, supplements version 1.01 Seis
2.04 24.06.2004 Revision, supplements to version 1.02
2.05 23.01.2005 Revision, supplement to software versions from 2.00 MASH
2.06 29.04.2005 Revision, supplement to software versions from 2.06 MASH
2.07 22.05.2005 Error code description 5121 changed. Löw
3.01 16.03.2006 Supplements with respect to TIER3 engines. Fault treatment. Löw
3.02 11.08.2006 List of "selected fault reactions" corrected Löw
Documentation of error codes revised
List of machine types changed
3.03 13.11.2006 Fault codes 5127 and 5136 added. Löw
26.01.2007 Machine types of new Tier 3 machines supplemented. Vogt
21.02.2007 Fault description for steering supplemented. MASH
22.02.2007 Note for code list added MASH
3.23 22.10.2007 Input codes 3070 to 3072 to activate/deactivate the towed plate MASH
option for circular exciter machines added.
3.31 30.01.2008 Description of differentiated fault monitoring of the SEPA-filter in MASH
TIER3 machines: Input codes 5030 to 5033.
3.32 08.02.2008 Description of changed sequence control for seat contact and MASH
arm rest control in history (15).
3.33 24.10.2008 Machine types for new BW 177/179 Tier 3 machines Vogt
Fault codes 3060 changed to 3077
3.37 30.10.2008 Description of changes up to firmware V3.37 added. MASH
3.38 23.03.2009 Text corrections MASH
3.39 04.05.2009 Description concerning electric steering supplemented/changed MASH

Version/Status: V3.39 / 22.01.10 Page 6 of 88

Author: Seis,MASH,LOEW / TE/TES
Dateiname:

356 BOMAG 008 914 20

Machine related electrics 12.1

Service Training WZ-4 from Version DH

1.2 Software

Ver. Date Description of changes resp.

1.03 02.09.2004 Surge currents travel system teach function changed. Schroeder,
Known faults. Fondel
Revision of error codes.
Deactivation of electric steering on BVC machines.
How to proceed when replacing components?
2.00 16.12.2004 List of error codes extended. Schroeder
Fondel
MASH
2.02 08.03.2005 Adaptive adaptation of gradability. Display codes for the MASH
factors "Front top" 1500 and "Tail top" 1501.
Input code to shut down the speed dependent Vib-limitation
(3047..3049).
Error message (8440..8443) for invalid BabyBoard
equipment of the ESX-travel control.
Overspeed protection for wheel drives (axle and drum drives)
2.06 29.04.2005 Input codes (1158/1159) for manual adaptation of axle speed MASH
recording.
Input codes to record the pulse frequency of the drives:
Recording of speeds (1160..1169).
Adapted tank characteristic.
Change of speed limitation for operation with plates.
2.07 22.05.2005 Tank characteristic values changed. MASH
2.16 22.02.2006 Explanation concerning fault messages concerning steering MASH
3.00 supplemented.

2.18 10.03.2006 Supplements with respect to TIER3 engines. MASH

3.01 Fault treatment extended. Löw
Description of "known faults" extended.
2.19 20.03.2006 Fault correction travel pressure monitoring. MASH
3.02 Löw
3.04 18.05.2006 Fault monitoring steering wheel revised MASH
3.05 10.07.2006 Problem with start-up of new controls eliminated Löw
3.05 26.07.2006 Optimized CANopen functionality MASH
Changed fault treatment for steering (faults 2200 and 2201).
Rotary speed (vibration frequency) control and fault
monitoring changed
3.29 04.10.2006 Implementation of circular exciter machines with plate MASH
compactors.
3.31 30.01.2008 Changeover parameters: Sepa filter monitoring with engine MASH
shut-down (like EMR2)
Hydraulic filter monitoring with monitoring delay (5 min) after
start.
High idle speed read from engine control unit is used as max.
speed in congtrol (previously parameter).
3.32 08.02.2008 See: MASH
- 6.1.2 Changing the arm rests and seat contact logic
- 6.1.3 Change of the vibration logic: Limitation of the lower
speed in vibration operation.

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3.33 08.02.2008 Does not work in BVC-machines (...16). MASH

- Evaluation of torque characteristic from the data set of the
engine control unit read in through CAN.
- Preparation of various speed requirements based on the
torque/speed data of the engine control unit.
- Differentiation for machines 177/9 of whether BFM2012 or
TCD2011 engine is used, dynamic control in travel system
depending on this.
3.34 08.08.2008 Do not use this version! MASH
Changes to version V3.33 are also available for BVC machines.
ERROR IN TEACHING SURGE CURRENTS!
3.35 10.09.2008 Changes in attachment plate function (see 6.1.4 Page 33) MASH

3.36 26.10.2008 Changes in attachment plate function (see 6.1.4 Page 33) MASH

3.37 30.10.2008 Flashing of the yellow indicator light in the LCD when plate is MASH
lowered with activated float position (DH + BVC).
Change of activation logic for float position with plates.
Float position switch (old): Function is activated by
switching over the switch. Switching off therefore no
longer possible, the switch can be immediately returned
to position "Off". Switching off only possible by actuating
the plate lift button in the travel lever.
Float position switch (new): Function is activated by
pressing the button. Switching off only possible by
actuating the plate lift button in the travel lever.
Switching off by pressing the button again has not been
planned, because such a function would violate the
compatibility with the switch version.
3.38 21.11.2008 Ramping of the specified engine speed MASH
3.39 25.02.2009 Range monitoring of minimum surge current for travel pump MASH
reduced from 300mA to 280mA.
Surge currents for wheel motors of all types set to 300mA.
-> Eliminates jolting problems in transition range pump max.
wheel motors swashing (travel speed approx. 2.5 km/h).
Tolerance range calculation for permissible speed
differences drum/axle changed.
-> Eliminates the problem of speed reduction with very low
travel speeds in vibration mode caused by slip control
({overspeed protection).
3.40 05.03.2009 Test version. Basis V3.38. MASH
3.41 09.03.2009 Fault in float position of plates on DH-machines rectified. MASH
3.42 27.04.2009 Implementation of electric steering as option for DH4-machines. MASH
3.43 30.04.2009 Tolerance range calculation for permissible speed MASH
differences drum/axle from 3/39:. Fault in reverse travel on
BVC-machines rectified.
Introduction of travel speed reduction in case of overloading
of engine. This prevents stalling of engine caused by rapid
load increase.
Fault in adaptation of max. travel speed.
-

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2 Displayed monitoring activities with fault reactions

Reaction Symbol in fault Warning Warning Engine stop

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

Engine oil pressure

(from EMR) 5100 5101
5112 5112
Coolant temperature
(from EMR)
5100 5101
5116 5116
Coolant level
5024 5025
after 5s after 10s
Engine air filter
5026 5027
after 5s after 2min.
ASC
Various error causes and reaction times.
See error codes
Hydraulic oil filter
5502 5503
(ATTENTION! Delay after 5s after 2min.
in acceleration time)
See 6.1.1)
Water separator in
fuel filter 5028 5029
TIER II Engines after 5s after 2min.
(can be activated for (5100
TIER3-engines -> see
5.14) 5119)
Water separator in
fuel filter 5100
TIER III Engines
5119
Seat contact
1300
Arm rest
2300

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

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 "Fault 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
The display shows various engine faults (Code Faulty assessment of engine faults in the EMR3
51xx), even though neither code 5100 nor 5101 is control unit. Remedy: Deletion of active and
displayed. passive engine faults
(see 4.4 Delete engine control fault log)

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4 The diagnostics system

The machine is equipped with a diagnostics system consisting of display unit (LC-Display) and button-
type input unit (in the travel lever) to report machine faults, display measuring values and to set
parameters.

4.1 Display functions

The field t in the LC-Display shows the following diagnostic readings:

Type of indication Flashing Flashing "d" Flashing "d" Comment

warning Of the fields
triangle next to the
warning
triangle

Fault message
* * *
Warning
* *
Note
* *
Display, measuring Values ranging from
values 0 0 0 0 ...9 9 9 9 to be called up via
input codes
Parameter setting Values ranging from
0 0 0 0 ...9 9 9 9 to be called up via
input codes

Negative display values are identified by a "Minus sign".

If several faults are detected, the displayed fault codes will change in a 3 second cycle.

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4.2 General facts and operation

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

4.2.1 Calling up service mode

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

Change
Werte values
ändern Navigate
Navigieren
(green)
(grün) (blue)
Taste
INFO 1 button (blau)
(gelb)
(yellow)

INFO 2 button
Taste
(gelb)
(yellow) Werte ändern
Change values
(grün)
(green)
Navigieren
Navigate
(blau)
(blue)
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.

4.2.2 Entering input codes

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

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Normal mode (travel

Normalmodus lever in
(Fahrhebel inbrake lock!)
Bremsraste!)
Call up optional
Aufruf displays
optionaler by pressing
Anzeigen INFO
über INFO button
- Taste 1 1
and INFO button 2
und INFO - Taste 2

"Input" mode- Modus:

Eingabe
Changeover
Umschaltungof display function
Displayfunktion
Display settings
Einstellungen Display
Operate INFO 1
Betätigen INFO 1
+ INFO 2 for about
Plate adjustment deactivated!
Plattenverstellung inaktiv!
+ INFO 2 ca. 3s
3 seconds

Bet. INFO
Operate INFO1 +1 +
Eingabe
Input of
INFO22for
INFO ca.about
3s
Zugangangscode
access code
oder
3s orFahrhebel
travel lever 9999
9999
aus
out ofBremsr.
brake lock

Service-
"Service" Modus:
mode:
CODE -CODE input
Eingabe "0000"
0000" oder Input of diagnostics
Eingabe Diagnosecodes code
or ignition
Zündung aus off
Invoke / delete fault
Fehlerspeicher log / löschen
abrufen
Set machine types
Maschinentypen umstellen
Plate adjustment deactivated!
Plattenverstellung inaktiv!

Fahrhebel
Travel lever aus
out Bremsraste:
of brake lock:
Diagnosemodus
Diagnostics modeimactive
Vordergrund aktiv!
in foreground!

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4.3 Fault log display and delete

4.3.1 Showing stored faults

This function is only valid from software version 1.10!

Switch on function "Show stored faults":

Enter code number 0 7 0 0 (!WITHOUT service code 9999). This code number enables the
function "Show stored faults“.

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

Switch off function "Show stored faults":

Enter code number 0 7 0 1 (!WITHOUT service code 9999). This code number disables the
function "Show stored faults“.

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

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

4.3.2 Delete all stored faults

This function is only valid from software version 1.10!

Execute the function "Delete all stored faults":

The engine must not be running!
Enter code number 0 7 1 0 (!WITHOUT service code 9999).
Switch the ignition off and on again.

All stored faults are now deleted.

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

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

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4.4 Delete engine control fault log

4.4.1 Deleting logged engine faults

This function is only valid from software version 2.18 or 3.01 respectively!

Execute the function "Delete all logged faults in engine control unit":
The engine must not be running!
Service code 9 9 9 9 .
Enter code number 0 7 6 0 .
Switch the ignition off and on again.

All stored engine faults are now deleted.

4.4.2 Deleting active engine faults

This function is only valid from software version 2.18 or 3.01 respectively!

Execute the function "Delete all logged faults in engine control unit":
The engine must not be running!
Service code 9 9 9 9 .
Enter code number 0 7 6 1 .
Switch the ignition off and on again.

All active engine faults are now deleted.

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5 Settings and queries

5.1 Adjusting the machine type

Since the same control software is used for all single drum rollers of generation DH-4 (with
electronically controlled engines), the control must be matched to the machine in which it is actually
installed (setting the machine type).
This is necessary during first time commissioning as well as in case of a spare parts replacement.
This type setting is necessary, because different machine types/variants can have different parameter
sets, e.g. different wheel or axle drive motors (different numbers of pulses) or electrically different
hydraulic components (valve spools), or may be equipped with attachment plates or other optional
equipment.

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

The following machine types can be adjusted:

Machine type First serial number Last serial number Code Available from
version
Standard1 - - 7200 1.00

177 DH 101 582 21 1001 XXX XXX XX XXXX 7201 1.00

177 DH 101 583 32 1001 XXX XXX XX XXXX
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7202 1.00
177 PDH 101 583 31 1001 XXX XXX XX XXXX
179 DH 101 582 24 1001 XXX XXX XX XXXX 7203 1.00
179 DH 101 583 33 1001 XXX XXX XX XXXX
179 PDH 101 582 25 1001 XXX XXX XX XXXX 7204 1.00
179 PDH 101 583 35 1001 XXX XXX XX XXXX
213 DH 101 582 51 1001 XXX XXX XX XXXX 7205 1.00
213 DH 101 583 14 1001 XXX XXX XX XXXX
213 DH plates 101 583 37 1001 XXX XXX XX XXXX
214 DH 101 582 58 1001 XXX XXX XX XXXX
214 DH 101 583 19 1001 XXX XXX XX XXXX
213 PDH 101 582 52 1001 XXX XXX XX XXXX 7206 1.00
213 PDH 101 583 15 1001 XXX XXX XX XXXX
214 PDH 101 582 59 1001 XXX XXX XX XXXX
214 PDH 101 583 20 1001 XXX XXX XX XXXX
216 DH-4 101 582 60 1001 XXX XXX XX XXXX 7209 1.00
216 DH-4 101 582 64 1001 XXX XXX XX XXXX
216 PDH-4 101 582 61 1001 XXX XXX XX XXXX 7210 1.00
216 PDH-4 101 582 65 1001 XXX XXX XX XXXX
219 DH-4 101 582 70 1001 XXX XXX XX XXXX 7211 1.00
219 DH-4 101 582 77 1001 XXX XXX XX XXXX
219 PDH-4 101 582 71 1001 XXX XXX XX XXXX 7212 1.00
219 PDH-4 101 582 78 1001 XXX XXX XX XXXX
226 DH-4 147kW 101 582 80 1001 XXX XXX XX XXXX 7213 1.00
226 DH-4 150kW 101 582 88 1001 XXX XXX XX XXXX
226 PDH-4 147kW 101 582 81 1001 XXX XXX XX XXXX 7214 1.00
226 PDH-4 150kW 101 582 89 1001 XXX XXX XX XXXX
226 DH-4 174kW 101 582 83 1001 XXX XXX XX XXXX 7215 1.00
226 PDH 174kW 101 582 84 1001 XXX XXX XX XXXX 7216 1.00

1
The standard machine type does not represent a real machine, but is the initial point for not yet set controls
during initial commissioning or after replacing a control.

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177 BVC 101 582 23 1001 XXX XXX XX XXXX 7250 1.00
177 BVC 101 583 28 1001 XXX XXX XX XXXX
213 BVC 101 582 53 1001 101 582 53 1082 7251 1.00
up to design status
01.12.05
213 BVC plates 101 582 54 1001 101 582 54 1038 7252 1.00
up to design status
01.12.05
226 BVC 147kW 101 582 82 1001 XXX XXX XX XXXX 7253 1.00
226 BVC 150kW 101 582 86 1001 XXX XXX XX XXXX
226 BVC 174kW 101 582 85 1001 XXX XXX XX XXXX 7254 1.00
213 BVC 101 582 53 1083 XXX XXX XX XXXX 7255 3.00
From design status
01.12.05
101 583 16 1001 XXX XXX XX XXXX
213 BVC 101 582 12 1001 XXX XXX XX XXXX
Variocontrol
213 BVC plates 101 582 54 1039 XXX XXX XX XXXX 7256 3.00
From design status
01.12.05
101 583 06 1001 XXX XXX XX XXXX
213 BVC plates 101 582 13 1001 XXX XXX XX XXXX
Variocontrol +

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

Note:

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

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

5.1.1 Procedure for initial commissioning of a control

The control has been installed into the machine.
Switch the ignition on. Approx. 4 seconds after switching on the letters C O D E are displayed for
a period of approx. 3 seconds. After this the display changes and shows code 7000.
Use the Arrow Up or Arrow Down keys to select the correct machine code from the list of codes.
Confirm the selection with the Arrow Right key.

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

5.1.2 Procedure for changing a machine type

Enter code number 9 9 9 9 (activation of service mode)
Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type“.

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

Select the machine code from the table above and confirm it with the Arrow Right key. After
operating the Arrow Right key the control switches automatically off and on again.

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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 setting, 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.

5.2 Driving against the closed brake

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

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

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

5.3 Teaching the travel direction sensor

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

5.4 Automatic detection of surge currents in travel system

This function is only valid from software version 1.09!

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

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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 350 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!

5.4.1 Procedure
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:

Determination of control surge currents 1 0 9 1

After the input of the above code number the display shows " F O R E ". Shifting the travel lever
forward starts the first surge current measurement for forward travel.
During the measurement the actual current is displayed (display value = current in mA).
Once the surge current measurement is finished the display will show the reading O K for a period
of 5 seconds.
After this wait time the display reading changes to " B A C K ". Now shift the travel lever backward
to start the surge current measurement in reverse.
During the measurement the actual current is displayed (display value = current in mA).
After completion of the measuring process in reverse the display will show O K again.
The travel lever must now be returned to braking position.

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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.

5.4.2 Procedure with software version 1.07 and 1.08

The speed selection switch must be in position ECO.
If necessary enter code number 9 9 9 9 to access the service mode.
Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents
in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This
code number must be entered to be able to perform the following steps.

From this point the machine can no longer be operated with the travel lever! The travel lever
will only be in function again after the teach function has been completed or the machine
has been restarted.
Both measurements (forward/reverse) must be started by entering a code number. The code
numbers for both travel directions are:

Determine surge current for control forward 1 0 9 1

Determine surge current for control reverse 1 0 9 2

After entering one of the above code numbers the measurement will only start after moving the
travel lever to the respective travel direction.

ATTENTION: The ASC fault indicator light will come on during the teach process. In this case this
is of no relevance. The warning will disappear when restarting the machine.

During the measurement the actual current is displayed (display value = current in mA).
Teaching is required for both travel directions.
When returning the travel lever to neutral position after the two measurements, the display will
show O K for 3 seconds and the averaged values will be saved.
Once both surge currents have been measured the machine can be operated again with the travel
lever. The new surge current values for the travel system are valid from the next start.
The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.

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5.5 Adjustment of the steering unit

Availability: From version 1.09 for BVC-machinesd, from version V3.34 for DH-machines.

By standard all BVC-4 machines (code 725x) are equipped with, DH-machines with circular exciter
without electric steering. For machines, which are, deviating from the standard, equipped with the
respective other steering system (electric or hydraulic), the corresponding steering system must be
setup in the travel control.

5.5.1 Procedure
Enter code number 9999 (activation of service mode)
Enter code number 2060. This code number activates the function "Adjusting the steering unit“.
The following code numbers are available to activate the assembled steering unit.

Hydraulic steering 2062

Electric steering 2061

The display shows O K

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

5.6 Teaching the steering end stops (electric)

Attention: Applies only for machine with electric steering!

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 code).

The end positions can be calibrated by using the values of the steering angle sensor, to make sure
that the end positions of the steering cylinder are approached gently.

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

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Possible fault causes (code 9 9 9 9 ):

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

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

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START
Machine on level ground

Tires or metal plate

under drum

Machine on level ground

Enter 9999

Enter 2010

Travel lever in neutral

position

Turn steering wheel

CLOCKWISE, until STOP is
reached (noise from pressure
relief valve, cylinder fully
extended or retracted).

Travel lever in
braking position

Display shows Display shows

Enter 2012 2222 9999
OK FAULT
Travel lever in neutral
position

Turn steering wheel ANTI-

CLOCKWISE, until STOP is
reached (noise from pressure
relief valve, cylinder fully
extended or retracted).

Travel lever in braking

position

Display shows Display shows

Enter 2013
3333 9999
OK FAULT

Switch the ignition off

and on again. OR Enter 2011

FINISHED

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5.7 Automatic surge current detection for electric steering valves

Attention: Applies only for machine with electric steering!

Note: Perform this function only AFTER

"Teaching the steering end stops (electric) (5.6)".

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

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

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

Example BW 177 BVC:

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

5.7.1 Procedure
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 surge current
detection for electric steering valves"; the display now shows the reading 0 0 0 0 with the first digit
flashing.
Now code number 2 0 0 1 must be entered.
After entering one of the above mentioned code numbers the measurement of the surge current
will start immediately.
The drum is thereby first steered to the right and then to the left.
During the measurement the actual valve current is displayed (display value in mA).
Attention! During the measurement the drum cannot be steered! The steering wheel has no
effect.
During the measurement the machine should not be driven!
Once the measurement is completed the display value OK will appear for 3 seconds, after this the
code number 0000 is displayed with the first digit flashing, the next measurement can be started.
The new surge current values are valid from the next start.

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5.7.2 Reading out actual surge current values

Surge current values currently saved in the control can be read out with the following
input codes.

The values should not differ more than +/- 50!

Show surge current for left hand valve control 2 1 0 6

Show surge current for right hand valve control 2 1 0 8

In case of excessively differing surge currents you should first of all run a new teach procedure.

5.8 "Trimming" the speed measurement

5.8.1 Procedure
Enter 9 9 9 9 : Switch on service mode.
Enter 1 1 5 8 : Allow function "Trimming the speed measurement".
Enter 1 1 5 9 : Start function "Trimming the speed measurement".
The display shows: F O R E : Move the travel lever forward (or back).
Green button up = raise indicated speed (measuring value too low)
Green button down = reduce indicated speed (measuring value too high)
Travel lever in braking position: D O N E = FINISHED! Procedure finished.

5.8.2 Explanation
In order to adjust the speed display (LCD) e.g. to the BOMAG measuring system to reference tests
benches, the machine integrated travel speed detection may be "trimmed", i.e. adjusted.
For this purpose the input codes 1 1 5 8 (enable function) and 1 1 5 9 (start function) are used to
activate the function Speed detection, trimming of measuring values (chapter 14.4.3, page 80).
As a result, the travel speed measured by the machine appears in the LCD-Display.
With the green button on the travel lever an internal calibration value can now be changed to such an
extent, that the displayed speed corresponds with the actual travel speed.

ATTENTION! If the speed detection is extremely falsified because of operating errors, this can
lead to uncomfortable travel behaviour and a reduced ASR control quality.

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5.9 Calibrating the speed detection (calibration of wheel diameter)

5.9.1 Procedure
see also 14.2.14 Calibrating the wheel diameter

Enter 9 9 9 9 : Switch on service mode.

Enter 1 1 6 0 : Allow function "Calibrate the speed detection".
Enter 1 1 6 1 : Start function "Calibration of speed detection" for a 5m distance.
or enter 1 1 6 2 : For a 100m distance
or enter 1 1 6 3 : For a 20m distance
or enter 1 1 6 4 : For a 50m distance
or enter 1 1 6 5 : For a 100m distance

The display shows: F O R E : Move the travel lever forward (or back).
Green button up = raise indicated speed (measuring value too low)
Green button down = reduce indicated speed (measuring value too high)
Travel lever in braking position: D O N E = FINISHED! Procedure finished.

Enter 1 1 6 8 : Load original value.

Enter 1 1 6 9 : Save the values.

5.9.2 Explanation
The function Speed detection, teaching of distance pulses offers the possibility to calibrate the
internal calibration value of the speed detection.
For this purpose the input code 1 1 6 0 (enable function) and 1 1 6 1 - 1 1 6 5 (start the
respective function) can be used to select a distance, which is then travelled with the machine (as
exact as possible).
During travel a numeric value is displayed.
The measurement is subsequently saved by means of the input code 1 1 6 9 and is now a valid
criterion for the speed detection.

With the input code 1 1 6 8 it is also possible to adjust the basic value for series machines ->
(1 1 6 0 - > 1 1 6 9 )

ATTENTION! If the speed detection is extremely falsified because of operating errors, this can
lead to uncomfortable travel behaviour and a reduced ASR control quality.

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5.10 Activating/deactivating the vibration control

Availability: From version 3.20 (design status 01.05.2007)

With design status 01.05.2007 a switch was integrated in the dashboard on machines with circular
exciter (DH-4. Not BVC), which enables adjustment of the nominal vibration frequency.

Machines with an older design status and without this switch need to be adjusted accordingly when
using the the currently valid travelling software.

5.10.1 Procedure
see also 14.4.12 Vibration: Enable frequency setting

Enter 9 9 9 9 : Switch on service mode.

Enter 3 0 9 1 : Enable function "Switch over frequency setting".
Enter 3 0 9 2 : Activate frequency setting (machine with switch).
or
Enter 3 0 9 3 : Disable frequency setting (machine WITHOUT switch).

Viewing the current setting:

Enter 9 9 9 9 : Switch on service mode.

Enter 3 0 9 0 : View the current setting.

5.11 Activating/deactivating the attachment plates

Availability: From version 3.29 (design status 01.09.2007)

With design status 01.09.2007 the "attachment plate" option was released for machines with circular
exciter (DH-4. Not BVC).

ATTENTION: Machines with attachment plates are setup with the same software identification, as the
machines without plates (213 DH-4 = 213DH-4-plates = 7205)!

5.11.1 Procedure
see also 14.4.14:
Attachment plates (only circular exciter): Activating/deactivating the attachment plates option

Enter 9 9 9 9 : Switch on service mode.

Enter 3 0 7 0 : Enable changeover of options.
Enter 3 0 7 1 : Activate "Attachment plate" option).
or
Enter 3 0 7 2 : Disable option "attachment plates".

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5.12 Activating/deactivating the reversing lock for attachment plates

Availability: From version 3.36 (design status 01.10.2008)

With earlier firmware versions reversing with lowered plates was generally permitted.
From this version on reversing with lowered plates is generally disabled.
However, this locking can be deactivated with the described input procedure.

5.12.1 Procedure
see also 14.4.15:
Plates: Preventing reversing with plates lowered

Enter 9 9 9 9 : Switch on service mode.

Enter 3 0 7 7 : Allow reversing with plates lowered.
Enter 3 0 7 8 : Disable reversing with plates lowered.

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5.13 Setting the vibration motor type

Availability: From version 3.20 (design status 01.05.2007) or 3.21 (design status 01.06.2007)

Other vibration motors (type 2) were introduced as standard for machines (Code numbers 7205 to
7210)
from design status 01.05.2007 and for machines (Code numbers 7251, 7252, 7255, 7256) from design
status 01.06.2007.
Standard settings are shaded grey in the table (from design status 01.06.2007).

ATTENTION! If a machine with an older design status is furnished with the up-to-date travelling
software, the corresponding vibration motor type needs to be set (see 14.4.11).

Example:
BW213DH-4 (7205) with design status before 01.05.2007: -> 9 9 9 9 -> 3 0 3 1 -> 3 0 3 2 .
Check: -> 3 0 3 0 , display: 47 (see 5.13.2).

5.13.1 Table of vibration motor types

Vibration motor types

Machine Type 1 Type 2 Type 3 Type 4 Type 5 Type 6 Type 7 Type 8
type code (3032) (3033) (3034) (3035) (3036) (3037) (3038) (3039)

7201 MMF025
7202 MMF025
7203 MMF025
7204 MMF025
7205 A2FM56 90M055
7206 A2FM56 90M055
7207 A2FM56 90M055
7208 A2FM56 90M055
7209 A2FM56 90M055
7210 A2FM56 90M055
7211 A2FM63
7212 A2FM63
7213 A2FM80
7214 A2FM80
7215 A2FM80
7216 A2FM80

7250 MMF025
7251 A2FM56 90M055
7252 A2FM56 90M055
7253 A2FM80
7254 A2FM80
7255 A2FM56 90M055
7256 A2FM56 90M055

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5.13.2 Table of pulse numbers

For correct detection of the vibration frequency, the control must be aware of the number of pulses
(number of pulses per revolution) of the vibration motors. The pulse numbers are determined by the
vibration motor type.
The currently set pulse number can be read out with input code 3030.

Pulse numbers
Machine Type 1 Type 2 Type 3 Type 4 Type 5 Type 6 Type 7 Type 8
type code (3032) (3033) (3034) (3035) (3036) (3037) (3038) (3039)

7201 43
7202 43
7203 43
7204 43
7205 47 52
7206 47 52
7207 47 52
7208 47 52
7209 47 52
7210 47 52
7211 47
7212 47
7213 53
7214 53
7215 53
7216 53

7250 43
7251 47 52
7252 47 52
7253 53
7254 53
7255 47 52
7256 47 52

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5.14 Activate / deactivate engine shut-down by SEPA filter monitoring

Availability: From version 3.31

With software version we created the possibility of triggering an engine shut-down ion case of a SEPA
filter fault for all variants of the DH-4 (including BVC) machines with TIER3 engines.
In contrast to machines with TIER2 engines (where the engine shut down was active by standard),
this shut-down does not exist on TIER3 engines, because monitoring is part of the contropl package of
the engine control.
In the engine control no engine shut-down is therefore active.

By activating this function the engine shut-down can be activated through the BOMAG travel control.

Please note that in this case a collective message of all warning codes will appear: 5 0 2 8 /5 0 2 9 +
5100 + 5119

5.14.1 Procedure

Enter 9 9 9 9 : Switch on service mode.

Enter 5 0 3 1 : Function parameter change "Engine shut-down" released.
Enter 5 0 3 2 : No engine shut-down (standard)
or
Enter 5 0 3 3 : Engine shut-down active.

Viewing the current setting:

Enter 9 9 9 9 : Switch on service mode.

Enter 5 0 3 0 : View the current setting
Î 0 = no engine shut-down
Î 1 = engine shut-down active

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6 Other explanations

6.1 Extended machine functions

6.1.1 Hydraulic oil filter monitoring

In case of low temperatures the differential pressure switch for monitoring the hydraulic oil filter may
respond just after the engine has been started.
This actually does not indicate a contaminated filter, but represents a system related triggering of the
differential pressure switch caused by the viscosity appearance of the cold hydraulic oil.
With software version V3.31 we introduced a monitoring delay of 5 minutes.
This delay is in effect each time the engine is started and prevents a fault evaluation during this time
(engine shut-down).
Please note: Triggering of the differential pressure switch is always indicated (lamp).

6.1.2 Changing the arm rests and seat contact logic

Introduction: From version V3.32 (07.02.2008)

Explanation: When leaving the seat a delay will start after which the machine is stopped.

Fault: If the machine was stopped and the seat was left, the machine could start to travel if the
travel control lever was actuated within the delay time.

6.1.3 Change of the vibration logic: Limitation of the lower speed in vibration
operation.

Introduction: From version V3.32 (07.02.2008)

Explanation: The vibration system is equipped with a economy control, which intends to lower the
engine speed to the lowest possible level -> lower fuel consumption.
The control thereby uses the swashing angle (energy supply to the control valve) of the
vibration pump. If this is below 90%, the engine speed can be reduced, theoretically until
a swashing angle of 90% is reached for compensation. On some machines the engine
speed can thereby be reduced down to below 1000 rpm.

Problem: The lower the engine speed, the lower the engine power. The controller in the engine
control unit intersecting with the vibration frequency controller in the ESX-control may
result in erratic speed controlling characteristics.
The deregulation of the engine speed was only limited by the speed request from the
superimposed machine control.
In normal operation this is approx. 1500 rpm, which, according to current knowledge, is
more than just enough for reliable vibration operation.
However, with the brake applied the speed requested by the control is low idle speed.
In this condition this speed is used as bottom speed limit of the economy controller.
If vibration was activated at this point (unusual!) this can lead to the erratic behaviour of
the engine described above.

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6.1.4 Change to the attachment plate functions

Introduction: From version V3.35 (12.10.2008)

Reversing with lowered plates is disabled by standard (this locking can be deactivated via input
code -> 5.12).

Introduction: From version V3.37 (29.10.2008)

Activation logic for float position

- Float position switch (old): Function is activated by switching over the switch.
Switching off is therefore no longer possible, the switch can be immediately returned to
position "Off". Switching off is only possible by actuating the plate lift button in the travel lever.

- Float position switch (new): Function is activated by pressing the button.

Switching off is only possible by actuating the plate lift button in the travel lever.
Switching off by pressing the button again has not been planned, because such a function
would violate the compatibility with the switch version.

- With the plate lowered the yellow indicator lamp lights as follows:
- Permanently when float position is disabled.
- Flashing when float position is activated.

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7 Replacement of components

7.1 How to proceed when replacing components?

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

7.2 Replacement of an ESX-control

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

Attention: Before performing one of the following steps, the machine type must first be set
(see chap.5.1 on page 16)!
When changing the machine type all previously made adjustments will be lost!

Now the teach functions must be executed.

From DH
Automatic detection of surge currents in the travel system (see chapt. 5.4 on page 18)

On BVC
Automatic detection of surge currents in the travel system (see chapt. 5.4 on page 18)
Automatic detection of surge currents on steering valves (see chapt. 5.7 on page 24)
Teaching the electronic end stops of the steering angle sensor (see chapt. 5.6 on page 21)

7.3 Replacement of a travel pump / axle drive motor / drum drive motor
Automatic detection of surge currents in the travel system (see chapt. 5.4 on page 18)

7.4 Replacement of a steering valve

Automatic detection of surge currents on steering valves (see chapt. 5.7 on page 24)

7.5 Replacement of a steering angle sensor

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

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7.6 Component replacement without adjustment procedure

Which components can be replaced without a subsequent adjustment procedure?

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

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

recommended.

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8 Description of the signals on the ESX-control

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

ESX terminal Signal description Nominal values (voltage / current)

X35:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
angle 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 Interface RS 232 RxD, not used for normal operation. Measurement not possible!
X35:5 Interface RS 232 TxD, not used for normal operation. Measurement not possible!
X35:6 Not used ---
X35:7 Not used ---
X35:8 Not used ---

BOMAG
X35:9 Not used ---
X35:10 Not used ---
X35:11 Not used ---
X35:12 Input axle speed Signal changes between approx. 0V and approx. 12V, when machine is
Frequency input (0....7.5kHz) driving.
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 ---
X35:14 Not used ---

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ESX terminal Signal description Nominal values (voltage / current)
X35:15 Input seat contact switch Seat actuated ) 0V
Digital input active high Seat not actuated ) ?V
X35:16 Arm rest switch ---
X35:17 Input BTS brake (from travel lever) Brake released ) approx.12 V
Digital input active high Brake applied ) 0V
X35:18 Input steering sensor (S1/A) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned. Frequency depends on speed of turning
Machine related electrics

X35:19 Input steering sensor (S1/B) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned. Frequency depends on speed of turning
X35:20 Output steering left Steering left active ) 0.4..1.6 A
PWM digital output (max. 4 A) Steering left inactive ) 0A
X35:21 Output steering right Steering right active ) 0.4..1.6 A
PWM digital output (max. 4 A) Steering right inactive ) 0A
X35:22 Output vibration pump attachment plate valid current range: approx. 0..1.2 A
PWM power output (max. 4A) 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

BOMAG
Without this voltage the control cannot work correctly and will switch This voltage must be measured against AGND.
to override mode (emergency function).
X35:24 Output backup alarm Backup warning buzzer inactive ) 0V
Digital output (max. 2.5 A) Backup warning buzzer 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.
X35:29 Input steering angle sensor Position steering angle sensor (measured against AGND)
Analog 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

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ESX terminal Signal description Nominal values (voltage / current)

X35:30 Input longitudinal inclination of machine Inclination of machine (measured against AGND)
Analog input / voltage input 0..8.5 V -45° axle top ) 0.50..2.49 V
Neutral position ) 2.50 V
Max. lowering ) 2.51..4.50 V
X35:31 Input hydraulic pressure travel pump circuit 0 bar ) approx.4 mA
Analogue input (current input 4mA..20mA) from pressure sensor on 600 bar ) approx.20 mA
travel pump
X35:32 Not used ---
X35:33 Interface CAN-Bus 2 Wire -, is used for communication with the
travel lever and the engine EMR. Measurement not possible!
X35:34 Input drum speed Signal changes between approx. 0V and approx. 12V, when machine is
Frequency input (0....7.5kHz) driving.
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

BOMAG
) 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
Vib. Frequency XX Hz ) approx.XX Hz
X35:36 Input sense of rotation of vibration motor Sense of rotation forward ) approx. 12 V
(currently not used) Sense of rotation reverse ) approx. 12 V
Digital input active high

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ESX terminal Signal description Nominal values (voltage / current)
X35:37 Input sense of rotation of drum Sense of rotation forward ) approx. 12 V
Digital input active high Sense of rotation reverse ) approx. 12 V
X35:38 Input sense of rotation of axle Sense of rotation forward ) approx. 12 V
Digital input active high Sense of rotation reverse ) approx. 12 V
X35:39 Not used ---
X35:40 Input steering sensor (S2/A) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned. Frequency depends on speed of turning
Machine related electrics

X35:41 Input steering sensor (S2/B) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned. Frequency depends on speed of turning
X35:42 Output emergency steering Emergency steering active ) approx.12 V
Emergency steering inactive ) 0V
X35:43 Not used ---
X35:44 Not used ---
X35:45 Not used ---
X35:46 Output drum drive motor valid 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 valid current range: approx. 0..0.6 A

BOMAG
PWM power output (max. 4 A) Axle motor active ) 0.0..2.0 A
Axle motor not active ) 0A
X35:48 Output vibration pumpe valid current range: approx. 0..0.6 A
PWM power output (max. 4A) Axle motor active ) 0.0..2.0 A
Axle motor not active ) 0A
X35:49 Output travel pump forward Forward travel active ) 0.0..2.0 A
PWM power output (max. 4 A) Forward travel inactive ) 0A

Sauer components with EDC

Forward travel active ) 18..80 mA
Forward travel 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!

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ESX terminal Signal description Nominal values (voltage / current)

X35:54 Voltage supply for electronics (permanent voltage) Control running ) approx. 12 V
Control not running ) 0V
X35:55 Ground connection electronics 0 V measured against ground
X35:56 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:57 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:58 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:59 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:60 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:61 Output brake Brake released ) approx.12 V
Digital output (max. 4 A) Brake applied ) 0V
X35:62 Output blower coupling stage 2 (currently not used) Active ) approx.12 V
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 Forward travel active ) 0.0..2.0 A
PWM power output (max. 4 A) Forward travel inactive ) 0A

BOMAG
Sauer components with EDC
Forward travel active ) 18..80 mA
Forward travel inactive ) 0 mA
X35:65 Test connection Baby Boards approx. 0 V

X35:66 Test connection Baby Boards approx. 0 V

X35:67 Test connection Baby Boards approx. 0 V

X35:68 Test connection Baby Boards approx. 0 V

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Service Training WZ 4 Description of Signals on the Data Collector

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

PIN data Signal description Nominal values (voltage / current)

collector
Machine related electrics

X26:1 Input indicator right Direction indicator right active ) approx.12 V

Digital input active high Direction indicator right inactive ) 0V
X26:2 Input indicator left Direction indicator left active ) approx.12 V
Digital input active high Direction indicator left inactive ) 0V
X26:3 Input engine running (D+) Engine running ) approx. 12 V
Digital input active high Engine stopped ) 0V
X26:4 Not used ---
X26:5 Input hydraulic oil filter differential pressure Filter blocked ) 0V
Digital input active low Filter OK ) ?V
X26:6 Not used ---
X26:7 Input air conditioning Air conditioning on ) approx. 12 V

BOMAG
Digital input active high Air conditioning off ) 0V
X26:8 Input engine air filter Filter blocked ) 0V
Digital input active low Filter OK ) ?V
X26:9 Input background illumination Lighting on ) approx. 12 V
Digital input active high Lighting off ) 0V
X26:10 Input coolant supply Coolant level too low ) 0V
Digital input active low Sufficient coolant level ) ?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 ---
X27:4 Voltage supply for monitoring of water separation (PIN X27:9) Voltage supply OK ) approx. 12 V
No voltage supply ) 0V

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PIN data Signal description Nominal values (voltage / current)

collector
X27:5 Ground connection 0V (measured against ground)
X27:6 Interface CAN-Bus 1 Wire +, is used for communication with MESX, Measurement not possible!
ESX, LCD-display and BOP.
X27:7 Interface CAN-Bus 1 Wire -, is used for communication with MESX, Measurement not possible!
ESX, LCD-display and BOP.
X27:8 Voltage supply (permanent voltage) Control running ) approx. 12 V
Control not running ) 0V
X27:9 Input water separation If a sufficient amount of water has been separated, a low current flows
Current input over the over the contacts and the water in the separator bowl. This input
analyses this current.
No water separated ) I= 0A
Water separated ) I 0.03mA
X27:10 Not used ---
X27:11 Not used ---
X27:12 Not used ---

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

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

PIN travel Signal description Nominal values (voltage / current)

lever
Machine related electrics

X23:1 Voltage supply (permanent voltage) Electronics working ) 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
voltage is required to connect and evaluate further analog switches to This voltage must be measured against AGND.
the travel lever.

BOMAG
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)
X23:11 Input travel stage selector switch The voltage signal changes with the adjusted travel speed range
Analog input Travel stage min. ) ?? V
Travel stage max. ) ?? V
X23:12 Not used ---
X24:1 Not used ---
X24:2 Input high amplitude High amplitude active ) approx.12 V
Digital input active high High amplitude inactive ) approx.12 V

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PIN travel Signal description Nominal values (voltage / current)

lever
X24:3 Input low amplitude Low amplitude active ) approx.12 V
Digital input active high Low amplitude inactive ) approx.12 V
X24:4 Not used ---
X24:5 Not used ---
X24:6 Input arm rest left (not yet realized) ---
Digital input active high
X24:7 Output voltage supply for additional digital evaluations Voltage supply active ) approx.12 V
This output supplies the amplitude selector switch. This voltage is Voltage supply inactive ) 0V
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.)

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

008 914 20
11 Descriptions of signals on the LC - Display
Notes:
Wherever the value of 12 V is mentioned in the following text, it refers to the current battery voltage under due consideration of voltage drops in the lines.

PIN Display Signal description Nominal values (voltage / current)

X28:1 Voltage supply (permanent voltage "ignition on") Electronics working ) approx.12 V
Machine related electrics

Electronics not working ) 0V

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

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

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12 Description of Signals on DIOS-Module

(only for option with attachment plates)

DIOS terminal Signal description Nominal values (voltage / current)

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

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

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Machine related electrics 12.1

Service Training Fault codes of the ESX Control

13 Fault codes of the ESX control

13.1 Overview
Fault code Description of fault
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
8000 - Severe software fault 1
8999
9000 - Faults of external IO-nodes (joystick, data collector, Dios module,
9999 LC-display, etc.) 1

1
These faults are not broken down hereunder!

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13.2 Description of fault reactions

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

2 Warning.
Fault code is displayed.
Audible signal

3 Impairment of function, the faulty function is overridden by an emergency function.

Fault code is displayed.
Audible signal

4 Fault of a partial function, 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.

BOMAG
Fault code is displayed.
Audible signal

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

6 Fatal fault. The function of the control is no longer assured.

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

Note: Faults with fault reaction 1 and 2 are only warning messages and are NOT saved in the fault log!

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13.3 Note codes

Notes are a special form of fault messages.

The display shows note codes in the same way as fault codes, however, these do not require any service action, because they are just notes on particular operating
states of the machine.
Machine related electrics

Note Description of fault Possible causes Assignment Input code

Code DH-4 BVC-4 for
diagnose
1088 Travel pump valve surge currents The function "Teaching pump surge currents" for the travel pump has not
Surge currents for travel pump have NOT been learned. yet been executed. X X
See 5.4 Automatic detection of surge currents in travel system Î New machine/replacement of control

1500 Warning "Dangerous condition ASC" Due to counter-rotating drive units the machine was stopped and the brake
applied. X X
The brake can be released again after shifting the travel lever to braking
position, travel operation can be resumed.

2201 Steering logic Difference between steering wheel movement and This display is a Note, if steering at standstill is not possible. At standstill
steering movement too big -> machine has stopped! the steering forces may not be high enough. This is just a possible X X
operating state.

BOMAG
2068 Valves steering pump surge currents The function "Teaching surge currents" for the electric steering has not yet
Surge currents for steering pump have NOT been learned. been executed. X X
See 5.7 Automatic surge current detection for electric steering valves Î New machine/replacement of control
(Only machine with electric steering)

2198 Electric steering, steering end stops The function "Teaching steering stops" for the electric steering has not yet
Teaching of steering stops for electric steering NOT yet executed. been executed. X X
See 5.6 Teaching the steering end stops (electric) Î New machine/replacement of control
(Only machine with electric steering)

2300 Arm rest raised The arm rest has been raised or the magnetic switch under the left hand
Î Machine does not pick up throttle and is braked to stop. arm rest is defective X

3077 Warning ! Trying to drive in reverse with the attachment plates The attachment plates are lowered and an attempt is made to drive X
lowered. backwards.

5013 Diesel engine stalled various X X

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13.4 Detailed description of fault codes and their possible causes

13.4.1 General
Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
0500 Driving against brake warning A corresponding input code has been entered
The function "Driving against brake" is activated X X 2

0502 Simulated engine run - warning A corresponding input code has been entered
The function "Simulated engine run" is activated X X 2

0504 Ant- Slip Control (ASC) deactivated - warning A corresponding input code has been entered
The function "Anti Slip Control (ASC)" is deactivated X X 2

0507 Drum drive deactivated - warning A corresponding input code has been entered
Test mode "Drum drive deactivated" was activated. X X 2

0508 Axle drive deactivated - warning A corresponding input code has been entered
Test mode "Axle drive deactivated" was activated. X X 2

BOMAG
0560 Overvoltage 8.5V Connection of voltage level to operating voltage, another voltage X35:23
The voltage level of the 8,5V range is impermissibly potential or control defective X X 2
exceeded (see signal description)
0561 Undervoltage 8.5V Connection of voltage level to ground, another voltage potential X35:23
The voltage level of the 8,5V range is impermissibly fallen or control defective X X 2
short of (see signal description)
562 Error "Voltage Override Relay" 2
The voltage level of the 8,5V range is... X X

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13.4.2 brake
Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1001 Brake valve line breakage ) The connecting line between control output and control X35:61
The required control power cannot be transmitted to the solenoid is interrupted. X X 1001 6
control solenoid. ) The solenoid is defective
Machine related electrics

1002 Brake valve short circuit to ground ) The connecting cable has short circuit to ground X35:61
Signal outside the valid range (see signal description) ) Coil defective X X 1001 6

1003 Brake valve short circuit Ub ) The connecting cable has short circuit to battery voltage X35:61
Signal outside the valid range (see signal description) X X 1001 6

1004 Brake valve ) The connecting cable has short circuit to ground X35:61
Overheating of output driver in ESX ) Coil defective X X 1001 6

1005 BTS brake / plausibility (BTS=output driver) ) Hardware defect on travel lever X35:17
Plausibility conflict in evaluation of travel lever X- axis to ) Connection between ESX and travel lever interrupted X33:3 X X 5
the brake contact signal

BOMAG
13.4.3 Travel lever
Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1025 Travel lever sum error X-axis Internal fault in travel lever -> Replace travel lever. CAN
Error in redundant evaluation of axis X X 3

1026 Travel lever cable breakage X-axis Cable breakage in travel lever -> Replace travel lever. CAN
Signal outside the valid range (see signal description) X X 3

1027 Travel lever parameterization X-axis Internal fault in travel lever -> Replace travel lever. CAN
X X 3

1028 Travel lever direction evaluation X-axis Internal fault in travel lever -> Replace travel lever. CAN
The direction of travel lever movement could not be X X 3
determined

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Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1029 Travel lever difference error X-axis Internal fault in travel lever -> Replace travel lever. CAN
Error in redundant evaluation of travel lever signal X X 3

1030 Travel lever software error X-axis Internal fault in travel lever -> Replace travel lever. CAN
Software does not work fault free X X 3

Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1031 Travel lever sum error Y-axis Internal fault in travel lever -> Replace travel lever. CAN
Error in redundant evaluation of axis X X 3

1032 Travel lever cable breakage Y-axis Cable breakage in travel lever -> Replace travel lever. CAN
Signal outside the valid range (see signal description) X X 3

1033 Travel lever parameterization Y-axis Internal fault in travel lever -> Replace travel lever. CAN
X X 3

BOMAG
1034 Travel lever direction evaluation Y-axis Internal fault in travel lever -> Replace travel lever. CAN
The direction of travel lever movement could not be X X 3
determined

1035 Travel lever difference error Y-axis Internal fault in travel lever -> Replace travel lever. CAN
Error in redundant evaluation of travel lever signal X X 3

1036 Travel lever software error Y-axis Internal fault in travel lever -> Replace travel lever. CAN
Software does not work fault free X X 3

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13.4.4 Travel speed range selector switch
Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1040 Travel range selector switch "Ground connection" Cable breakage in ground line, or connecting cable sensor / X23:8
Signal outside the valid range (see signal description) ground supply has come loose X X 1040 3
1041 Travel range selector switch "Supply connection" Cable breakage in ground line, or connecting cable sensor / X23:5
Machine related electrics

Signal outside the valid range (see signal description) ground supply has come loose X X 1040 3
1042 Travel speed range selector switch Higher contact resistances have possibly caused a faulty signal. X23:11
Signal outside the valid range (see signal description) The switch must be replaced. X X 1040 3

13.4.5 Travel system

Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1070 Output travel pump forward The connecting line from the output of the control to the X35:49
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid is X X 5
proportional solenoid. defective
-> Line interrupted/cable breakage.

BOMAG
1071 Fault of current regulator forward Faults in valve control Check wiring. X35:49
X X 5

1072 Fault of current regulator forward Faults in valve control Check wiring. X35:49
X X 5

1073 Output travel pump forward Short circuit of connecting line (control to proportional valve) to X35:49
Supply voltage UB applied to the output to the proportional voltage supply X X 5
valve.
1074 Output travel pump forward - Short circuit of connecting line (control to proportional valve) X35:49
Output to proportional valve shorted to ground. to machine frame or a ground cable. X X 5
- Proportional valve defective.
1075 Error in teaching the surge current forward Machine mechanically blocked X35:49
Travel system bypass valves out of adjustment X X 5

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Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1080 Output travel pumps reverse The connecting line from the output of the control to the X35:64
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid is X X 5
proportional solenoid. defective
) Line interrupted/cable breakage.

1081 Fault of current regulator reverse Faults in valve control Check wiring. X35:64
X X 5

1082 Fault of current regulator reverse Faults in valve control Check wiring. X35:64
X X 5

1083 Output travel pumps reverse Short circuit of connecting line (control to proportional valve) to X35:64
Supply voltage UB applied to the output to the proportional voltage supply X X 5
valve.
1084 Output travel pumps reverse - Short circuit of connecting line (control to proportional valve) X35:64
Output to proportional valve shorted to ground. to machine frame or a ground cable. X X 4
- Proportional valve defective.
1085 Error in teaching the surge current reverse Machine mechanically blocked X35:64
Travel system bypass valves out of adjustment X X 3

BOMAG
1088 Travel pump surge currents Note, no fault! See 13.3 Note codes
Surge currents for travel pump have NOT been learned. X X 1
See 5.4

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Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1100 Output front travel motor The connecting line from the output of the control to the X35:46 X X 4
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid is
proportional solenoid. defective
Î Line interrupted/cable breakage.

1105 Speed sensor pulses front travel motor Check connecting lines and plugs on wheel speed sensor, if X35:34 X X 4
Machine related electrics

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 4
Incorrect or non-existent signal "Direction" necessary replace the wheel speed sensor

1107 Output front travel motor Short circuit of connecting line (control to proportional valve) to X35:46 X X 5
Supply voltage UB applied to the output to the proportional voltage supply
valve.
1108 Output front travel motor - Short circuit of connecting line (control to proportional valve) X35:46 X X 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.
- Proportional valve defective.

1110 Output rear travel motor The connecting line from the output of the control to the X35:47 X X 4
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid is
proportional solenoid. defective

BOMAG
Î Line interrupted/cable breakage.

1115 Speed sensor pulses rear travel motor Check connecting lines and plugs on wheel speed sensor, if X35:12 X X 4
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 4
Incorrect or non-existent signal "Direction" necessary replace the wheel speed sensor

1117 Output rear travel motor Short circuit of connecting line (control to proportional valve) to X35:47 X X 4
Supply voltage UB applied to the output to the proportional voltage supply
valve.
1118 Output rear travel motor - Short circuit of connecting line (control to proportional valve) X35:46 X X 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.
- Proportional valve defective.

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Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1140 Travel system pressure sensor "Signal" The connecting line from the output of the control to the pressure X35:31 X X 1
The current signal is not transmitted (see signal sensor is interrupted or the pressure sensor is defective
specification
1141 Travel system pressure sensor "Signal range" The pressure sensor is defective X35:31 X X 1
The current signal is outside the valid range (see signal
specification)
1142 Travel system pressure sensor "no pressure" No pressure connection on sensor or supply line clogged, orno X35:31 X X 4
The electric signal indicates that the travel pressure is travel pressure is built up.
permanently missing.

1145 Inclination sensor "Supply connection" Cable breakage in supply line, or connecting cable sensor / X35:?? X X 3
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 3
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 2
not seated!)

BOMAG
1500 Warning "Dangerous condition ASC" Note, no fault! See 13.3 Note codes X X 2

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13.4.6 Steering
(Only machine with electric steering)
Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
2000 Limp home steering valves active X 1

2040 Output steering valve right The connecting line from the output of the control to the X35:20 X 4
Machine related electrics

The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid is
proportional solenoid. defective
Î Line interrupted/cable breakage.

2041 Output steering valve right Faults in valve control Check wiring. X35:20 X 4
Fault current regulator

2042 Output steering valve right Faults in valve control Check wiring. X35:20 X 4
Fault current regulator

2043 Output steering valve right Short circuit of connecting line (control to proportional valve) to X35:20 X 5
Supply voltage UB applied to the output to the proportional voltage supply
valve.
2044 Output steering valve right - Short circuit of connecting line (control to proportional valve) X35:20 X 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.

BOMAG
- Proportional valve defective.

2050 Output steering valve left The connecting line from the output of the control to the X35:21 X 4
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid is
proportional solenoid. defective
Î Line interrupted/cable breakage.

2051 Output steering valve left Faults in valve control Check wiring. X35:21 X 4
Fault current regulator

2052 Output steering valve left Faults in valve control Check wiring. X35:21 X 4
Fault current regulator

2053 Output steering valve left Short circuit of connecting line (control to proportional valve) to X35:21 X 5
Supply voltage UB applied to the output to the proportional voltage supply
valve.
2054 Output steering valve left - Short circuit of connecting line (control to proportional valve) X35:21 X 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.
Proportional valve defective.

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Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
2065 Error when teaching the surge current for the right Drum was not moved, maximum current was reached, steering is X35:20 X 4
hand valve blocked (e.g. articulation lock applied)
2066 Error when teaching the surge current for the left hand Drum was not moved, maximum current was reached, steering is X35:21 X 4
valve blocked (e.g. articulation lock applied)
2068 Valves steering pump surge currents Note, no fault! See 13.3 Note codes X 1
Surge currents for steering pump have NOT been learned.
See 5.7 Automatic surge current detection for electric
steering valves (Only machine with electric steering)
2170 Steering wheel (arm rest) "direction change" Wiring fault or steering sensor in left hand arm rest defective X35:18 X 4
X35:19
X35:40
X35:41
2171 Steering wheel (arm rest) "Pulse coverage" Steering sensor in left hand arm rest defective. X35:18 X 4
High difference in measuring values between sensor 1 and X35:19
2 X35:40
X35:41
2172 Steering wheel (arm rest) "Sensor 1 pulse range" Check the connecting lines to steering sensor 1, or replace the X35:18 X 4
The detected steering pulses on steering sensor 1 are steering sensor in the left hand arm rest, if required. X35:19
outside the valid range ( see signal description)

BOMAG
2173 Steering wheel (arm rest) "Sensor 2 pulse range" Check the connecting lines to steering sensor 2, or replace the X35:40 X 4
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 4
X35:19
2175 Steering wheel A45 (arm rest) "Sensor 2" Steering sensor in left hand arm rest defective. X35:40 X 4
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 4
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 4
breakage" steering sensor in the left hand arm rest, if required. X35:41
2178 Steering wheel A45 (arm rest) "Sensor 1 sensor fault" Sensor fault. If this occurs frequently, change steering wheel. X 4

2179 Steering wheel A45 (arm rest) "Sensor 2 sensor fault" Sensor fault. If this occurs frequently, change steering wheel. X 4

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Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
2190 Steering "steering angle sensor... initialization" Replace the control! X 4
Internal control fault.
2191 Steering angle sensor B65 "Measuring value" Steering angle sensor on the articulated joint X35:29 X 4

2192 Steering angle sensor B65 "Supply cable breakage" Voltage supply line to steering angle sensor interrupted or X35:23 X 4
steering angle sensor on articulated joint defective
Machine related electrics

- Ground connection of signal line

2193 Steering angle sensor B65 "Ground cable breakage" Ground cable to steering angle sensor interrupted or steering X35:1 X 4
angle sensor on articulated joint defective

2198 Electric steering, steering end stops Note, no fault! See 13.3 Note codes (X) 4
Teaching of steering stops for electric steering NOT yet
executed.
See 5.6 Teaching the steering end stops (electric)
(Only machine with electric steering)
2200 Steering logic Difference between steering wheel Steering valve "jammed". No hydraulic oil supply.
movement and steering movement too big -> machine Surge currents have not been taught (correctly) (see also 5.7
travelling! Automatic surge current detection for electric steering valves .
2201 Steering logic Difference between steering wheel Note, no fault! See 13.3 Note codes X 2
movement and steering movement too big -> machine has
stopped!

BOMAG
13.4.7 Driver's seat arm rest sensor
(Only machine with electric steering)
Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
2300 Note! "Arm rest raised" Note, no fault! See 13.3 Note codes X35:16 X 2
-> Machine does not pick up throttle and is braked to
stop.
2301 Signal fault Cable breakage in the signal line of the magnetic switch, or X35:16 X 2
Signal outside the valid range (see signal description) magnetic switch under left hand arm rest defective.
-> !!Machine can be driven normally!!
2302 Supply cable breakage Voltage supply line to magnetic switch interrupted or magnetic X35:16 X 4
-> !!Machine can be driven normally!! switch under left hand arm rest defective.

2303 Ground cable breakage Ground cable to magnetic switch interrupted or magnetic switch X35:16 X 4
-> !!Machine can be driven normally!! under left hand arm rest defective.

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13.4.8 Vibration
Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
3000 Vibration sensor "No signal" Check connecting lines and plugs to the vibration sensor, if X35:35 X X 1
The sensor in the vibration motor does not pick up any necessary replace the sensor in the vibration motor
pulses.

3001 Valve vibration pump (low amplitude on DH) Details in 3004 – 3008 X35:48 X X 1
General fault.
3002 Valve vibration pump (low amplitude on DH) System fault! Replace the control! X35:48 X X 1
Internal system fault.
3003 Valve vibration pump (low amplitude on DH) "Current Fault in the connecting line or connection to another potential X35:48 X X 1
range" (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 from the output of the control to the X35:48 X X 1
Line interruption proportional solenoid is interrupted or the proportional solenoid is
defective, or the changeoverf relay / bridge is missing.
3005 Valve vibration pump (low amplitude on DH) System fault! Replace the control! X35:48 X X 1
Internal system fault.

BOMAG
3006 Valve vibration pump (low amplitude on DH) "Control Fault in the connecting line, incorrect valve coil or connection to X35:48 X X 1
fault regulation down" 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) "Control Fault in the connecting line, incorrect valve coil or connection to X35:48 X X 1
fault regulation up" 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 1
Internal system fault.
3009 Valve vibration pump (low amplitude on DH) Short circuit of connecting line (control to proportional valve) to X35:48 X X 1
Supply voltage UB applied to the output to the proportional voltage supply
valve.
3010 Valve vibration pump (low amplitude on DH) - Short circuit of connecting line (control to proportional valve) X35:48 X X 1
Output to proportional valve shorted to ground. to machine frame or a ground cable.
- Proportional valve defective.

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Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
3011 Vibration adaptation control (low amplitude on DH) Wear or damage in vibration system hydraulic circuit. X35:48 X X 2
"Frequency adaptation" Valve sticking/defective.
Adjustment range reached!
(see signal specification)
3012 Vibration adaptation control (low amplitude on DH) Wear or damage in vibration system hydraulic circuit. X35:48 X X 2
"Frequency adaptation" Valve sticking/defective.
Machine related electrics

Upper adjustment range reached!

(see signal specification)
3013 Vibration adaptation control (low amplitude on DH) Wear or damage in vibration system hydraulic circuit. X35:48 X X 2
"Frequency adaptation" Valve sticking/defective.
Lower adjustment range reached!
(see signal specification)
3014 Vibration frequency (low amplitude on DH) Vibrations frequency exceeded by more than 5Hz. X35:48 X X 4
Frequency/speed to high Emergency shut down to protect bearings.
After replacement of a vibration pump or peripheral equipment in
the vibration circuit this fault may occur as a result of
unfavourable component tolerances.
In this case normal operation can be reached by multiple
activation of the vibration, after the fault has been rectified.
ATTENTION! It must be assured, that the fault has not be
caused by a faulty component (pump, control,

BOMAG
3021 Vibration pump valve (only DH: high amplitude) Details in 3014 – 3018 X35:48 X 1
General fault.
3022 Vibration pump valve (only DH: high amplitude) System fault! Replace the control! X35:48 X 1
Internal system fault.
3023 Vibration pump valve (only DH: high amplitude) "Current Fault in the connecting line or connection to another potential X35:48 X 1
range" (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3024 Valve vibration pump "Cable breakage" The connecting line from the output of the control to the X35:48 X 1
(only DH: high amplitude) proportional solenoid is interrupted or the proportional solenoid is
Line interruption defective, or the changeover relay / bridge is missing.
3025 Vibration pump valve (only DH: high amplitude) System fault! Replace the control! X35:48 X 1
Internal system fault.

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Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
3026 Vibration pump valve (only DH: high amplitude) Fault in the connecting line, incorrect valve coil or connection to X35:48 X 1
"Control fault regulating up" another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3027 Vibration pump valve (only DH: high amplitude) Fault in the connecting line, incorrect valve coil or connection to X35:48 X 1
"Control fault regulating down" another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3028 Vibration pump valve (only DH: high amplitude) System fault! Replace the control! X35:48 X 1
Internal system fault.
3029 Vibration pump valve (only DH: high amplitude) Short circuit of connecting line (control to proportional valve) to X35:48 X 2
Supply voltage UB applied to the output to the proportional voltage supply
valve.
3030 Vibration pump valve (only DH: high amplitude) - Short circuit of connecting line (control to proportional valve) X35:48 X 2
Output to proportional valve shorted to ground. to machine frame or a ground cable.
- Proportional valve defective.

3031 Vibration adaptation control (only DH: high amplitude) Wear or damage in vibration system hydraulic circuit. X35:48 X 2
Frequency adaptation

BOMAG
Limits of adaptation range exceeded
(see signal specification)
3032 Vibration adaptation control (only DH: high amplitude) Wear or damage in vibration system hydraulic circuit. X35:48 X 2
"Frequency adaptation" Valve sticking/defective.
Upper adjustment range reached!
(see signal specification)
3033 Vibration adaptation control (only DH: high amplitude) Wear or damage in vibration system hydraulic circuit. X35:48 X 2
"Frequency adaptation" Valve sticking/defective.
Lower adjustment range reached!
(see signal specification)
3034 Vibration frequency (only DH: high amplitude) Vibrations frequency exceeded by more than 5Hz. X35:48 X 4
Frequency/speed to high Emergency shut down to protect bearings.
After replacement of a vibration pump or peripheral equipment in
the vibration circuit this fault may occur as a result of
unfavourable component tolerances.
In this case normal operation can be reached by multiple
activation of the vibration, after the fault has been rectified.
ATTENTION! It must be assured, that the fault has not be
caused by a faulty component (pump, control, valve)

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13.4.9 Attachment plates
Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
3051 Vibration pump, plates, valve Details in 3052 – 3058, this fault always is connected with one of X35:22 X 1
General fault. the faults listed below
Machine related electrics

3052 Vibration pump, plates, valve "hysteresis" X35:22 X 1

3053 Vibration pump, plates, valve "current range" X35:22 X 1

The control current is outside the valid range (see signal
specification)

3054 Vibration pump, plates, valve "Cable breakage" The connecting line from the output of the control to the X35:22 X 1
Line interruption proportional solenoid is interrupted or the proportional solenoid is
defective, or the changeover relay / bridge is missing.

Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose

BOMAG
3055 Vibration pump, plates, valve System fault! Replace the control! X35:22 X 1
Internal system fault.

3056 Vibration pump, plates, valve X35:22 X 1

"Control fault positive limit"
The control current is outside the valid range (see signal
specification)
3057 Vibration pump, plates, valve X35:22 X 1
"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 1
Internal system fault.

3077 Warning Attempt to drive in reverse with the Note, no fault! See 13.3 Note codes X 2
attachment plates lowered.

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13.4.10 Diesel engine

Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
5013 Diesel engine stalled Note, no fault! See 13.3 Note codes X X 1
5024 Diesel engine "Coolant level" warning Coolant level too low or sensor defective X26:10 X X 2
5025 Diesel engine "Coolant level" fault shut-down Coolant level too low or sensor defective X26:10 X X 5
5026 Diesel engine "Air filter" warning Air filter soiled or sensor defective X26:8 X X 2
5027 Diesel engine "Air filter" fault shut-down Air filter soiled or sensor defective X26:8 X X 5
5028 Water separator warning Water or other dirt in fuel filter X27:4 X X 2
X27:9
5029 Water separator fault shut-down Water or other dirt in fuel filter X27:4 X X 5
X27:9

13.4.11 Diesel engine EMR

Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
5100 Diesel engine EMR "Warning light" Collective warning X X 2

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 2
) see further fault code for more accurate fault diagnose
5102 Diesel engine EMR has more than one logged fault. Collective message for engine shut down X X 2
) see further fault code for more accurate fault diagnose

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Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
5110 Diesel engine EMR "Nominal speed value" ) CAN connection between ESX and EMR interrupted X X 2
) 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 2
Machine related electrics

5112 Diesel engine EMR "Oil pressure" ) Engine oil pressure too low X31:21 X X 2
5113 Diesel engine EMR "Charge air pressure" ) Charge air pressure too low X31:24 X X 2
5114 Diesel motor EMR "Temperature in intake line" ) Charge air temperature too high X31:4 X X 2
5116 Diesel engine EMR "Coolant temperature" ) Coolant temperature too high X31:9 X X 2
5117 Diesel engine EMR "Fuel temperature" ) Fuel temperature too high X X 2
5118 Diesel engine EMR "Engine speed" ) Speed sensor 1 or 2 defective X31:13 X X 2
) Connection between EMR and speed sensor 1 or 2 X31:11
interrupted

5119 Water separator (EMR3) Water or other dirt in fuel filter X X 2

5120 Diesel engine EMR "CAN communication" ) CAN connection between ESX and EMR interrupted X X 2
) CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.

BOMAG
) ESX without voltage supply
) Battery charge level too low
5121 Diesel engine EMR "CAN communication" ) CAN connection between ESX and EMR interrupted X X 5
) 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 X X 2
) 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 X30:12 X X 2
X30:13
5124 Diesel engine EMR CAN communication ) CAN communication between EMR and ESX X30:12 X X 2
X30:13
5125 Diesel engine EMR CAN communication ) CAN communication between EMR and ESX X30:12 X X 2
X30:13
5126 Diesel engine EMR CAN communication ) CAN communication between EMR and ESX.# X30:12 X X 2
Occurs also when the ESX travel control switches off for X30:13
longer than 5 seconds (LCD-display flickers) while the engine
is running.

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Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
5127 Diesel engine EMR "Low pressure fuel pressure" ) Fuel pre-pressure too low (possibly filter clogged) X31:13 X X 2
X31:23
X31:40
5130 Diesel engine EMR "Oil pressure sensor" ) Sensor defective X31:20 X X 2
) Wire breakage in current path X31:21
) Current path has short circuit to ground X31:22
5131 Diesel engine EMR "Charge air pressure sensor" ) Sensor defective X31:23 X X 2
) Wire breakage in current path X31:24
) Current path has short circuit to ground X31:25
5132 Diesel engine EMR "Charge air temperature" ) Sensor defective X31:4 X X 2
) Wire breakage in current path X31:23
) Current path has short circuit to ground X31:25
5133 Diesel engine EMR "Coolant temperature sensor" ) Sensor defective X31:8 X X 2
) Wire breakage in current path X31:9
) Current path has short circuit to ground
5134 Diesel engine EMR "Speed sensor" ) Speed sensor 1 or 2 defective X31:10 X X 2
X31:11
X31:12
X31:13

BOMAG
5135 Water separator (EMR2) Water or other dirt in fuel filter X X 2

5136 Diesel engine EMR "Fuel low pressure sensor" ) Sensor defective X31:13 X X 2
) Wire breakage in current path X31:23
) Current path has short circuit to ground X31:40
5140 Diesel engine EMR "unknown fault" Fault diagnostics only possible with DEUTZ diagnostics tool X X 2
(SERDIA)

13.4.12 Miscellaneous
Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
5502 "Hydraulic oil filter" warning Hydraulic oil filter soiled or sensor defective X X 2
5503 "Hydraulic oil filter" fault shut-down Hydraulic oil filter soiled or sensor defective X X 5
5504 "Oil temperature" warning Hydraulic oil temperature too high or sensor defective X X 2
5005 "Oil temperature" fault shut-down Hydraulic oil temperature too high or sensor defective X X 5

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13.4.13 Machine type
Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
7011 Warning "Change of machine type" Only change the machine type after applying appropriate X X 6
This warning is displayed when the machine type is measures; e.g. conversion from D to PD (different rolling
changed. circumference of roller drum)
7012 "Conflict machine type" The machine type has been changed to such an extent, that the X X 4
Machine related electrics

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)

13.4.14 Optional functions

Fault Description of fault Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
9400 Communication error travel control engine control ) Fault on CAN (2) line X34:C X X 4
) Travel lever defective X34:D
) Immobilizer not yet unlocked

BOMAG
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14 Input Codes for ESX Control

Display and adjustment functions can generally only be accessed by entering "service code" 9999 beforehand!

14.1 Fault log

without service code!

Input code Description of display function Display values

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

14.2 Value displays

BOMAG
14.2.1 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)

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

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14.2.3 Travel lever / driving
Input code Description of display function Display values
1020 Display "Travel lever end positions" 100 = Forward
0 = Neutral
10 = Reverse
1000 = left
10000 = Right
Machine related electrics

Combinations are possible, e.g. 1100 for forward

1021 Display "Values for axle forward reverse" 0..1000 = Forward
0..-1000 = Reverse
1022 Display "Values for axle right left" left -> - 1000..0..1000 -> right, i.e. brake gate
1025 Display "Travel lever actuating direction" 100 = Forward
0 = Neutral
1 = Reverse
1026 Display "Travel direction" 0 = Neutral
(actual machine movement) 1 = Forward
2 = Reverse
1027 Display "Travel lever release" 0 = locked

BOMAG
1 = released

14.2.4 Travel speed range selector switch

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

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Input code Description of display function Display values

1042 Display "Voltage value for speed range / gear standardized" Stage 1 956 Stage 2 916 Stage 3 875
Stage 4 835 Stage 5 795 Stage 6 756
Stage 7 716 Stage 8 675 Stage 9 637
Stage 10 597 Stage 11 557 Stage 12 517
Stage 13 478 Stage 14 436 Stage 15 396
Stage 16 357 Stage 17 318 Stage 18 279
Stage 19 238 Stage 20 200 Stage 21 160
Stage 22 120 Stage 23 80 Stage 24 40
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
14.2.5 Travel pump: Travel direction forward
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)

14.2.6 Travel pump: Travel direction reverse

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

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

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14.2.7 Travel motor front (drum)
Input code Description of display function Display values
1100 Actual coil current Display in mA (0..600..1000)
1101 Coil current Nominal value Display in mA (0..600..1000)
1105 Travel speed Display in m/min
1106 Pulses of speed sensor Counts the pulses up to 99'999 and starts again at 0
Direction signal of speed sensor 2 = Forward
Machine related electrics

1107
1 = Standstill and reverse
1108 Travel direction logics 1 = Forward
0 = Standstill
2 = Reverse

14.2.8 Travel motor rear (wheel axle)

Input code Description of display function Display values
1110 Actual coil current Display in mA (600..1000)
1111 Coil current Nominal value Display in mA (600..1000)
1115 Travel speed Display in m/min

BOMAG
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

14.2.9 Shut-down of drives1

Input code Description of display function Display values
1120 Enable shut-down (force max. displacement)
1121 Drum drive
1122 Wheel drive

1
Settings will not be saved. After shutting down the machine all drives are engaged again!

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14.2.10 Adaptation values for speed regulation

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

14.2.11 Travel pressure sensor

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

14.2.12 Inclination sensor

Input code Description of display function Display values
1145 Standardized measuring value –1000..0..1000. (0 = 0%)
1146 Raw measuring value (voltage in V) 0..8.5V (-> 0..1000)

BOMAG
1147 Standardized measuring tube value 0..8.5V = 0..1000
1148 Function status (internal logic -> diagnose) 0=Not initialized, 1=Normal operation, 2=Fault

14.2.13 Travel condition values

Input code Description of display function Display values
1150 Current travel speed (in km/h) 0.00..20.00

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14.2.14 Calibrating the wheel diameter
See 5.9 Calibrating the speed detection
Input code Description of display function Display values
1160 Activate the function
1161 Travel a distance of 5m
1162 Travel a distance of 10m
Machine related electrics

1163 Travel a distance of 20m

1164 Travel a distance of 50m
1165 Travel a distance of 100m
1168 Setting of standard values
1169 Saving the measuring value.
Speed detection has been parameterized anew!

14.2.15 Speed limitation

Input code Description of display function Display values
1210 Current setting (in km/h) 0 = No limitation
6 = 6 Kmh

BOMAG
7 = 7 Kmh
8 = 8 Kmh
9 = 9 Kmh
10 = 10 Kmh
11 = 11 Kmh
12 = 12 Kmh

14.2.16 Arm rest contact

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

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14.2.17 Adoption values traction control

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

14.2.18 Steering: Steering valve

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

2106 Display "Current min value (surge current) left hand steering valve" Display in mA
2107 Display "max current value hand steering valve left" Display in mA
2108 Display "min current value (surge current) steering valve right" Display in mA

BOMAG
2109 Display "max current value steering valve right" Display in mA

14.2.19 Steering: Angle sensor in articulated joint

Input code Description of display function Display values
2110 Raw measuring value (voltage in V) 0...8,5VDC
- Middle position approx. 4,5V
- Steering left = lower voltage (approx. 2V..4,5V)
- Steering right = lower voltage (approx. 4,5V..4.7V)
2111 Standardized measuring value 0...1000 (left= high value (approx. 750), right = low value
(approx. 220)
2112 Standardized actual steering angle position -1000...0...1000 (left = negative value, right positive value)

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14.2.20 Steering: Steering wheel
Input code Description of display function Display values
2120 Standardized nominal steering angle position -1000/01000

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

14.2.21 Vibration
Input code Description of display function Display values

BOMAG
3000 Display "Switch for vibration mode" Value DH4 BVC
0 off on
1 low amplitude on
2 high amplitude ---
3001 Display "Status of vibration relay“ 0 = Relay K43 not switched
1 = Relay K43 switched

14.2.22 Vibration (up to version 3.24 )

Input code Description of display function Display values
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.
3004 Actual working frequency (low amplitude on DH) Display value = Hz
3005 Actual working frequency (high amplitude on DH) Display value = Hz
3006 Actual control factor (low amplitude on DH) 2000 – 8000 (machine type dependent)

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Input code Description of display function Display values

3007 Actual control factor (high amplitude on DH) 2000 – 8000 (machine type dependent)
3009 Actual Vario status (only BVC) -1 ... 7

14.2.23 Vibration control; Vario and low amplitude circular exciter (from version 3.25 )
Input code Description of display function Display values
3002 Display "Vibration pump valve current" (low amplitude on DH) Display value = mA
The display shows the actual pump current.
3003 Display "Vibration pump nominal valve current" (low amplitude on DH) Display value = mA
The display shows the nominal pump current.
3004 Actual working frequency (low amplitude on DH) Display value = Hz
3006 Actual control factor for frequency controller (low amplitude on DH) 2000 – 8000 (machine type dependent)
3007 Actual control factor valve flow controller (high amplitude on DH) 2000 – 8000 (machine type dependent)
3008 Actual fault counter valve flow controller (high amplitude on DH) 1000

14.2.24 Vibration control; high amplitude circular exciter (from version 3.25 )

BOMAG
Input code Description of display function Display values
3012 Display "Vibration pump valve current" Display value = mA
The display shows the actual pump current.
3013 Display "Vibration pump nominal valve current" Display value = mA
The display shows the nominal pump current.
3014 Current working frequency Display value = Hz
3016 Current control factor frequency controller 2000 – 8000 (machine type dependent)
3017 Current control factor valve current controller 2000 – 8000 (machine type dependent)
3018 Current fault counter valve current controller 1000

Input code Description of display function Display values

3030 Vibration motor number of pulses per revolution (vibration motor type 30 ... 60
dependent) (see 5.13 "Setting the vibration motor type")

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14.2.25 Attachment plates, option (only BW213 BVC)
Input code Description of display function Display values
3050 Display "Attachment plates activated" OFF, i.e. software for plates switched off
ON, i.e. software for plates switched on
3051 Display "Sensor for height shut-down" OFF = Sensor has switched, senses metal, plates raised
ON = Sensor has not switched, senses no metal, plates
lowered
Machine related electrics

3052 Display "Sensor for middle position" OFF = Sensor has not switched, senses no metal
ON = Sensor has switched, senses metal, plates in middle

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

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

BOMAG
3056 Display "Potentiometer value frequency setting of plates" 0..1000 standard, 0 = min. frequency, 1000 = max. frequency

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

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14.2.26 Engine
Input code Display values
Description of display function
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

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

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

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

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

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14.3 Test settings

14.3.1 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
Machine related electrics

lever out of the brake gate

0501 Deactivates the function "Driving against the closed brake" O K for 3 seconds, then 0000

14.3.2 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 valve not energized. The motor should now swash to max.
displacement position.
1122 Function "Disable electric supply for drum drive motor"
Motor valve not energized. The motor should now swash to max.

BOMAG
displacement position.
1123 Function "Switch of power supply for drum drive motor TOGETHER
WITH wheel drive motor"
Motor valves not energized. The motors should now swash to max.
displacement position.
1124 Switch off function "Disable electric supply for drum drive motor"
The motor valve is max. energized. The motor should now swash to
min. displacement position.
1125 Function "Disable electric supply for wheel drive motor"
The motor valve is max. energized. The motor should now swash to
min. displacement position.
1126 Function "Switch on power supply for drum drive motor TOGETHER
WITH wheel drive motor"
Motor valves max. energized. The motors should now swash to min.
displacement position.

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14.4 Settings / Teach / Emergency functions

14.4.1 Changing the machine code

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

14.4.2 Automatic detection of surge currents in travel system

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

BOMAG
14.4.3 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

14.4.4 Speed detection, teaching of distance pulses

Input code Description of display function Display values
1160 Permit teach function
1161 Activate the function: Measurement over a travel distance of 5m Pulses read
1162 Activate the function: Measurement over a travel distance of 10m Pulses read
1163 Activate the function: Measurement over a travel distance of 20m Pulses read
1164 Activate the function: Measurement over a travel distance of 50m Pulses read
1165 Activate the function: Measurement over a travel distance of 100m Pulses read
1168 Reset to basic values "saved"
1169 Storing the learned values "saved"

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14.4.5 Detection of wheel rotation
Input code Description of display function Display values
1200 Permit teach function
1201 Teach sense of rotation1 Raise travel speed over 10m/min
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14.4.6 Engine shutdown by SEPA filter monitoring

Input code Description of display function Display values
5030 View the current setting Î 0 = no engine shut-down
Î 1 = engine shut-down active
5031 Release parameter change
5032 No engine shut-down (standard) Confirmation by text display: "OK".
5033 Engine shut-down active. Confirmation by text display: "OK".

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

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14.4.7 Steering: Automatic detection of surge currents on steering valve

Input code Description of display function Display values
2000 Activate function "Teach steering start current" see chapter 0
2001 Function "Teach steering start current" see chapter 0

14.4.8 Steering: Determining the steering stops

Input code Description of display function Display values
2010 Activate function "Teach steering stops" see chapter 5.6
2011 Deactivate function "Teach steering stops" 0000
2012 Function "Accept right hand steering stop" see chapter 5.6
2013 Function "Accept left hand steering stop" see chapter 5.6

14.4.9 Steering: Emergency function

Input code Description of display function Display values
2050 Steering with joystick buttons "OK". In case of steering wheel failure

BOMAG
2051 Steering with steering wheel (uncontrolled) "OK". In case of steering angle potentiometer failure

14.4.10 Steering: Other functions

Input code Description of display function Display values
2060 Activates function "Change steering unit“ see chapter 5.5
2061 Setting to electric steering unit see chapter 5.5
2062 Setting to hydraulic steering unit see chapter 5.5

14.4.11 Setting the vibration motor type

Input code Description of display function Display values
3030 View current setting of pulse numbers see chapter 5.13
3031 Activate function "Adjust vibration motor type“ see chapter 5.13
3032.. Select vibration motor type 1..8. see chapter 5.13
3039 Follow the selection table in 5.13.

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14.4.12 Vibration: Travel speed dependent vibration lock
Input code Description of display function Display values
3047 Enable function "Changeover of travel speed dependent vibration
lock"
3048 Activate vibration lock from travel speed stage 12
3049 Disable vibration lock.
Machine related electrics

14.4.13 Vibration: Enable frequency setting

Input code Description of display function Display values
3090 View the current setting. 0, 1
3091 Enable function "Switch over frequency setting".
3092 Activate frequency setting (machine with switch).
3093 Disable frequency setting (machine WITHOUT switch).

14.4.14 Attachment plates (only circular exciter): Activating/deactivating the attachment plates option

BOMAG
Input code Description of display function Display values
3070 Enable optional changeover.
3071 Activate option "attachment plates".
3072 Disable option "attachment plates".

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!

14.4.15 Plates: Preventing reversing with plates lowered

Input code Description of display function Display values
3077 Activate function "Prevent reversing with plates lowered"
3078 Allow reversing with plates lowered.
3079 Prevent reversing with plates lowered.

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15 History

15.1 Changing the arm rests and seat contact logic

Introduction: From version V3.32 (07.02.2008)

Explanation: When leaving the seat a delay will start after which the machine is stopped.

Fault: If the machine was stopped and the seat was left, the machine could start to travel if the
travel control lever was actuated within the delay time.

15.2 Changing the vibration logic -> limitation of lower speed in vibration
operation

Introduction: From version V3.32 (07.02.2008)

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16 Terminology in connection with ESX

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

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

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

Terminal, cable lug

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

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Short circuit to ground

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

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

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

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

Disturbance variable (z)

Input (w) Output (y)

Control Distance

Closed loop control

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

Disturbance variable (z)

Input (w) Output (y)

Regulator Distance

Marking Closed loop control Control

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

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Current and voltage measurement

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

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

PWM digital output

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

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MESX

Electrics MESX 12.2

Service Training MESX

Version Date Description of changes resp.

4.00 01.05.2005 Î Languages Slovakian, Slovenian, Czech, Romanian Löw
added
Î Function "vCheckMMISoftwareVersion" corrected
Î Teach mode for distance via BCM implemented
Î Triggering of a relay for GPS receiver voltage supply
implemented
Î GPS mode changed: Off and ON now independent from
engine run, Automatic depending on engine run!
Î Setting of work number in serial number has been
realized
Î ATTENTION: Signal distribution for CAN message
MMI_CONFIG_DATA_2 0x156 was changed!!!
Î new machine types:211PD, 213PD, 216PD, 219PD + "low
cost" designs:
177D40,1777DHC,177D_40,177DHC,177PDHC,177PDH
_40,179DHC,179PDHC,211D_40,211PD_40,213D_40,21
3DHC,213PDHC,213PD_40,214DHC,214PDHC,216DHC
,216PDHC,212D_40,212PD_40
Î Pulse numbers changed to 10m for BW219D
Î VM classes taken from V3.90, VM class is sent to BCM
4.01 23.05.2007 Î Vibration detection low/high amplitude adapted Löw
4.02 07.05.2008 Î Pulse numbers for BW213DHC and PDHC adapted Löw,
Î Faulty input for VM8 for machine type BW219DHC Nick
corrected
4.03 27.01.2009 Î Minimum Evib-value limited to 1, so that BCM does no Löw
longer interpret this value incorrectly
4.04 17.11.2009 Î Machine types BW216D_40, BW216PD_40 and Löw
BW218D_40 implemented

Status:14.12.2009 Page 5 of 61
Author: T.Löw / TE

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3 Proof of software change BOP

Version Date Description of changes resp.

1.00 25.03.2004 first software version for series production Löw

1.01 13.04.2004 Revision of BVC diagnostics screen Löw

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

3.00 15.10.2004 Î Realization of imperial display Löw

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

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

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

4.01 04.11.2008 Î - additional variable for brightness control OPUS21C Löw

added
Î - Representation of SW TN instead of "High-TN"
Î - Return to diagnostic page corrected for French
version
Î - SimulScreen activated for French version
Î - Changeover of GPS-mode prevented (jump to
page GPS-mode deactivated)
4.02 13.01.2009 Î Return to selection page "Scale type" corrected. Löw

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

Behaviour of machine Possible cause

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

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5 How to proceed when replacing components?

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

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

5.1 How to proceed when replacing an ESX control?

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

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

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

After setting the machine type check the following items:

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

5.2 How to proceed when replacing a rear axle sensor?

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

5.3 Which components can be replaced without a subsequent

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

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

recommended.

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5.4 List of machine types

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

The following machine types can be adjusted:

Machine type First serial number Last serial number Code Available from
version
177 D 101 582 20 1001 XXX XXX XX XXXX 7500 1.00
101 583 27 1001
177 PD 101 583 43 1001 XXX XXX XX XXXX
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
101 583 32 1001
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7502 3.03
101 583 31 1001
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7503 1.00
101 583 28 1001
179 DH 101 582 24 1001 XXX XXX XX XXXX 7511 3.03
101 583 33 1001
179 PDH 101 582 25 1001 XXX XXX XX XXXX 7512 3.03
101 583 35 1001
211 D 101 582 40 1001 XXX XXX XX XXXX 7520 1.03
101 582 41 1001
101 583 09 1001
211 PD 101 582 45 1001 XXX XXX XX XXXX 7529 4.00
101 583 10 1001
213 D 101 582 50 1001 XXX XXX XX XXXX 7530 1.03
101 583 08 1001
213 DH 101 582 51 1001 XXX XXX XX XXXX 7531 1.03
101 583 14 1001
101 583 37 1001
213 PD 101 582 46 1001 XXX XXX XX XXXX 7539 4.00
101 583 13 1001
213 PDH 101 582 52 1001 XXX XXX XX XXXX 7532 3.03
101 583 15 1001
213 BVC 101 582 53 1001 XXX XXX XX XXXX 7533 1.02
101 583 16 1001
213 BVC plates 101 582 54 1001 XXX XXX XX XXXX 7534 3.00
101 583 06 1001
213 BVC DI 101 582 53 1001 XXX XXX XX XXXX 7535 1.05
101 583 16 1001
214 D 101 583 42 1001 XXX XXX XX XXXX
214 DH 101 582 58 1001 XXX XXX XX XXXX 7541 3.03
101 583 19 1001
214 PDH 101 582 59 1001 XXX XXX XX XXXX 7542 3.03
101 583 20 1001
216 D 101 582 62 1001 XXX XXX XX XXXX 7550 3.03
101 583 23 1001
216 DH 101 582 60 1001 XXX XXX XX XXXX 7551 3.03
101 582 64 1001
216 PD 101 582 63 1001 XXX XXX XX XXXX 7559 4.00
101 583 24 1001

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

057 667 72
15/54

The following description describes the input of code numbers.

6.2 Input of code numbers

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

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

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

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6.3 Changing the machine type (only via display module)

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

Setting the machine type requires the following sequence:

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

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

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

Select and enter the machine from the table above.

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

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

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

Switch the ignition off and on again.

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

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

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

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6.4 Inverting the direction signal (only via display module)

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

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

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

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

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

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

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

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

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6.5 Changing the bit rate (only with display module)

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

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

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7 Adjustment/display possibilities on machines with BOP

7.1 Adjusting the machine type (BOP)

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

Press "ESC" to leave the page.

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

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7.3 Accessing the diagnostics menu

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

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

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

Press "ESC" to leave the page.

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

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7.3.1 Extended diagnostics on machines with circular exciter (BTMplus,

BTMprof)

4.23 V Ubv: actual voltage front acceleration transducer

4.24 V Ubh: actual voltage rear acceleration transducer

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

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

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

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

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

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

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

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7.3.2 Extended diagnose BVC machines

4.25 V Uexciter: current voltage exciter position potentiometer

4.23 V Ubv: actual voltage front acceleration transducer

4.24 V Ubh: actual voltage rear acceleration transducer

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

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

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

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

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

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

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

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

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

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

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

Press "ESC" to leave the page.

"0" OFF GPS Receiver always switched off

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

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8 Possible settings on the BCM05mobile

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

8.1 Reading the software version

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

8.2 Changing the language

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

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

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

8.3 Changing the unit system (metric/imperial)

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

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

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

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BOMAG
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10 Block diagram BTMplus / VARIOCONTROL

BOMAG
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BOMAG
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BOMAG
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12 Description of the signals on the ESX-control
Electrics MESX

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

ESX terminal Signal description Nominal values (voltage / current)

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

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

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

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

X44:6

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

Open circuit voltage (vibration off): ) 4.2 .. 4.3 V

Analog input / voltage input 0..8.5 V
X44:8

X44:9 Input exciter position front Position of front exciter (measured against AGND)
Analog input / voltage input 0..8.5 V Stop bottom ) approx. 2.2 V
Neutral position ) approx. 4.25 V
Stop top ) approx. 6.6 V

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ESX terminal Signal description Nominal values (voltage / current)

X44:10

X44:11

X44:12

X44:13

X44:14

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

Digital input active high Vibration off: )approx.0 V
X44:16 Input button START (option) Push button pressed ) 12 V
Digital input active high Button not pressed ) 2V
X44:17 Input button STOP (option) Push button pressed ) 12 V

BOMAG
Digital input active high Button not pressed ) 2V
X44:18 Input button PRINT (option) Push button pressed ) 12 V
Digital input active high Button not pressed ) 2V
X44:19 Input button CLEAR (option) Push button pressed ) 12 V
Digital input active high Button not pressed ) 2V
X44:20

X44:21

X44:22

X44:23 Output voltage supply for sensors Nominal voltage = 8.5 V

This output supplies steering joystick, speed range selector switch, etc. Permissible range: approx. 7.65 .. 9.35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override mode (emergency function).
X44:24

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ESX terminal Signal description Nominal values (voltage / current)
Electrics MESX

X44:25

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

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

Digital input active high Control switched off ) 12 V
This signal must be present, so that the control can work.
X44:29 Input acceleration transducer VV/VL15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): ) 4.2 .. 4.3 V

Analog input / voltage input 0..8.5 V
X44:30 Input acceleration transducer VH/VR15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): 4.2 .. 4.3 V

BOMAG
)
Analog input / voltage input 0..8.5 V
X44:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): ) 4.2 .. 4.3 V

Analog input / voltage input 0..8.5 V
X44:32

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

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

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ESX terminal Signal description Nominal values (voltage / current)

X44:36

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

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

X44:40

X44:41

X44:42

X44:43

BOMAG
X44:44

X44:45

X44:46 Output valve 1 front valid current range: approx. 0..1.5 A

PWM digital output (max. 4 A)
X44:47 Output valve 2 front valid current range: approx. 0..1.5 A
PWM digital output (max. 4 A)
X44:48

X44:49

X44:50

X44:51

X44:52

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ESX terminal Signal description Nominal values (voltage / current)
Electrics MESX

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

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

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

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

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

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

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

BOMAG
X44:61

X44:62

X44:63

X44:64

X44:65 Mouse port Baby Boards approx. 0 V

X44:66 Mouse port Baby Boards approx. 0 V

X44:67 Mouse port Baby Boards approx. 0 V

X44:68 Mouse port Baby Boards approx. 0 V

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13 Fault codes of the ESX control

13.1 Overview

Fault code Description of fault

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

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13.2 Description of fault reactions

Fault reaction Description of fault reaction

1 Warning.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
2 Impairment of function, the faulty function is overridden by an emergency function.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
3 Fault of a partial function, the partial function cannot be overridden by an emergency function.
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
4 Fault of a partial function, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective

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

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

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13.3 Detailed description of fault codes and their possible causes
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Fault Description of fault Possible cause Termina Input Fault

code l on code for reaction
ESX diagnose
4 5 0 1 Input exciter potentiometer front ) Wire breakage in current path X44:09 5
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) Fuse FM ? has tripped or wire breakage in voltage supply
current path
) Potentiometer defective
4 5 0 2 Input exciter potentiometer front ) Current path has connection to +12 V / +8,5 V X44:09 5
The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective

BOMAG
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Fault Description of fault Possible cause Termina Input Fault

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

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

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

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

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

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

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

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Fault Description of fault Possible cause Termina Input Fault
code l on code for reaction
Electrics MESX

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

4 5 3 2 Position controller negative limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low

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

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

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

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

Status: 14.12.2009 Fault Code Description ESX control Page 51 of 61

Author: T. Löw / TE
12.2

495
496
12.2

Service Training MESX Description of fault codes of the ESX control

Fault Description of fault Possible cause Termina Input Fault

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

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

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

Status: 14.12.2009 Fault Code Description ESX control Page 52 of 61

Author: T. Löw / TE
Electrics MESX

008 914 20
Service Training MESX Description of input codes of the ESX control

008 914 20
14 Input codes for ESX control (only via BEM display module)
Electrics MESX

14.1 Travel system

Input code Description of display function Display values

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

1001 Travel direction 1000 ) Forward travel detected

Displays the travel direction derived by the control from the 0000 ) Neutral position
"transducer for travel direction". 000I ) Reverse travel detected

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

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

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

Status: 14.12.2009 Description of Control Input Codes Page 53 of 61

Author: T. Löw / TE
12.2

497
498
12.2

Service Training MESX Description of input codes of the ESX control

14.2 Vibration

Input code Description of display function Display values

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

14.3 Light

Input code Description of display function Display values

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

BOMAG
Status: 14.12.2009 Description of Control Input Codes Page 54 of 61
Author: T. Löw / TE
Electrics MESX

008 914 20
Service Training MESX Description of input codes of the ESX control

008 914 20
14.4 Acceleration transducer
Electrics MESX

Input code Description of display function Display values

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

14.5 Diesel engine

Input code Description of display function Display values

5000 Input MD+ 0000 ) Engine OFF
Show status of diesel engine. 0001 ) Engine ON

BOMAG
Status: 14.12.2009 Description of Control Input Codes Page 55 of 61
Author: T. Löw / TE
12.2

499
500
12.2

Service Training MESX Description of input codes of the ESX control

14.6 Setting the machine type

Input code Description of display function Display values

7000 Shows the adjusted machine type
7010 Switches on function "Set machine type"
7011 Confirms entered machine type
7500..76 Pre-select machine type
99

BOMAG
Status: 14.12.2009 Description of Control Input Codes Page 56 of 61
Author: T. Löw / TE
Electrics MESX

008 914 20
Service Training MESX Description of input codes of the ESX control

008 914 20
14.7 Parameter change
Electrics MESX

Input code Description of display function Display values

7600 Switch on function "Invert travel direction" Display value 7 6 0 0
7601 Inverts the actually adjusted travel direction see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!

BOMAG
Status: 14.12.2009 Description of Control Input Codes Page 57 of 61
Author: T. Löw / TE
12.2

501
12.2 Electrics MESX

Service Training MESX

15 Terminology in connection with ESX

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

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

Terminal, cable lug

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

Status: 14.12.2009 Terminology Page 58 of 61

Author: T.Löw / TE

502 BOMAG 008 914 20

Electrics MESX 12.2

Service Training MESX

Short circuit to ground

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

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

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

Status: 14.12.2009 Terminology Page 59 of 61

Author: T.Löw / TE

008 914 20 BOMAG 503

12.2 Electrics MESX

Service Training MESX

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

Closed loop control

Marking Closed loop control control

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

Status: 14.12.2009 Terminology Page 60 of 61

Author: T.Löw / TE

504 BOMAG 008 914 20

Electrics MESX 12.2

12.4 Electric module A108

008 914 20 BOMAG 513

12.4 Electric module A108

514 BOMAG 008 914 20

008 914 20
Rotary switch for cabin fan Rotary switch for air conditioning system
Electric module A108

BOMAG
Cabin fan 1 Cabin fan 2
12.4

515
12.4 Electric module A108

516 BOMAG 008 914 20

13 Service Training

008 914 20 BOMAG 517

518 BOMAG 008 914 20
13.1 Service Training

008 914 20 BOMAG 519

13.1 Service Training

520 BOMAG 008 914 20

Service Training 13.1

Service Training

Single Drum Rollers

BW 216 DH / PDH - 4
BW 219 DH / PDH - 4
BW 226 DH / PDH - 4

008 914 20 BOMAG 521

13.1 Service Training

Service Training
Table of contents
Foreword A1
Documentation A2
General A3

New features A5

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

BW 216 / 219 / 226 DH / PDH -4

522 BOMAG 008 914 20

Service Training 13.1

Service Training

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

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

BW 216 / 219 / 226 DH / PDH -4

008 914 20 BOMAG 523

13.1 Service Training

Service Training
Foreword and new features
Reliable construction equipment is of greatest advantage for all parties involved:

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

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

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

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

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

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

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

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

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

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

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

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

BW 216 / 219 / 226 DH / PDH -4 -A1-

524 BOMAG 008 914 20

Service Training 13.1

Service Training
Documentation

This Service Training is valid for the following BOMAG single drum rollers of series 4:

BW 216 DH / PDH -4
BW 219 DH / PDH-4
BW 226 DH / PDH-4

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

1. Operating and maintenance instructions

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

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.

BW 216 / 219 / 226 DH / PDH -4 -A2-

008 914 20 BOMAG 525

13.1 Service Training

Service Training
General
The new BOMAG single drum rollers of series 4 are mainly further developments of their predecessors
of series 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.

BW 216 / 219 / 226 DH / PDH -4 -A3-

526 BOMAG 008 914 20

Service Training 13.1

Service Training
Important characteristics of the new generation of single drum rollers are

• strong ROPS/FOPS according to SAE-standard

• wear free service brake by closed hydrostatic travel circuits

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

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

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

• automatic engine shut down after 15 seconds, if the engine temperature is too high

• automatic engine shut down after 10 seconds, if the coolant level is too low
and the engine oil pressure is too low.

The single drum rollers of series 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.

BW 216 / 219 / 226 DH / PDH -4 -A4-

008 914 20 BOMAG 527

13.1 Service Training

Service Training
New features
The multi-function travel lever and the display

Back Front

down

BW 216 / 219 / 226 DH / PDH -4 -A5-

528 BOMAG 008 914 20

Service Training 13.1

Service Training
Control, operation, data collector,

BW 216 / 219 226 DH / PDH -4 -A -

008 914 20 BOMAG 529

13.1 Service Training

Service Training

Translation

Rückseite Back
Vorderseite Front
Rechts Right
Auf Up
Vibr. Taste Vibr. button
Links Left
Ab Down
INFO Teste 1 INFO button 1
INFO Taste 2 INFO button 2

Translation:

Fahrhebel Travel lever

Datensammler Data collector
Luftfilter Air filter
Blink. L Indic. l
Blink. R Indic. r
Licht an Lights on
D+ Signal D+ signal
Hyd. Ölfilt. Hyd. oil filter
Hyd. Temp. Hyd. temp.
Klimaanl. Aircon
Ampere Ampere
Wasserab. Water separ.
Kühl. Füll. Coolant level

Fahrhebel Travel lever

Stufenschalter Speed range switch
Sitzkontaktschalter Seat contact switch
Drucksensor Pressure sensor
Verstellung Control
Sensor Sensor
Vorderrahmen Front frame
Hinterrahmen Rear frame
Verstellung Control
Fahrmotor vorne Front travel motor
Neigungssensor Inclination sensor
Sensor Sensor
Verstellung Control
Fahrmotor hinten Rear vtravel motor
Fahrpumpe Travel pump

BW 216 / 219 226 DH / PDH -4 -A -

530 BOMAG 008 914 20

Service Training 13.1

Service Training
Diesel engine with EMR

BW 216 / 219 / 226 DH / PDH -4 -A -

008 914 20 BOMAG 531

13.1 Service Training

Service Training
Travel System

BW 216 / 219 / 226 DH / PDH -4 -A -

532 BOMAG 008 914 20

Service Training 13.1

Service Training
Travel system

Charge pressure filter

Charging
from

BW 216 / 219 / 226 DH / PDH-4

-E1-

008 914 20 BOMAG 533

13.1 Service Training

Service Training

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

diagram
10 BW 216 travel pump 90R075 EP 10
10 BW 219 and 226 travel pump 10
90R100 EP
12 Drum drive motor electr.-prop. 12
51C110
13 Axle drive motor, electr.-prop. 13
51D110
14 Axle 14
25 BW 216 and 219 reduction gear CR 25
51
25 BW 226 reduction gear 715 C 3B 25

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

• travel pump with control and safety elements,

• Drum drive motor with reduction gear;

• axle drive motor,

• two charge pumps,

• hydraulic oil filter (in charge circuit),

• hydraulic oil cooler with thermostat

• hydraulic lines.

Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump. The travel pump is the first pump section, flanged directly to the flywheel side
of the diesel engine.
The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to Δp = 400 bar between low and high pressure
sides.
The flushing valves in axle drive and drum drive motors flush a certain oil quantity out of the closed
circuit when the machine is driving (Δp between the two sides of the closed circuit). Leakage in the
individual components of the circuit are replaced by the charge circuit through the boost check valves
in the travel pump.
The charge 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.

BW 216 / 219 / 226 DH / PDH-4

-E2-

534 BOMAG 008 914 20

Service Training 13.1

Service Training
Travel pump

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

4
1 2

Charging

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

diagram
1 BW 216 travel pump 90R075 EP 10 75ccm
1 BW 219 and 226 travel pump 10 100cm
90R100 EP
2 Charge pressure relief valve 10 26 bar
3 Control, electr.-prop. 10
4 Multi-function valve 10 400 bar

BW 216 / 219 / 226 DH / PDH-4

-E3-

008 914 20 BOMAG 535

13.1 Service Training

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

1 Electric prop. control 5 Cylinder block

538 BOMAG 008 914 20

Service Training 13.1

Service Training
Description of function

2 3 4 5 6
1

8 6 7

Fig. 4: Function of travel pump

1 Drive shaft 5 Cylinder block

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

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

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

BW 216 / 219 / 226 DH / PDH-4

-E7-

008 914 20 BOMAG 539

13.1 Service Training

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

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

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

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

BW 216 / 219 / 226 DH / PDH-4

-E8-

540 BOMAG 008 914 20

Service Training 13.1

Service Training
Travel and vibration pump as tandem pump

BW 216 / 219 / 226 DH / PDH-4

-E9-

008 914 20 BOMAG 541

13.1 Service Training

Service Training
Sauer-Danfoss tandem pump general, connections and adjustment points

Thermostat
housing

Fig. 5: Connections and adjustment points

BW 216 / 219 / 226 DH / PDH-4

- E 10 -

542 BOMAG 008 914 20

Service Training 13.1

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

BW 216 / 219 / 226 DH / PDH-4

- E 11 -

008 914 20 BOMAG 543

13.1 Service Training

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

Control piston in pump

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

• when shutting the engine down,

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

BW 216 / 219 / 226 DH / PDH-4

- E 12 -

544 BOMAG 008 914 20

Service Training 13.1

Service Training
Multi-function valves

High pressure limitation

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

1 2

3
A

6 5

B
4

Fig. 6: Multi-function valves

1 to the control 6 Drive shaft

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

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

BW 216 / 219 / 226 DH / PDH-4

- E 13 -

008 914 20 BOMAG 545

13.1 Service Training

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

2 3
4
5
1

6
9 7
8
10
11

Fig. 7: Multi-function valve, details

1 Reducing fitting 7 Check valve

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

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

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

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

BW 216 / 219 / 226 DH / PDH-4

- E 14 -

546 BOMAG 008 914 20

Service Training 13.1

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

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

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.

BW 216 / 219 / 226 DH / PDH-4

- E 18 -

550 BOMAG 008 914 20

Service Training 13.1

Service Training
Speed sensor in form of a flange sensor

The Sauer-Danfoss travel motors of series 51 with electrical proportional control have a flange sensor
for speed and travel direction.
Due to the simple fastening of the flange sensor time-consuming adjustment work is no longer
necessary.
The sensor is plugged in against the stop and fastened with a socket head cap screw.

BW 216 / 219 / 226 DH / PDH-4

- E 19 -

008 914 20 BOMAG 551

13.1 Service Training

Service Training
Excerpt from the electric wiring diagram: Page 004, rear travel motor B60 and front travel motor B59

BW 216 / 219 / 226 DH / PDH-4

- E 20 -

552 BOMAG 008 914 20

Service Training 13.1

Service Training
Flushing valve

Fig. 8Cross-section of flushing valve

1 Flushing spool with flushing quantities from 10 to 16 l/min

2 Flushing quantity limitation valve (16 bar )

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.

BW 216 / 219 / 226 DH / PDH-4

- E 21 -

008 914 20 BOMAG 553

13.1 Service Training

Service Training
Manual releasing of brake on axle drive

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

Fig. 9: Manual releasing of rear axle brakes

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

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

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

Attention!

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

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

BW 216 / 219 / 226 DH / PDH-4

- E 22 -

554 BOMAG 008 914 20

Service Training 13.1

Service Training
BW 216 and 219 DH-4

Drum drive motor 51C110 with reduction gear CR 51

The drums on the DH-4 and PDH-4 versions are driven by a 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.

The motor is a plug-type motor plugged into a reduction gear CR51.

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

BW 216 / 219 / 226 DH / PDH-4

- E 23 -

008 914 20 BOMAG 555

13.1 Service Training

Service Training
Reduction gear CR 51
6
3 4 5
7 8 9 10
2

11
1
7

15 14

1 Travel motor 9 Planet gear 2nd stage

2 Brake releasing device 10 Planet gear 3rd stage
3 Fastening on frame 11 End cover
4 Mechanical seal 12 Planet shaft
5 Oil filler screw 13 Sun gear
6 Housing and fastening on drum 14 Brake discs
7 Tapered roller bearing 15 Brake piston
8 Planet gear 1st stage 16 Brake spring

BW 216 / 219 / 226 DH / PDH-4

- E 24 -

556 BOMAG 008 914 20

Service Training 13.1

Service Training
Brake control

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

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

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

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

BW 216 / 219 / 226 DH / PDH-4

- E 25 -

008 914 20 BOMAG 557

13.1 Service Training

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

Brake releasing device in

position “brake manually
released”

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

BW 216 / 219 / 226 DH / PDH-4

- E 26 -

558 BOMAG 008 914 20

Service Training 13.1

Service Training
BW 226 DH-4
Drum drive motor 51C110 with reduction gear 715 C 3B

2 5 4 7
6 8
9

11
10 13 12

1 Travel motor 8 Planet gear 2nd stage

2 Brake releasing device 9 Planet gear 3rd stage
3 Oil drain plug 10 Brake spring
4 Mechanical seal 11 Sun gear
5 Oil filler screw 12 Brake discs
6 Planet gear 1st stage 13 Brake piston
7 Roller bearing
This gear has no manual brake releasing device

BW 216 / 219 / 226 DH / PDH-4

- E 27 -

008 914 20 BOMAG 559

13.1 Service Training

Service Training
Travel circuit with drum drive motor 51C110 and gear

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

Travel circuit 51 C 110 and CR 51 or 715 C 3B

BW 216 / 219 / 226 DH / PDH-4

- E 28 -

560 BOMAG 008 914 20

Service Training 13.1

Service Training
Brake control BW 226 (with Sauer motor 51C110 and 715 C 3B)

Brake valve

Charge pressure
Brake releasing pressure
Leak oil

BW 216 / 219 / 226 DH / PDH-4

- E 29 -

008 914 20 BOMAG 561

13.1 Service Training

Service Training
Test and adjustment points, travel system

Charge pressure filter and travel pump

2
2

3
3

1
5
4
4

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

diagram
1 charge oil filter 16
2 Charge oil filter pressure differential B21 Page 005 Δp 3,5 bar
switch
3 Pressure test port, charge pressure MA 26 bar
4 Travel pump - pressure test port 10 / A / MD max. 426 bar
Travel pressure forward
5 Test port travel pump forward A 10 / A

BW 216 / 219 / 226 DH / PDH-4

- E 30 -

562 BOMAG 008 914 20

008 914 20 BOMAG 565

13.1 Service Training

Service Training
Travel motor (drum drive)

4
3

1
5
2

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

572 BOMAG 008 914 20

Service Training 13.1

Service Training
Trouble shooting

The display shows the fault codes

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

All electric faults are mainly shown by the display

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

BW 216 / 219 / 226 DH / PDH-4

- E 41 -

008 914 20 BOMAG 573

13.1 Service Training

Service Training
Procedure:

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

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

Maschine fährt mit Fahrhebel in Stellung 'Neutral'

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

Hydrauliköl wird zu heiss

BW 216/219/226 DH/PDH-4 SYMPTOME

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

BW 216 / 219 / 226 DH / PDH-4

- E 42 -

574 BOMAG 008 914 20

Service Training 13.1

Machine does not move (forward and reverse)

Machine travels with travel lever in 'Neutral'

Machine moves to one direction only

Max. travel speed is not reached

TROUBLE SHOOTING TRAVEL
SYSTEM

Hydraulic oil overheats

BW 216/219/226 DH/PDH-4

SYMPTOMS

POSSIBLE CAUSES
Brake valve (eletrical/mechanical/hydraulical) 1
Brake axle/drum drive motor (mechanical/hydraulical) 2 2 3
Proportional solenoid travel system /defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/high pressure limitation travel pump
3 2 3 3
dirty/deadjusted/defective
Travel lever 1 2
Travel pump neutral position 3 3
Travel pump(s) defective 3 3 2
Travel motor control valve (electrical / mechanical / hydraulical) 1 2
Flushing valve for travel motors stuck 3
Travel motor(s) defective 3 3
Hydraulic oil cooler soiled (internally/externally) 1
Thermostat (hydraulics) soiled/jammed/defective 2
Coupling engine - pump 2
Engine 1
Flange-type speed sensors in travel motor (wiring) 1 1 2

TROUBLE SHOOTING

008 914 20 BOMAG 575

13.1 Service Training

Service Training
Vibration

3
4

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

diagram
1 Vibration pump 75 cm³ 11
2 Integrated charge pump 17 cm³ 11
3 Multi-function valves with high 11 400 bar
pressure limitation and boost check
valve function
4 Proportional control 11

BW 216 / 219 / 226 DH / PDH -4 -F1-

576 BOMAG 008 914 20

Service Training 13.1

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

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

The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit.

The main components of this circuit are

vibration pump,

Vibration motor

and the pressure resistant hydraulic hoses.

Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the
diesel engine.

By operation of a proportional valve the pilot oil is guided to one of the control piston sides. This actuates
the pump from neutral position to one of the two possible maximum displacement positions.

When changing the swashing angle through the neutral position to the opposite side, the flow direction
of the oil and the sense of rotation of the vibration motors will change.

Since the engine speed is variable in "Position ECO", 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.

BW 216 / 219 / 226 DH / PDH -4 -F2-

008 914 20 BOMAG 577

13.1 Service Training

Service Training

Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract
from the basic weights.

Basic weight + change-over weight = high amplitude

Basic weight - change-over weight = low amplitude

The displacement of the pump may be different to both flow directions. This results in different exciter
shaft speeds for the different senses of rotation of the motor.

The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled
with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.

Sense of rotation of exciter shaft

BW 216 / 219 / 226 DH / PDH -4 -F3-

578 BOMAG 008 914 20

Service Training 13.1

Service Training

Vibration pump

The vibration pump is a swash-plate controlled axial piston pump with variable displacement of type 90
R 075 EP from Sauer-Danfoss. The pump is fitted with all control and safety elements needed for
operation in a closed hydraulic circuit.

5 4

2 6 3

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

diagram
1 Vibration pump 75 cm³ 11
2 Integrated charge pump 17 cm³ 11
3 Multi-function valves with high 11 400 bar
pressure limitation and boost check
valve function
4 Prop. solenoids X 6 and X 7 11
5 servo control 11
6 Safety valve in charge circuit 11

BW 216 / 219 / 226 DH / PDH -4 -F4-

008 914 20 BOMAG 579

13.1 Service Training

Service Training
Function

1 2

5 4 3

Cross-section of vibration pump

1 Servo piston

2 Working pistons

3 Charge pump

4 Valve plate

5 Roller bearing

6 Swash plate

BW 216 / 219 / 226 DH / PDH -4 -F5-

580 BOMAG 008 914 20

Service Training 13.1

Service Training

1
2
5

4 3

Cross-section of vibration pump

1 Control

2 Servo piston

3 Friction free swash plate bearing

4 Attachment plate

5 Spool valve

BW 216 / 219 / 226 DH / PDH -4 -F6-

008 914 20 BOMAG 581

13.1 Service Training

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.

Multi-function valve

BW 216 / 219 / 226 DH / PDH -4 -F7-

582 BOMAG 008 914 20

Service Training 13.1

Service Training
As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.

1 From the charge pump

2 Closed circuit

3 High pressure relief valve with integrated boost check valve

Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 426 bar
(pressure difference between high and low pressure side = 400 bar + charge pressure = 26 bar).

The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit.

Vibration motor

BW 216 / 219 / 226 DH / PDH -4 -F8-

008 914 20 BOMAG 583

13.1 Service Training

Service Training
The vibration motor is a Bosch-Rexroth axial piston motor of series A2FM 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.

Vibration motors of the machines: BW 216- A2FM56, BW 219- A2FM63, BW 226- A2FM80

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

BW 216 / 219 / 226 DH / PDH -4 -F9-

584 BOMAG 008 914 20

Service Training 13.1

Service Training
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).

Hard ground = High operating pressure

Loose ground = Low operating pressure

A MA

3 1

B MB

Circuit diagram of vibration motor

1 Vibration motor

2 Flushing valve

3 Flushing pressure relief valve

Flushing valve

All vibration motors are fitted with a flanged on flushing valve

BW 216 / 219 / 226 DH / PDH -4 - F 10 -

008 914 20 BOMAG 585

13.1 Service Training

Service Training
The vibration motor is equipped with an integrated flushing valve. This flushing valve is located inside
the bolted on connecting block. When switching the vibration on a pressure difference will appear
between the two sides of the closed circuit. The higher pressure moves the valve spool of the flushing
valve against the neutral setting spring, so that oil can flow out of the low pressure side.

1
A

Flushing valve

1 Flushing spool

2 Flushing pressure relief valve

The flushing valve is fitted with a downstream 16 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.

This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.

BW 216 / 219 / 226 DH / PDH -4 - F 11 -

586 BOMAG 008 914 20

Service Training 13.1

Service Training
Speed sensor

The vibration system fixed displacement motor A2FM is equipped with a Hall effect rotary speed sensor
from Bosch Rexroth HDD1L or HDD2L

Fixed displacement motor

A2FM

BW 216 / 219 / 226 DH / PDH -4 - F 12 -

008 914 20 BOMAG 587

13.1 Service Training

Service Training
Connection in wiring diagram, vibration speed sensor B16 on page 006

BW 216 / 219 / 226 DH / PDH -4 - F 13 -

588 BOMAG 008 914 20

Service Training 13.1

Service Training
Drum

4
14

5 9

7 13
6
10
3 8 11

Fig. 1Cross-section of drum

1 Drum shell 8 Change-over weight

2 Vibration bearing 9 Coupling vibr.-motor – vibrator shaft
3 Basic weight 10 Travel bearing
4 Vibrator housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Vibrator shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing

BW 216 / 219 / 226 DH / PDH -4 - F 14 -

008 914 20 BOMAG 589

13.1 Service Training

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. 400+26 bar
4 High pressure port high amplitude 11 - A max. 400+26 bar
5 Multi-function valve with high 11 - B
pressure limitation low amplitude
6 Multi-function valve with high 11 - A
pressure limitation high amplitude
7 Solenoid valve, low amplitude Y07 / X 8 11 - B 12V / 0,4 - 1,2A
8 Solenoid valve, high amplitude Y07 / X 7 11 - A 12V / 0,4 - 1,2A

BW 216 / 219 / 226 DH / PDH -4 - F 15 -

590 BOMAG 008 914 20

Service Training 13.1

Service Training
Vibration motor BW 216 and 219 DH-4

5 3

1
1 2
2

4
3

2 31

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

diagram
1 High pressure port high amplitude 15 - A
2 High pressure port, low amplitude 15 - B
3 Flushing valve with pressure 15
retaining valve
4 Leakage and flushing 15 approx. 8-10 l incl.
flushing quantity

BW 216 / 219 / 226 DH / PDH -4 - F 16 -

008 914 20 BOMAG 591

13.1 Service Training

Service Training
Vibration motor BW 216 and 219 DH-4

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

diagram
1 RPM-sensor B 16 15

BW 216 / 219 / 226 DH / PDH -4 - F 17 -

592 BOMAG 008 914 20

Service Training 13.1

Service Training
Vibration motor BW 226 DH-4

2 3 1

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

BW 216 / 219 / 226 DH / PDH -4 - F 18 -

008 914 20 BOMAG 593

13.1 Service Training

Service Training
Trouble shooting

The display shows the fault codes

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

All electric faults are mainly shown by the display

BW 216 / 219 / 226 DH / PDH -4 - F 19 -

594 BOMAG 008 914 20

Service Training 13.1

Service Training
Procedure:

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

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

Erregerwellendrehzahl nicht korrekt

Keine Vibration (Speisedruck OK)
Vibration nur in einer Amplitude
FEHLERSUCHE VIBRATION
BW 216/219/226 DH/PDH-4

SYMPTOME

MÖGLICHE URSACHEN
Vibrationschalter (Amplitudenvorwahl) 1 1
Fahrhebel, Taster Vibration (an/aus), Verkabelung 1
Elektrik defekt / Verkabelung 2 2
Pumpenansteuerung (elektrisch / hydraulisch) 1 1
Druckabschneidung/ Hochdruckbegrenzung Vibrationspumpe
2
verschmutzt/verstellt/defekt
Speisepumpe / Speisedruckbegrenzungsventil
2
verschmutzt/defekt
Frequenzeinstellung Vibrationspumpe 2
Vibrationspumpe defekt 2 2
Kupplung zwischen Dieselmotor und Fahrpumpe defekt
Erregerwellenlager defekt 3
Vibrationsmotorkupplung defekt 2
Vibrationsmotor defekt 2 1
Dieselmotor 1 1 1
Drehzahlsensor (Verkabelung) 1 1 1
Spülventil Vibmotor hängt 2

FEHLERSUCHE

BW 216 / 219 / 226 DH / PDH -4 - F 20 -

008 914 20 BOMAG 595

13.1 Service Training

No vibration (charge pressure OK)

Vibration only with one amplitude
Exceiter shaft speed not correct
TRROUBLE SHOOTING
VIBRATION
BW 216/219/226 DH/PDH-4

SYMPTOMS
POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1
Travel lever, vibration button (on/off), wiring 1
Electrics defective / wiring 2 2
Pump control (electric / hydraulic) 1 1
Pressure override/ high pressure limitation vibration pump
2
soiled/deadjusted/defective
Charge pump / charge pressure relief valve
2
soiled /defective
Vibration pump frequency setting 2
Vibration pump defective 2 2
Coupling between engine and travel pump defective
Exciter shaft bearing defective 3
Vibration motor coupling defective 2
Vibration motor defective 2 1
Engine 1 1 1
Rotary valve (wiring) 1 1 1
Flushing valve in vibration motor stuck 2

TROUBLE SHOOTING

596 BOMAG 008 914 20

Service Training 13.1

Service Training
Steering
Single drum rollers BW 216 / 219 / 226 of series 4 are equipped with a hydrostatically operated
articulated steering system.

The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.

to charge
system
1
7
6
5
3

2
4

from steering pump

Fig. 1Steering hydraulics

1 Rating pump
2 Distributor valve
3 Steering pressure relief valve (Δp =175 bar)
4 Check valve (pre-loaded to 0.5 bar)
5 Anti-cavitation valve
6 Shock valves (240 bar)
7 Steering cylinders

The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.

When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.

The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.

BW 216 / 219 / DH / PDH -4 -G1-

008 914 20 BOMAG 597

13.1 Service Training

Service Training
Charge pump

The charge pump for travel circuit and vibration works also as steering pump The pump is an external
gear pump with fixed displacement.

The oil flow generated by the charge pump is joined together with the return flow from the steering valve
before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and vibration
pump.

BW 216 / 219 / DH / PDH -4 -G2-

598 BOMAG 008 914 20

Service Training 13.1

Service Training
Steering pump

The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.

9 9 6 1 7

8
2

4 5

Fig. 2Steering pump

1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals

BW 216 / 219 / DH / PDH -4 -G3-

008 914 20 BOMAG 599

13.1 Service Training

Service Training
Working principle of the gear pumps

The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of
both gears mesh with minimum clearance when rotating.

The displacement chambers are created between the tooth flanks, the inside wall of the housing and
the faces of the bearing plates.

When the pump is running the chambers transport hydraulic oil from the suction side to the pressure
side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The
tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.
To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic
fluid can be transported from the suction side to the pressure side without any losses.

For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.

This pressure field is always under the actual system pressure.

BW 216 / 219 / DH / PDH -4 -G4-

600 BOMAG 008 914 20

Service Training 13.1

Service Training
Steering valve

The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and
shock valves.

9 2

5
8

Fig. 3Cross-sectional view of steering valve

1 Neutral setting springs

2 Housing
3 Inner spool
4 Outer spool
5 Universal shaft
6 Ring gear
7 Gear
8 Check valve
9 Pressure relief valve
When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating
pump. The rating pump guides the oil flow through the distributor valve to the corresponding
sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the
rotation angle of the steering wheel.
This oil flow to the steering cylinders articulates the machine and causes a steering movement.

BW 216 / 219 / DH / PDH -4 -G5-

008 914 20 BOMAG 601

13.1 Service Training

Service Training

240 bar

Δp = 175 bar

240 bar

0,5 bar

Fig. 4Steering valve, hydraulic diagram

The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.
The charge pressure value must be added to this pressure, because the oil leaving the steering system
is fed into the charge circuit for the closed travel circuits.

The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks
which may occur, e.g. when driving over obstructions, and protect the system against overloads.

Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.

A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case
of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would
act as pumps and press the oil back to the pump.

BW 216 / 219 / DH / PDH -4 -G6-

602 BOMAG 008 914 20

Service Training 13.1

Service Training
Articulated joint

Front and rear frames of series 4 single drum rollers are connected by an oscillating articulated joint.
This ensures that drum and wheels are at all times in contact with the ground, even when driving
extreme curves.

Fig. 5Articulated joint

BW 216 / 219 / DH / PDH -4 -G7-

008 914 20 BOMAG 603

13.1 Service Training

Service Training
The rear console is tightly bolted to the rear frame.

The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.

The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.

The steering cylinder anchor point is welded to the front console.

When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.

All bearings on the articulated joint are maintenance free and do not require any lubrication.

Notes on assembly:

When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.

Please follow the instructions in the repair manual for the articulated joint.

BW 216 / 219 / DH / PDH -4 -G8-

604 BOMAG 008 914 20

Service Training 13.1

Service Training
Test and adjustment points steering points

3 4
1
1

2 2
2

Steering pump

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

diagram
1 Steering pump (and charge pump) 09
2 Steering pressure test port MB max.170+26 bar

BW 216 / 219 / DH / PDH -4 -G9-

008 914 20 BOMAG 605

13.1 Service Training

Service Training
Vibration and noise damper

The damper is located in the steering/charge circuit directly after the steering and charge pump.

It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.

The damper is mounted to the front plate of the rear frame, between both steering cylinders.

BW 216 / 219 / DH / PDH -4 - G 10 -

606 BOMAG 008 914 20

Service Training 13.1

Service Training
Trouble shooting

The display shows the fault codes

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

All electric faults are mainly shown by the display

BW 216 / 219 / DH / PDH -4 - G 11 -

008 914 20 BOMAG 607

13.1 Service Training

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
BW 213/214 DH/PDH-4
Endanschläge werden nicht erreicht
Lenkung schwergängig
Keine Lenkfunktion
SYMPTOME

MÖGLICHE URSACHEN
Lenkorbitrol 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2

BW 216 / 219 / DH / PDH -4 - G 12 -

608 BOMAG 008 914 20

Service Training 13.1

TROUBLE SHOOTING STEERING

BW 213/214 DH/PDH-4
End stops are not reached
Steering hard to move
No steering function
SYMPTOMS

POSSIBLE CAUSES
Orbitrol steering valve 2 2 1
Steering/charge pump 1 1 2
Steering cylinder 3 3 3
Articulated joint 3 3 2

TROUBLE SHOOTING

008 914 20 BOMAG 609

13.1 Service Training

610 BOMAG 008 914 20

13.2 Service Training BVC

008 914 20 BOMAG 611

13.2 Service Training BVC

612 BOMAG 008 914 20

Service Training BVC 13.2

Service Training

Variocontrol

Single drum roller - 4

BW 177 / 213 / 226 BVC

Teile-Nr. 008 099 94 12/2004

008 914 20 BOMAG 613

13.2 Service Training BVC

Service Training
Table of contents
Foreword A1
Documentation A2

General B1
Peculiarities B3

Electric steering C1
Steering circuit C2
Steering pump C4
Steering wheel C5
Steering valve C6
Steering angle sensor C12
Trouble shooting C15

Compaction measuring system D1

BEM D1
BTM plus D2
BTM prof. D3
BVC D4

BVC - System E1
Exciter system E4
Gear pump E5
Valve block E7
Swashing motor E9
Acceleration transducer E 10
MESX-control E 11
BOP E 12

Working principle of the system F1

Variocontrol Single Drum Rollers Series 4

614 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Repair and adjustments G1
Replacement of swashing motor G2
Replacement of potentiometer G3
Potentiometer adjustment G4

Trouble shooting H1

Electrics I1
Service Training
MESX - Service Training

Wiring diagram

Hydraulic diagrams

Variocontrol Single Drum Rollers Series 4

008 914 20 BOMAG 615

13.2 Service Training BVC

Service Training
Foreword
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.

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

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

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

Variocontrol Single Drum Rollers Series 4 -A1-

616 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Documentation
These Variocontrol training documents are valid for the following single drum rollers of series 4:

BW 177 DH-4 BVC

BW 213 DH-4 BVC

BW 213 DH-4 BVC + vibratory plates

BW 226 DH-4 BVC

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

Attention!

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

1. Operating and maintenance instructions

Variocontrol Single Drum Rollers Series 4 -A2-

008 914 20 BOMAG 617

13.2 Service Training BVC

Service Training
General

BOMAG VARIOCONTROL (BVC)

The increased demands concerning quantity and quality in the application and compaction of soils and
rolled asphalt inevitably requires a permanent further development of vibratory rollers.

From the contractor's point of view a vibratory roller must fulfil three major requirements:

1. efficient operation

2. fulfilment of a task according to specification

3.flexible in use

Due to the inflexible parameterization, standard compaction systems are not able to adapt to the
permanently changing construction conditions in an optimal way.

However, this problem can be solved by the introduction of intelligent compaction systems. The control
values required for an automatic optimization of the compaction parameters are directly gained from the
interaction between drum and material to be compacted.

BOMAG VARIOCONTROL is a compaction system, which improves the quality and reproducibility of
compaction and enhances the efficiency of the roller, independently from the roller operator.

BOMAG VARIOCONTROL offers the user the following advantages:

1.Automatic adaptation of the emitted compaction energy to the actual compaction status

2. Better, reproducible results on all materials

3.No jump operation and therefore no particle destruction or loosening of material

4. The resulting direction of force is automatically adapted to the travel direction. This improves the
surface quality of the material and the gradability of the roller.

5.Low vibration loads for driver and environment

The further development of the VARIOCONTROL system for earthwork was founded on experiences
gained with the VARIOMATIC system used for asphalt compaction . The basic difference between
VARIOCONTROL and VARIOMATIC is the new exciter system.

It meets the demands of many users for an "intelligent" roller with automatic adaptation
of compaction.

Variocontrol Single Drum Rollers Series 4 -B1-

618 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Part of this new further development is the new display and control element BOP (Bomag
Operation Panel) in connection with the MESX.

Besides the display of the entire operation of the measuring technology the BOP also enables a simple
self diagnose of the overall system.

The operation of the BOP is described in detail in the operating and maintenance instructions.

Error and input codes can be found on the electrics page (MESX Service Training).

BOP ----- Bomag Operation Panel

Variocontrol Single Drum Rollers Series 4 -B2-

008 914 20 BOMAG 619

13.2 Service Training BVC

Service Training
Specialities

All BVC single drum rollers of series 4 are equipped with an electric steering
system as standard.

The hydraulic steering is also available as an option.

Variocontrol Single Drum Rollers Series 4 -B3-

620 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Electric steering
The electric steering consists of an electronically controlled closed control loop and a hydraulic steering
circuit.

The electronically controlled circuit consists of a small electric steering wheel (in the left hand seat
armrest), the ESX-control (located in the electric junction box), which converts the signal from the
steering wheel into electric signals for the proportional solenoids of the steering valve and the
steering angle sensor (located on the articulated joint), which feeds the steering angle back to the
control.

The hydraulic steering circuit consists of steering pump, high pressure filter, steering valve and
steering cylinders.

Variocontrol Single Drum Rollers Series 4 -C1-

008 914 20 BOMAG 621

13.2 Service Training BVC

Service Training

Variocontrol Single Drum Rollers Series 4 -C2-

622 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Hydraulic steering circuit

to charging

to emergency steering
and Vario control valve

from
hydr.
tank

Variocontrol Single Drum Rollers Series 4 -C3-

008 914 20 BOMAG 623

13.2 Service Training BVC

Service Training

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

diagram
05 one steering cylinder on BW 177 05
05 two steering cylinders 05
on BW 213 and 226
06 Steering valve with 2 proportional Y92 / Y93 06
solenoids and an integrated Page 006
accumulator
07 High pressure filter 12μm 07
09 Steering pump and charge pump 09 / MB 200 +/-10 bar
17 additional gear pump 5.5 cm³ on 17 / MG 80 bar
BW 177 BVC
17 additional gear pump 8 cm³ on BW 17 / MG 120 bar
213 and 226 BVC
20 High pressure line filter for 20
Variocontrol 100 μm
21 Optional emergency steering valve Y112 / Y113 21
with 2 B/W solenoids Page 006

Emergency steering:

The emergency steering valve is only an option and can only be operated via a special
input code. The valve is supplied by the additional Variocontrol gear pump.

Variocontrol Single Drum Rollers Series 4 -C4-

624 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Steering pump with filter

Steering pump

Pressure test port

Steering pressure

Filter outlet

High pressure filter

Steering circuit
12 μm with
Pressure differential switc
3,5 bar

Filter inlet

Variocontrol Single Drum Rollers Series 4 -C5-

008 914 20 BOMAG 625

13.2 Service Training BVC

Service Training
Steering wheel
The small steering wheel is located in the left hand armrest of the driver's seat

VCC 8,5 V

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

diagram
Electric steering wheel A 45
Page 006

Variocontrol Single Drum Rollers Series 4 -C6-

626 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Steering valve, electrically proportional
The steering valve, together with the optional emergency steering valve, is located
behind a protection box on the right hand side of the frame under the operator's stand
or the cabin.

to the
Steerin
cylinder

from the
pump

to the charge
system

Variocontrol Single Drum Rollers Series 4 -C7-

008 914 20 BOMAG 627

13.2 Service Training BVC

Service Training
Steering valve
5

7 8

6 1 4 2

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

diagram
1 Steering valve port P 06
2 Steering valve port T 06
3 Steering valve ports A and B 06
4 Steering valve, pressure relief valve 06 175 + 25 bar
5 Steering valve, shock valves 06 230 bar
6 Steering valve, accumulator 06 Accumulator
pressure 50bar
7 Steering valve, prop. solenoid Y 93 Page 006 0,4 - 1,2 A
8 Steering valve, prop. solenoid Y 92 Page 006 0,4 - 1,2 A
9 Emergency steering valve B/W Y 113 Page 006 0/12 V
solenoid
10 Emergency steering valve B/W Y 112 Page 006 0/12 V
solenoid

Variocontrol Single Drum Rollers Series 4 -C8-

628 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Emergency steering valve (option, can only be operated via input code) !!!

9
10

Variocontrol Single Drum Rollers Series 4 -C9-

008 914 20 BOMAG 629

13.2 Service Training BVC

Service Training
BW 177 BVC

3 2

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

diagram
1 Steering valve Y92 / Y93 06
2 Optional emergency steering valve Y112 / Y113 21
3 High pressure line filter 100μm in 20
Vario-circuit

Variocontrol Single Drum Rollers Series 4 - C 10 -

630 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Piping BW 177

Variocontrol Single Drum Rollers Series 4 - C 11 -

008 914 20 BOMAG 631

13.2 Service Training BVC

Service Training
BW 213 and 226 BVC

5 3

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

diagram
1 Steering valve Y92 / Y93 06
2 Optional emergency steering valve Y112 / Y113 21
3 Pressure retaining valve, 22 110 / 99 bar
Variocontrol circuit
4 Accumulator for Variocontrol circuit 23 Accumulator
pressure 85bar
5 High pressure line filter 100μm in 20
Vario-circuit

Variocontrol Single Drum Rollers Series 4 - C 12 -

632 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Piping BW 213 and 226

Variocontrol Single Drum Rollers Series 4 - C 13 -

008 914 20 BOMAG 633

13.2 Service Training BVC

Service Training
Steering angle sensor
The steering angle potentiometer is located on the articulated joint BW 177 and BW 213

The steering angle potentiometer is located inside the articulated joint BW 226

Variocontrol Single Drum Rollers Series 4 - C 14 -

634 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
BW 177 and 213 BVC

Variocontrol Single Drum Rollers Series 4 - C 15 -

008 914 20 BOMAG 635

13.2 Service Training BVC

Service Training
BW 226 BVC

Variocontrol Single Drum Rollers Series 4 - C 16 -

636 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Trouble shooting

The display shows error codes

A detailed description of how to read out the error codes and on the display
can be found in chapter "Electrics" (Service Training "Electrics")

All electric faults are primarily displayed in the display.

Variocontrol Single Drum Rollers Series 4 - C 17 -

008 914 20 BOMAG 637

13.2 Service Training BVC

Service Training
Procedure:

The following trouble shooting chart mainly lists 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 elektr.LENKUNG
BVC-4 Maschinen
Endanschläge werden nicht erreicht
Lenkung schwergängig
Keine Lenkfunktion
SYMPTOME

MÖGLICHE URSACHEN
Lenkventil 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2

FEHLERSUCHE
Variocontrol Single Drum Rollers Series 4 - C 18 -

638 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Compaction measuring system for single drum rollers:

BEM

(Bomag E-vib Meter) for circular exciters

CAN Bus I

BMFSA

E vib
150

50 200
!
0 E VIB 250
MN/mm²
Signale

Beschleunigung
VV / VL 15g

MESX Befehle

Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g

Vibrationspumpe
Stromsignal

Variocontrol Single Drum Rollers Series 4 -D1-

008 914 20 BOMAG 639

13.2 Service Training BVC

Service Training
BTM prof

(Bomag Terrameter) for circular exciters

CAN Bus I

Drucker

RS 232
BOP

!
Signale

Beschleunigung
VV / VL 15g

Drehzahlsensor
hinten
MESX
Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g

Vibrationspumpe
Stromsignal

Variocontrol Single Drum Rollers Series 4 -D2-

640 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
BTM plus

(Bomag Terrameter) for circular exciters

CAN Bus I

BOP

!
Signale

Beschleunigung
VV / VL 15g

Drehzahlsensor
hinten
MESX
Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g

Vibrationspumpe
Stromsignal

Variocontrol Single Drum Rollers Series 4 -D3-

008 914 20 BOMAG 641

13.2 Service Training BVC

Service Training
BVC

(Bomag Variocontrol) for Vario exciters

CAN Bus I

Drucker

RS 232
BOP

!
Signale

Beschleunigung
VV / VL 15g

Drehzahlsensor MESX Befehle

hinten
Lageregelung Lageregelung
Ventil 2 vorn Ventil 1 vorn
Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g

Vibrationspumpe
Stromsignal

Erreger
Position vorn

Variocontrol Single Drum Rollers Series 4 -D4-

642 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
BVC - System

BOMAG VARIOCONTROL is able to control the compaction power, independently from the driver. For
this purpose the size and direction of the effective amplitude is automatically adjusted in dependence
on compaction status and travel direction of the roller. This optimal adaptation of compaction ensures
that the roller emits the max. compaction power to the soil at any time. Apart from this, jumping of the
drum with the related over-compaction of the material is automatically prevented.

The VARIOCONTROL system consists of the following primary

components:

1. Exciter unit
2. Additional gear pump with line filter
3. Valve block with pressure relief valve and shock valves and (accumulator on
BW 213 and BW 226)
4. Variable displacement motor with integrated potentiometer based distance
measuring system
5. 2 acceleration transducers
6. Programmable logic control = MESX
7. Display and control unit = BOP
8. ) Optional printer

Variocontrol Single Drum Rollers Series 4 -E1-

008 914 20 BOMAG 643

13.2 Service Training BVC

Service Training
BVC Circuit diagram for BW 177 DH-4
Legend from the hydraulic
diagram:

17) External gear pump

front rear
5.5 cm³

18) Valve block with 80

bar pressure relief valve

19) Swivel drive, variable

displacement motor

20) High pressure line

filter

Y141 Y140

to the
20 tank

from
tank

to filter
to steering system

Variocontrol Single Drum Rollers Series 4 -E2-

644 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
BVC Circuit diagram for BW 213 / 226 DH-4
Legend from the hydraulic diagram:

17) External gear pump 8cm³

front rear

18) Valve block with pressure relief valve (120 bar)

19) Swivel drive, variable displacement motor

20) High pressure line filter

22) Pressure override valve (99-110 bar)

23) Accumulator (1.4l, 85bar)

Y141 Y140

to
Emergency
steering

to the

tank
from
tank

to filter
Steering valve

Variocontrol Single Drum Rollers Series 4 -E3-

008 914 20 BOMAG 645

13.2 Service Training BVC

Service Training
Exciter unit

BVC uses a new type of exciter system with two counter-rotating, concentrically arranged
shafts, generating directed vibrations (see Fig. below).
One common shaft carries three eccentrics, the two smaller weights near the ends and the
larger eccentric weight in the middle of the exciter shaft. The middle eccentric weight rotates in
opposite direction to the outer weights. The resulting centrifugal forces add up to a directed
vibration. The effective direction of this directed vibration can be adjusted by turning the
complete vibrator unit. Any desired angle position between horizontal and vertical oscillating
direction is possible.

The adjustment of the exciter unit is accommodated by a hydraulic swashing motor with
integrated displacement measuring system (potentiometer). The vibrator system is driven by a
hydraulic motor, the eccentrics are synchronized by gears.

General design of the VARIOCONTROL - exciter unit

Variocontrol Single Drum Rollers Series 4 -E4-

646 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Gear pump with high pressure filter

additional
gear pump
for Variocontrol system

Test port input

Variocontrol system

BW 177 BVC

Filter
Input

High pressure
Line filter

Filter
Output

Variocontrol Single Drum Rollers Series 4 -E5-

008 914 20 BOMAG 647

13.2 Service Training BVC

Service Training
BW 213 and 226 BVC

The pressure retaining valve with accumulator is located between Vario pump and valve block.

It helps to keep any losses through the pressure relief valve as low as possible.

7 1
2
8
3
9 4

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

diagram
1 P3 Input 22
2 P5 to valve block 22
3 T 22
4 T 22
5 Pressure retaining valve, opens and 22 110 bar / 99 bar
closes
6 P6 to accumulator 23 Preload pressure
85bar
7 High pressure line filter 22
8 T1 22
9 P4 22

Variocontrol Single Drum Rollers Series 4 -E6-

648 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Valve block
The valve block has the function of triggering the adjusting motor. It consists of an electrical proportional
valve.

On BW 213 and BW 226 the valve is equipped with an upstream pressure retaining valve.

Assignment of valves to adjusting motor with exciter:

Y140 ---- valve outlet B ----- control Direction vertical forward

Y141 ---- valve outlet A ----- control Direction vertical backward

8 1

9 2
3
4
10 5
6
8
7
11
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
1 Test port BW 177 18 80 bar
1 Test port BW 213 and 226 18 120 bar
2 P2 18
3 A 18
4 T1 18
5 P1 18
6 B 18
7 T2 18
8 Shock valves 18 120 bar
9 Prop. solenoid Y 141 Page 008 18 0,4 - 1,2 A
10 Prop. solenoid Y 140 Page 008 18 0,4 - 1,2 A
11 Pressure relief valve BW 177 18 80 bar

Variocontrol Single Drum Rollers Series 4 -E7-

008 914 20 BOMAG 649

13.2 Service Training BVC

Service Training
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
11 Pressure relief valve BW 213 and 18 120 bar
226

Valve block installation front left and protection housing for electric connections

Pressure relief valve

Potentiometer

Variocontrol Single Drum Rollers Series 4 -E8-

650 BOMAG 008 914 20

Service Training BVC 13.2

Service Training

Under the protection

housing there are the
cable connections for
X 22 - speed sensor
X 47 - potentiometer for swa
X 48 - Acceleration
tranducer front
X 49 - Acceleration
transducer rear

Variocontrol Single Drum Rollers Series 4 -E9-

008 914 20 BOMAG 651

13.2 Service Training BVC

Service Training
Swashing motor
with integrated potentiometer based distance measuring
system

As with the VARIOMATIC system, the resulting force may occur at any angle position
between horizontal and vertical direction of vibration. The adjusting motor is equipped
with an integrated displacement measuring system. This displacement measuring
system is based on a potentiometer mounted on the motor output shaft. Each position
of the motor has a resistance or voltage value assigned.

Potentiometer voltage:

Vertical forward approx. 2 V, Horizontal approx. 4,25 V, Vertical backward

approx. 6,5 V

Swashing motor, principle – cross-sectional view (Pleiger)

Variocontrol Single Drum Rollers Series 4 - E 10 -

652 BOMAG 008 914 20

Service Training BVC 13.2

Service Training

Variocontrol Single Drum Rollers Series 4 - E 11 -

008 914 20 BOMAG 653

13.2 Service Training BVC

Service Training
Acceleration transducer
The Variocontrol system is equipped with two acceleration transducers arranged one after the other on
the gearbox on the left hand side of the drum. These are mounted under an angle of 45° on either side
of the vertical. These transducer permanently deliver acceleration signals, which form the basis for the
entire control system.

There are two connection assignments

the signal outputs of the transducers:

BW 177 BVC signal brown 20g

BW 213 and 226 BVC signal blue 15g

see wiring diagram, page 008, path 8 and10, B62

Acceleration transducer

Variocontrol Single Drum Rollers Series 4 - E 12 -

654 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
MESX-control
The MESX-control is located inside the electric junction box, below the ESX-travel control inside the
door of the electrics terminal box. The MESX takes over the function to control the Variocontrol system.
The sticker on the MESX control informs about the installed software version.

A detailed description can be found in the chapter "Electrics", Service

Training MESX.

MESX

Variocontrol Single Drum Rollers Series 4 - E 13 -

008 914 20 BOMAG 655

13.2 Service Training BVC

Service Training
BOP
Bomag Operation Panel

The operation of the BOP is described in detail in the operating and maintenance instructions!

1 EVIB display 11) Rotary switch for mode selection (Automatic/Manual)

2 not used 12) Push button F12 automatic operation
3 Push button F5 START 13) Push button F11 manual operation
4 Push button F6 STOP 14) Rotary switch, manual setting of amplitude direction
5 Push button F7 PRINT 15) Push button F10 vertical effective direction
6 Push button F8 DELETE 16) Push button F9 horizontal effective direction
7 Display of vibration frequency 17) Travel speed display
8 Rotary switch for setpoint adjustment (automatic operation) 18) Amplitude display
9 Push button F14 setpoint increase 19) Optional measuring value printer
10 Push button F13 Setpoint reduction

Variocontrol Single Drum Rollers Series 4 - E 14 -

656 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Working principle of system

Die Messung der Bodenkontaktkraft zwischen der Bandage und dem Einbaumaterial
erfolgt durch die beiden Beschleunigungsaufnehmer an der Bandage, die das
dynamische Verhalten kontinuierlich überwachen. Die Beschleunigungssignale, die
aus der dynamischen Wechselwirkung zwischen dem Walzenkörper und der
Unterlage resultieren, werden an die MESX-Steuerung weitergeleitet.
Werden bestimmte Grenzzustände bzw. Sollzustände erreicht, wird von der MESX ein
Signal auf die Verstelleinheit gegeben und dadurch die Verdichtungsenergie an den
neuen Einbauzustand angepaßt.
Signalisieren die Beschleunigungsaufnehmer eine geringe Bodensteifigkeit, schwenkt
das Erregersystem so weit in Richtung der vertikalen Arbeitsrichtung, bis die maximal
mögliche Verdichtungsenergie abgegeben wird. Nimmt die Bodensteifigkeit zu und
werden bestimmte Grenzwerte bzw. Sollwerte erreicht, schwenkt das Erregersystem
in Richtung der horizontalen Arbeitsrichtung, bis die Sollwerte unterschritten werden.
Das Ergebnis dieser Regelung ist, daß das VARIOCONTROL-System die maximal
mögliche Verdichtungsenergie automatisch an den jeweiligen Einbauzustand anpaßt.
Das System muß dabei sehr schnell auf die Steifigkeitsänderungen reagieren. Die
Verstellzeiten von vertikaler zu horizontaler Arbeitsrichtung liegen unter einer Sekunde.
Damit kann das System

1. auf Veränderungen der Bodensteifigkeit unmittelbar reagieren

2. und zerstörende Bewegungen der Bandage verhindern.

Variocontrol Single Drum Rollers Series 4 -F1-

008 914 20 BOMAG 657

13.2 Service Training BVC

Service Training
Vibration parameters

Für den Verdichtungserfolg ist schon die erste dynamische Überfahrt von entscheidender
Bedeutung.
Die VARIOCONTROL Walzenzüge sind daher auf besonders hohe Zentrifugalkräfte bzw.
Amplituden ausgelegt. Hierdurch wird eine sehr hohe Verdichtung und eine gute
Tiefenwirkung erzeugt.
Durch die große Amplitude würde die VARIOCONTROL Walzenzüge früher springen als
Standardwalzenzüge gleichen Betriebsgewicht. Durch die Automatik wird aber der
Vertikalanteil der Amplitude dann automatisch zurückgenommen und so ein Springen der
Walze verhindert.

Dichte
Hochleistungswalze
große Amplitude

Standardwalze

0 1 2 3 4 5 6 7 Übergänge

BW 177 BW 213 BW 219 BW 225

BVC Standard BVC Standard Standard BVC Standard

Schwingende Masse kg 2440 1970 4800 4250 5500 6630 6300

Zentrifugalkraft kN 189 126/100 365 275/198 326/250 402 330/182

Amplitude mm 2,5 1,8 / 1,0 2,4 1,8 / 0,9 2,1 / 1,2 2,3 2,0 / 1,1

Frequenz Hz 28 30 / 36 28 30 / 36 26 / 30 26 26 / 26

Variocontrol Single Drum Rollers Series 4 -F2-

658 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Repair and adjustments

Replacement of swashing motor and potentiometer

Swashing motor

Potentiometer

Fastening
screws
Potentiometer

Variocontrol Single Drum Rollers Series 4 -G1-

008 914 20 BOMAG 659

13.2 Service Training BVC

Service Training

Locking screw
vertical reverse

Locking screw
horizontal

Variocontrol Single Drum Rollers Series 4 -G2-

660 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Replaceing the swashing motor

1. If necessary remove the vibration motor

2. Unscrew the bottom plug (Pos.26, P/N 076 320 16) from the gearbox

3. Disconnect the hydraulic hoses and the electric connections from the potentiometer on the swashing
motor

4. Connect the hand pump to the front port (in travel direction) of the swashing motor (Pos.5) and pump
to the right, until the locking recess in the gear is in line with the bore in the gearbox.

5. Turn the locking screw (P/N 955 822 11) into the gearbox, the exciter is thus blocked in position
vertical reverse.

6. Remove the manual pump

7. Remove the swashing motor

8. Connect the manual pump again zo the front port of the new swashing motor and pump to the right
to the same position as with the removed swashing motor (position vertical forward)

9. Install the swashing motor, grease the splined shaft (with Optimol White P/N 009 960 01) and connect
hydraulically and electrically.

10. Remove the bottom locking screw (P/N 955 822 11) again and turn in the plug (Pos.26, P/N
076 320 16) with seal ring.

11. Tighten all fastening screws with the specified torque.

Variocontrol Single Drum Rollers Series 4 -G3-

008 914 20 BOMAG 661

13.2 Service Training BVC

Service Training

Variocontrol Single Drum Rollers Series 4 -G4-

662 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Adjusting the potentiometer

1. Unscrew the top plug (Pos.16, P/N 076 320 16) from the gearbox

2. Connect the hand pump to the rear port (in travel direction) of the swashing motor (Pos.4) and pump
to the left (middle position of swashing motor), until the locking recess in the upper gear is in line with
the bore in the gearbox.

3. Turn the locking screw (P/N 955 821 69) into the upper bore in the gearbox, the exciter is thus blocked
in position horizontal.

4. Loosen the fastening screws for the potentiometer so that it can be adjusted in the slots.

Variocontrol Single Drum Rollers Series 4 -G5-

008 914 20 BOMAG 663

13.2 Service Training BVC

Service Training
5. Switch on the ignition and measure the supply voltage between X2:67 and X2:68 (e.g. U=8,42V).

6. Measure the signal voltage between X2:69 (white cable) and X2:68 (AGND).
The terminal bar X2 for the volatge measurement is located inside the electrics junction box.

7. Nominal value = 1/2 supply voltage (e.g. 8,42/2 = 4,21V) in case of deviations turn the potentiometer,
until the nominal value is reached.

Wiring diagram Bl 008, Pf 11, B61

8. Fasten the potentiometer.

9. Remove the blocking screw and insert the plug with a new seal ring.

10. Check the swashing motor by pumping it to both end positions with the hand pump and measure the
voltage values. Nominal values: left hand stop vertical forward approx. 2V and right hand stop vertical
reverse approx. 6,5V

This process 1 - 10 must also be performed when changing a potentiometer.

Variocontrol Single Drum Rollers Series 4 -G6-

664 BOMAG 008 914 20

Service Training BVC 13.2

Service Training
Exciter lock in vertical reverse

Exciter lock in horizontal

Variocontrol Single Drum Rollers Series 4 -G7-

008 914 20 BOMAG 665

13.2 Service Training BVC

Service Training
Trouble shooting
In case of a fault in the Vario system the red triangular lamp lights up.

Show the fault code by pressing button „?“ followed by button „F5“
Red fault light

Button „F5“

Button „?“

For detail info on reading out fault codes please refer to the chapter "Electrics, Training MESX".

Variocontrol Single Drum Rollers Series 4 -H1-

666 BOMAG 008 914 20

14 Engine

008 914 20 BOMAG 667

14.1 Diesel engine

14.1 Diesel engine The engines are characterized by the following posi-
tive features:
Series 4 single drum rollers are powered by 4 or 6 cyl- l compact design
inder Deutz diesel engines type TCD 2013 or a 6-cyl- l low noise level
inder engine TCD 2012.
l almost vibration free operation
The engines are water cooled in-line engines with
EMR3 electronics.
l low fuel consumption
The engines are mainly designed in two-valve tech-
l low exhaust emission EPA/COM IIl
nology with turbo charging and intercooler. They are l high power density
highly compact and come with a Deutz-Common-Rail l excellent access to all service locations.
injection system, called DCR in short. l high reliability
All engines are designed with exhaust gas recircula- l low running costs,
tion and thus reach emission values complying with
EPA/ COM/ Tier/ stage lll
l long lifetime

Fig. 1 Deutz diesel engine TCD 2012 and 2013

668 BOMAG 008 914 20

Engine description TCD 2012 14.2
14.2 Engine description TCD 2012

Fig. 1 Deutz diesel engine TCD 2012, right hand side 13 Flywheel or (transmission connection SAE)
14 Crankcase ventilation valve
1 Lubrication oil filling neck 15 Transport device
2 Combustion air inlet 16 Charge air line
3 Cover 17 Fuel control unit
4 Fan
5 Generator
6 Fuel lift pump
7 Idler pulley
8 Lubrication oil cooler
9 Fuel filter
10 Replaceable lubrication oil filter
11 Lubrication oil sump
12 Possible installation of hydraulic pump or com-
pressor (optional)

008 914 20 BOMAG 669

14.2 Engine description TCD 2012

Fig. 2 Deutz diesel engine TCD 2012, left hand side

1 Exhaust manifold
2 Exhaust turbo charger
3 Lubrication oil filling neck (optional)
4 Engine mounts
5 Lubrication oil return line from exhaust gas turbo
charger
6 Relay (starter)
7 Ribbed V-belt
8 Coolant inlet
9 Coolant outlet
10 Coolant pump
11 Connection cabin heater ort compensation line

670 BOMAG 008 914 20

Lubrication oil circuit TCD 2012 / 2013 14.3
14.3 Lubrication oil circuit TCD
2012 / 2013

25 26 23 22 18 12
12
123 19 20 21 17 15 11
12

8 7 6
5

27 1
1
1 14 13 16 10 9 4 2 3
Fig. 1 Lubrication oil diagram 17 Piston cooling nozzle with pressure maintaining
valve
1 Lubrication oil sump 18 Plunger with rocker arm pulse lubrication
2 Lubrication oil suction pipe 19 Push rod, lubrication oil supply for rocker arm lu-
brication
3 Lubrication oil pump
20 Rocker arm
4 Pressure relief valve
21 Return line to lubrication oil sump
5 Lubrication oil cooler
22 Lubrication oil flow to exhaust turbo charger
6 Return flow check valve (only on 2012)
23 Exhaust turbo charger
7 By-pass valve
24 Return line from compressor / hydraulic pump to
8 By-pass valve lubrication oil filter
crankcase
9 Pressure control valve
25 Compressor or hydraulic pump
10 Replaceable lubrication oil filter
26 Lubrication oil line to crankshaft and camshaft,
11 Main lubrication oil lines compressor / hydraulic pump
12 Internally switched exhaust gas recirculation 27 Return flow from exhaust turbo charger
13 Crankshaft bearings
14 Conrod bearings
15 Camshaft bearings
16 Line to spray nozzle

008 914 20 BOMAG 671

14.4 Coolant circuit TCD 2012 / 2013

14.4 Coolant circuit TCD 2012 /

2013

Fig. 1 Fuel diagram

1 Coolant outlet on radiator

2 Thermostat
3 Coolant - supply to water pump
4 Coolant pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder liner / head cooling
8 Coolant flow to heater
9 Cabin heater (optional)
10 Coolant to thermostat
11 Connection for cabin heater
12 Compensation line
13 Ventilation line to compensation tank
14 Coolant outlet to radiator
15 Compensation tank
16 Compensation line to heat exchanger

672 BOMAG 008 914 20

Fuel system TCD 2012 / 2013 14.5
14.5 Fuel system TCD 2012 / 2013

Fig. 1 Coolant diagram 12 Fuel return flow on cylinder head

13 Fuel return line to fuel tank
1 Fuel tank A= minimum distance 500 mm 14 Fuel lines from fuel control unit to high pressure
2 Fuel pre-filter with pre-pressure pumping possibil- pumps and rail
ity to fill the low pressure section (provided by cus- 15 Fuel lift pump 2013
tomer)
3 Line to fuel lift pump
4 Fuel lift pump
5 Fuel filter
6 Fuel supply line to fuel control unit
7 Rail
8 High pressure pump
9 Fuel supply line to injector
10 Injector
11 FCU (Fuel Control Unit)

008 914 20 BOMAG 673

14.5 Fuel system TCD 2012 / 2013

Fuel pre-filter

Fig. 2 Fuel pre-filter

1 Fuel supply to pump

2 Fuel return flow from FCU (Fuel Control Unit)
3 Manual fuel pump with bayonet lock to lock and
unlock
4 Thermostat valve with shut-down lever
5 Filter cartridge
6 Possibility to connect an electric water level sen-
sor
7 Drain tap
8 Water collecting bowl
9 Fuel inlet from fuel tank
10 Fuel return flow to fuel tank
A Electric water level sensor

674 BOMAG 008 914 20

Fuel system TCD 2012 / 2013 14.5
TCD 2013 Fuel filter system

5
2
2

11 13
4
4

Fig. 3 TCD 2013 Fuel system

1 Fuel pre-filter
2 Hand pump
3 Fuel pressure filter min. 3µm
4 Input fuel control unit
5 Fuel low pressure sensor

008 914 20 BOMAG 675

14.5 Fuel system TCD 2012 / 2013

TCD 2012 Fuel filter system

2
2

2
5
4
1 1
1
4 3 4

Fig. 4 TCD 2012 Fuel system

1 Fuel pre-filter
2 Hand pump
3 Fuel pressure filter min. 3µm
4 Input fuel control unit
5 Fuel low pressure sensor

676 BOMAG 008 914 20

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 14.6
14.6 Deutz Common Rail (DCR) in- tion solely controlled by mapping is only possible un-
der this condition. Injection timing and injection
jection system for TCD 2012 / quantity are controlled by the engine electronics. The
2013 electric signals control an electrically operated valve
per cylinder, which is integrated in the injection noz-
The diesel engines type TCD 2012 and 2013 are zle. The short distances between valve and injection
equipped with a "Deutz Common Rail" injection sys- nozzle result in short pressure rise times, which has a
tem, DCR in short. positive effect on the combustion process and its con-
The English term "Common Rail" indicates that the trol. Various types of injection van be realized, e.g.
system is based on a common rail. It describes the pre-injection, main injection and post-injection. These
use of a common high pressure fuel line with corre- are freely controllable, in dependence on the control
sponding branches to supply all cylinders with fuel. unit.
The "Common Rail" injection is an injection system for The electric control is accomplished by the electronic
combustion engines, in which a high pressure pump control unit (EDC16) with EMR3, in dependence on
pressurizes the fuel to a high pressure level. The pres- the operating parameters. The system is capable of
surized fuel fills a piping system, which is permanently providing a wide range of limp-home functions, should
under pressure while the engine is running. any of the sensors fail. This ensures a reliable and
safe completion of travel and work.
The general idea is the total isolation of the pressure
generation from the actual injection process. An injec-

Overview of electronic diesel fuel control

Sensors Control unit (EMR3) Actuators

Injector
Rail

Pump

Fig. 1 TCD 2012 and 2013

008 914 20 BOMAG 677

14.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

10
8

7
5

11
9
4 1

Fig. 2 Schematic of the Deutz Common Rail System "DCR" Under normal conditions the rail pressure is be-
tween 300 and 1350 bar
1 Fuel filter high pressure The PRV is set to 1600 bar
2 Fuel low pressure sensor (5-7bar) B145
If the PRV is defective or always open, the pres-
3 High pressure pumps
sure in the rail will only build up to max. 700 bar.
4 Fuel lift pump
5 Rail (high pressure pipe up to 1600 bar) The rail pressure must be at least 1.5 bar to start
the diesel engine
6 PRV (max. rail pressure limitation 1600bar)
7 Rail pressure sensor (B935) The fuel low pressure sensor is located after the
fuel filter and the pressure is normally between 5
8 Injectors (Y148)
and 7 bar.
9 FCU Fuel Control Unit (Y137)
10 Engine control EDC16 - EMR3 The solenoid valve of the Fuel Control Unit (FCU)
is dead, open towards the tank.
11 Fuel filter with water separator
12 Hand pump The voltage applied to the injectors is normally
approx. 40 V.

678 BOMAG 008 914 20

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 14.6
FCU Fuel Control Unit (Y137)

electric connection

Fig. 3 Fuel Control Unit FCU

Two high pressure pumps

High pressure

Low
pressure

High pressu
pumps

Fig. 4 High pressure pump

008 914 20 BOMAG 679

14.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

Injector ( Y148 )

electric connections

Return flow

Armature group

Nozzle

Supply

Fig. 5 Injector

Wiring diagram page 4

Engine control EDC16 - EMR3

FCUFCU

Fig. 6 Excerpt from the wiring diagram

680 BOMAG 008 914 20

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 14.6
TCD 2013

5
7 6

2
4

1 3

Fig. 7 TCD 2013

1 Fuel pre-filter
2 Hand pump
3 Fuel filter
4 FCU Fuel Control Unit (Y137)
5 Rail
6 Fuel low pressure sensor (B145)
7 Connecting plug EMR3

008 914 20 BOMAG 681

14.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

TCD 2012

2 5
6
7
4
2
4
5 1
6

Fig. 8 Diesel engine TCD 2012

1 Rail pressure sensor (B93)

2 Rail pressure PRV
3 Fuel filter
4 FCU Fuel Control Unit (Y137)
5 Rail
6 Fuel low pressure sensor (B145)
7 Connecting plug EMR3

682 BOMAG 008 914 20

Exhaust gas recirculation TCD 2012 / 2013 14.7
14.7 Exhaust gas recirculation TCD
2012 / 2013
In order to be able to meet the exhaust gas stand-
ards EC and stage/Tier3, all engines are designed
with exhaust gas recirculation.

On 4-cylinder engines TCD 2012/2013 the exhaust

gas recirculation has been realized internally
through the intake valves, on 6-cylinders through
the exhaust valves. For this purpose the camshaft
has been manufactured with an additional cam for
short-term opening of the intake valve or exhaust
valve respectively.

Fig. 1 Exhaust/intake valve control TCD 2012 / 2013

008 914 20 BOMAG 683

14.8 Wastegate - charge pressure controller on TCD-engines

14.8 Wastegate - charge pressure tion with the exhaust gas bypass valve. Depending on
this bypass valve hot exhaust gases flow past the ex-
controller on TCD-engines haust gas turbine into the exhaust without the availa-
ble energy being utilized
The Wastegate is a exhaust gas bypass valve and
is located on or in the exhaust turbocharger The bypass valve is normally closed
The Wastegate (exhaust gas bypass valve) is used
to control the charge pressure
The charge pressure control takes place by means of
a charge pressure triggered pressure valve in connec-

Control line

Pressure contro

Bypass valve
closed

Fig. 1 Exhaust gas turbocharger with Wastegate

Wastegate active, charge pressure control, i.e. by-

pass valve open

Bypass valve
open

Fig. 1 Exhaust gas turbocharger with Wastegate

684 BOMAG 008 914 20

Wastegate - charge pressure controller on TCD-engines 14.8
Wastegate on TCD 2013

Fig. 2 Exhaust gas turbocharger with Wastegate

008 914 20 BOMAG 685

14.9 Engine problems

Fault Possible cause Remedy

Engine does not Temperature below starting limit Check

start or starts Oil level too low Fill up lubrication oil
poorly
Lubrication oil level too high Check the lubrication oil level, drain off
Lubrication oil cooler defective if necessary
Check

Exhaust gas counter pressure too high Check

V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose

Engine oil with wrong SAE viscosity class Change the lubrication oil

Fuel quality not as specified in the operating Change the fuel

instructions

Air in the fuel system Bleed the fuel system

Battery defective or not charged Check the battery

Cable to starter loose or oxidized Check cable connection

Starter defective or pinion does not engage Check starter

Engine does not Engine electronics prevent starting Check fault by fault code, repair as nec-
start and diag- essary
nostic lamp
flashing

Engine starts, V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
but runs irregu-
larly or misfires Incorrect valve clearance Adjust

Injector defective Replace

Injection valve defective Check / replace the injection valve

Glow plug defective Replace

Air in the fuel system Bleed the fuel system

Fuel pre-cleaner soiled Clean/replace

Fuel quality not as specified in the operating Change the fuel

instructions

Injection line leaking Check the injection line

Speed changes Engine electronics detected a system fault Check fault by fault code, repair as nec-
are possible and and activates a substitute speed essary
diagnostic lamp
lights

686 BOMAG 008 914 20

Engine problems 14.9
Fault Possible cause Remedy

Engine over- Bleeding line clogged Clean ventilation line

heating, temper-
ature warning Injector defective Replace
system re- Coolant heat exchanger soiled Clean
sponds
Coolant pump defective (V-belt torn or check, whether torn or loose
loose)

Lack of coolant Fill up

Charge air pipe leaking Check the charge air pipe

V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose

Lubrication oil filter soiled Replace

Lubrication oil level too low Fill up lubrication oil

Lubrication oil level too high Check the lubrication oil level, drain off
if necessary

Air filter clogged / exhaust turbocharger de- Check/replace

fective

Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary

Short circuit of heat in cooling system Check the cooling system

Resistance in cooling system too high / flow Check the cooling system
quantity too low

Engine has to Lubrication oil level too low Fill up lubrication oil
low or no oil
pressure Engine oil with wrong SAE viscosity class Change the lubrication oil

Insufficient en- Engine oil level too high Drain the engine oil down to the top dip-
gine power stick mark

Fuel quality not as specified in the operating Change the fuel

instructions

Air filter clogged / exhaust turbocharger de- Check/replace

fective

Charge air pipe leaking Check the charge air pipe

Intercooler soiled Clean

Injection line leaking Check the injection line

Injector defective Replace

Injection valve defective Check the injection valve

Insufficient en- Engine electronics reduces the power Check fault by fault code, repair as nec-
gine power and essary
diagnostic lamp
lights

Engine does not Injection line leaking Check the injection line
work with all cyl-
inders Injection valve defective Check / replace the injection valve

008 914 20 BOMAG 687

14.9 Engine problems

Fault Possible cause Remedy

Engine has ex- Lubrication oil level too high Check the lubrication oil level, drain off
cessive oil con- if necessary
sumption

Blue engine ex- Lubrication oil level too high Check the lubrication oil level, drain off
haust smoke if necessary

White engine Temperature below starting limit Check

exhaust smoke
Fuel quality not as specified in the operating Change the fuel
instructions

Injection valve defective Check/replace

Black engine ex- Air filter clogged / exhaust turbocharger de- Check/replace
haust smoke fective

Charge air pipe leaking Check charge air line

Injection valve defective Check / replace the injection valve

Injector defective Replace

688 BOMAG 008 914 20

Check the engine oil level 14.10
14.10Check the engine oil level

! Danger

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

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

Fig. 3
l Pull the dipstick (Fig. 3) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
l Pull the dipstick back out again.
l If the oil level is below the "MAX" mark fill in oil.
l If the oil level is above the “Max” mark determine the
cause and drain the oil off.

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

For quality and quantity of oil refer to the table of

fuels and lubricants.

008 914 20 BOMAG 689

14.11 Changing engine oil and oil filter cartridges

14.11Changing engine oil and oil fil-

ter cartridges

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

Danger
!
Fig. 5
Danger of scalding! l Thoroughly clean the outside of the filter cartridge
When draining off hot oil. (Fig. 5).
By hot oil when unscrewing the engine oil filter. l Unscrew the filter cartridge using an appropriate fil-
ter wrench.
Environment l Clean the sealing face on the filter carrier from any
Catch running out oil and dispose of environmen- dirt.
tally together with the engine oil filter cartridge. l Slightly oil the rubber seal on the new filter car-
tridge.

Fig. 4
l Unscrew the drain plug (Fig. 4) and catch running Fig. 6
out oil. l
Turn the new filter cartridge (Fig. 6) on by hand, until
l
Turn the drain plug tightly back in. the seal contacts.
l Tighten the filter element for another half turn.

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

690 BOMAG 008 914 20

Change the fuel pre-filter cartridge 14.12
For quality and quantity of oil refer to the table of 14.12Change the fuel pre-filter car-
fuels and lubricants.
tridge
l Tighten the oil filler cap properly.

Danger
!
!Caution
Fire hazard!
Before starting crank the engine with the starter
motor until the oil pressure warning light goes When working on the fuel system do not use open
out. fire, do not smoke and do not spill any fuel.
l After a short test run check the oil level on the dip- Catch running out fuel, do not let it seep into the
stick, if necessary top up to the top dipstick mark. ground.
l Check filter cartridge and drain plug for leaks after a Do not inhale any fuel fumes.
short test run.
l Shut the engine down and wait for about 15 min-
utes, so that all oil can flow back into the oil sump.
l Check the oil level again , if necessary fill up to the
Max.-mark.

Fig. 8
l
Slacken the bleeding screw (Fig. 8) on the fuel pre-
filter for 2 to 3 turns.

Fig. 9
l Pull the cable off the water separator and unscrew
the fuel filter cartridge (Fig. 9) using an appropriate
filter wrench.
l Clean the sealing face on the filter carrier from any
dirt.

008 914 20 BOMAG 691

14.12 Change the fuel pre-filter cartridge

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

Fig. 10
l Unscrew the water separator from the filter car-
tridge (Fig. 10).

Fig. 12
l With the bleeding pump loosened operate the hand
pump manually, until fuel flows out of the slackened
bleeding screw (Fig. 12) without air bubbles.
l
Then tighten the bleeding screw while pumping.

Fig. 11
l Apply a thin coat of oil to the rubber seal of the water
separator 1 (Fig. 11).
l Screw the water separator on by hand (2), until the
seal contacts.
l
Tighten the water separator for another half turn (3).
l
Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
l Tighten the filter element for another half turn (6).
l
Plug the water sensor cable back on.
l Check the filter cartridge for leaks after a short test
run.

i Note
Air in the fuel system causes irregular running of the
engine, a drop in engine power, stalls the engine and
makes starting impossible.
Therefore bleed the fuel system after changing the
fuel pre-filter.

692 BOMAG 008 914 20

Replace the fuel filter cartridge 14.13
14.13Replace the fuel filter car- l Tighten the filter element for another half turn.
tridge l Check the filter cartridge for leaks after a short test
run.

Danger
!
Bleed the fuel system
Fire hazard!
When working on the fuel system do not use open i Note
fire, do not smoke and do not spill any fuel. Air in the fuel system causes irregular running of the
Catch running out fuel, do not let it seep into the engine, a drop in engine power, stalls the engine and
ground. makes starting impossible.
Do not inhale any fuel fumes. Therefore bleed the fuel system after changing the
fuel pre-filter or working on the fuel system.

Fig. 13
l
Loosen and unscrew the fuel filter cartridge (Fig. Fig. 15
13) using an appropriate filter wrench. l
Slacken the bleeding screw (1) (Fig. 12) on the fuel
l
Clean the sealing face on the filter carrier from any pre-filter for 2 to 3 turns.
dirt. l
Unlock the bayonet lock of the fuel hand pump by
pressing it down and turning it anti-clockwise.
l Operate the fuel hand pump (2) manually, until fuel
flows out of the loosened bleeding screw without air
bubbles.
l
Then tighten the bleeding screw while pumping.
l
Lock the bayonet lock of the fuel hand pump by
pressing it down and turning it clockwise.
l Start the engine and run it 5 minutes with idle
speed.

Fig. 14
l Slightly oil the rubber seal (Fig. 14) on the new filter
cartridge.

!Caution
The filter cartridge must not be pre-filled. Danger
of contamination!
l Turn the new filter cartridge on by hand, until the
seal contacts.

008 914 20 BOMAG 693

14.14 Check, clean the water separator

14.14Check, clean the water sepa- 14.15Check the coolant level

rator
! Danger

Danger
! Danger of scalding!
Danger of injury! Fill up coolant only when the engine is cold.
Support the engine hood for all maintenance and
repair work. ! Caution
If, during the daily inspection the coolant level is
i Note found to have dropped, check all lines, hoses and
The service intervals for the water separator depend engine for leaks.
on the water content in the fuel and can therefore not Do not use radiator sealant to seal leaks.
be determined precisely. After taking the engine into
For quality and quantity of coolant refer to the "ta-
operation you should therefore check the water sepa-
ble of fuels and lubricants".
rator every day for signs of water.
If a to high quantity is drained off, the filter must be re-
filled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.

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

Fig. 17
l
Check the coolant level (Fig. 17).
l
To top up unscrew the filler cap and fill in coolant up
to the MAX-mark.

Fig. 16
l
Slacken the drain plug (Fig. 16) for a few turns and
catch running out fuel / water.
l Tighten the drain plug again and check for leaks, if
necessary replace the seal ring.

694 BOMAG 008 914 20

Change the coolant 14.16
14.16Change the coolant

! Danger

Danger of scalding!
Change the coolant only when the engine is cold.

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

Fig. 20
l Unscrew the cap and fill in coolant up to the MAX-
mark (Fig. 20).

For quality of coolant refer to the chapter 5.2, fuels

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

Fig. 18
l
Set the cock valve for the cabin heater (Fig. 18) to
position "warm".

Fig. 19
l Unscrew the plug (Fig. 19), let the coolant run out
and catch it .
l Screw the plug back in once all coolant has run out.

008 914 20 BOMAG 695

14.17 Checking the thermostat in disassembled state

14.17Checking the thermostat in The temperature increase should not exceed 1°C/
min, as otherwise the start of opening will be delayed
disassembled state accordingly.
The thermostat serves the optimal temperature con-
trol of the coolant, in order to promote efficient com-
bustion and to bring the engine quickly to operating
temperature after starting. At temperatures below ap-
prox. 83°C the thermostat is closed. Once the coolant
temperature has reached about 83°C, the thermostat
will start to open, at about 95° C it is fully open. In this
condition the full coolant flow is guided through the ra-
diator.

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

Stroke = b - a

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

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

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

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

696 BOMAG 008 914 20

Service the combustion air filter 14.18
14.18Service the combustion air fil- Removing the main filter element
ter

Caution
!

Perform cleaning, maintenance and repair work

only with the engine shut down. Do not start the
engine after removing the filter element.

Fig. 6
l Loosen both locking hooks (Fig. 6) on the housing
cover and take the cover off.

Fig. 4
Maintenance of the dry air filter is due when control
light 1 (Fig. 4) in the fault monitoring board lights per-
manently when the engine is running, but at the latest
after 2 years.

i Note
Once the air filter service indicator lights up, work may
be continued until the end of the day.
Fig. 7
l Pull out the main filter element (Fig. 7) with light
turning movements.

Cleaning the main filter element

!Caution
If necessary, the main filter element may be
cleaned up to five times. It must be renewed at the
latest after a maximum utilization period of two
years.
The number of cleaning intervals of the main filter
Fig. 5 element can be marked on the safety element with
a ball pen or a felt pen.
l Open the engine hood (Fig. 5) completely and se-
cure it. Cleaning does not make sense if the main filter el-
ement is covered with a sooty deposit. Use a new
filter cartridge.
Incorrectly handled inserts may be ineffective be-
cause of damage (e.g. cracks) and cause damage
to the engine.
Replace the safety cartridge if the main filter ele-
ment is defective!

008 914 20 BOMAG 697

14.18 Service the combustion air filter

Additional cleaning intervals between two filter Cleaning the dust bowl
services signalized by the fault monitoring board
are not necessary.

Fig. 10
l Pull the internal part (Fig. 10) out and remove the
Fig. 8
dust from the cover.
l Blow the filter cartridge out from inside to outside
with dry compressed air (max. 5 bar) (Fig. 8), until
l Reinsert the inner part.
all dust has been removed.
! Caution
When assembling the inner part make sure that
the notch in the cover engages in the opening of
the inner part.

Installing the main filter element

l
Slide the main filter element carefully into the hous-
ing.
When closing the housing cover the main filter ele-
ment is automatically forced in the correct position.

Changing the safety filter element

Fig. 9
l
Examine the filter cartridge with a torch for cracks ! Caution
and holes in the paper bellows (Fig. 9). The safety filter element must not be cleaned and
should not be used again after it has been re-
Caution
!
moved.
Do not continue to run the machine with a dam- Break the seal only to replace the safety filter ele-
aged main filter element. If in doubt use a new ment.
main filter element. The safety filter element must be replaced:
If the main filter element is defective.
after five service intervals of the filter cartridge,
at the latest after 2 years,
if the warning light comes on again after servicing
the main filter cartridge.
l
Remove the housing cover and pull the main filter
element off.

698 BOMAG 008 914 20

Check the dust separator 14.19
14.19Check the dust separator

Fig. 11
l Pull the safety element (Fig. 11) out by slight turning
movements. Fig. 12

l Push in a new safety filter element. l Unscrew wing nut 1 (Fig. 12) and remove cover (3).
l Reassemble main filter element and cover. l Clean housing (2).
l Reassemble the dust separator.
Caution
!

Make sure that the cover locks engage correctly.

008 914 20 BOMAG 699

14.20 Cleaning the oil bath air filter

14.20Cleaning the oil bath air filter * 14.21Adjusting the valve clearance

! Caution
We recommend to have this work carried out by
trained personnel or our after sales service.
Before checking the valve clearance let the engine
cool down for at least 30 minutes. The engine oil
temperature must be less than 80 °C.
After a short test run check the engine for leaks.
l Attach the cranking device over the V-belt pulley
fastening screws.
l Remove the valve cover (2).
l Crank the engine, until the valves on cylinder 1
Fig. 13
overlap.
l
Loosen the quick locks (Fig. 13), take the filter bowl l The individual cylinder positions can be taken from
off and empty it.
the section "valve adjustment schematic".
l
Clean the filter mesh by repetitive dipping into die-
sel fuel. Adjusting the valve clearance
l Clean the filter bowl with diesel fuel and fill in engine
oil up to the level mark.
l reinstall the filter bowl.

Fig. 14
l Loosen counter nut 1 (Fig. 14).

* Option

700 BOMAG 008 914 20

Adjusting the valve clearance 14.21
Overlapping of valves:
Exhaust valve not yet closed,
intake valve starts to open.

! Caution
With the intake valve opened, the exhaust valve
will temporarily open for about 2 mm.
This is no valve overlap condition!

Fig. 15

Fig. 16
l Attach the rotation angle disc 3 (Fig. 16) and the
spanner socket (4) to the valve adjustment screw 2
(Fig. 15).
l Fix the magnet (5) of the rotation angle disc.
l Turn the rotation angle disc counter-clockwise
against the stop (rocker arm no clearance) and set
the scale to zero.
l
Turn the rotation angle disc clockwise, until the
specified angle is reached.
Intake valve IN = 75° (0,3 mm)
Exhaust valves EX= 120° (0,5 mm)
l
Hold the rotation angle disc tight, so that it does not
turn, and tighten counter nut 1 (Fig. 14).
l Repeat this adjustment procedure an all other cylin-
ders, after cranking the crankshaft accordingly.
l Assemble the cylinder head cover with a new gas-
ket.

Valve adjustment schematic

l Firing sequence 1-5-3-6-2-4

Valves Cylinder
overlapping 1 5 3 6 2 4
adjustment 6 2 4 1 5 3

008 914 20 BOMAG 701

14.22 Checking / replacing the ribbed V-belt

14.22Checking / replacing the

ribbed V-belt

Danger
!

Danger of injury!
Work on the V-belt must only be performed with
the engine shut down.

Checking the wear limit of the ribbed V-

belt
Fig. 19
l
Press idling pulley 1 (Fig. 19) in direction of arrow
using a socket wrench (3), until the locking pin (4)
engages in the assembly bore.
The ribbed V-belt (2) is thus relieved from tension.
l Remove the ribbed V-belt first from the smallest roll-
er or from the idling pulley.
l Check the condition of the idling pulley, replace if
necessary.
l Install the new ribbed V-belt.
l Counter the idling pulley with the socket wrench and
Fig. 17 remove the locking pin.
l Check the distance between the tongue of the l Relieve the idling pulley and tension the ribbed V-
moveable tensioner arm and the fixed tensioner belt.
housing (Fig. 17).
l If measurement "a" is smaller than 3 mm, replace
the ribbed V-belt.

Changing the ribbed V-belt

Fig. 18
l Unscrew the fastening screws (Fig. 18) and slide
the fan forward.

702 BOMAG 008 914 20

Check the engine mounts 14.23
14.23Check the engine mounts 14.24Replacing the crank case
pressure ventilation valve

Fig. 20
l Tighten fastenings of intake and exhaust manifolds Fig. 21
(Fig. 20) on the cylinder heads. l Replace the crank case ventilation valve (Fig. 20).
l Check sockets and clamps between air filter, ex-
haust turbocharger and charge air line as well as
the lubrication air line for tight fit and leaks.
l Retighten the fastening screws for oil sump and en-
gine mounts.

008 914 20 BOMAG 703

14.25 Engine conservation

14.25Engine conservation
If the engine is to be shut down for a longer period of
time (e.g. over winter), please consult the service de-
partment of the engine manufacturer for further de-
tails.

704 BOMAG 008 914 20

Special tools, Deutz engine (TCD 2012 2V) 14.26
14.26Special tools, Deutz engine
(TCD 2012 2V)

TCD 2012 2V Standard tools

8002
Pressure pump
Checking fuel system for leak-tightness

057 250 66

8005
Compression pressure tester
for diesel engines
10 - 40 bar

057 250 67

8024
Assembly pliers
Removing valve stem gaskets

057 250 68

008 914 20 BOMAG 705

14.26 Special tools, Deutz engine (TCD 2012 2V)

Standard tools TCD 2012 2V

8113
Socket wrench insert
Torx - E 14

057 250 69

8114
Socket wrench insert
Torx - E 20

057 250 70

8115
V-belt tension meter
150 to 600 N
for checking the V-belt tension

079 947 09

706 BOMAG 008 914 20

Special tools, Deutz engine (TCD 2012 2V) 14.26

TCD 2012 2V Standard tools

8189
Torx tool set
Case containing:
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E10/E12
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)

079 947 01

8190
Rotation angle disc
with magnet
Setting valve clearance

057 250 72

8191
Screwdriver insert
for slotted screw
Valve clearance setting

057 250 74

008 914 20 BOMAG 707

14.26 Special tools, Deutz engine (TCD 2012 2V)

Standard tools TCD 2012 2V

8192
Bowl wrench
Fuel pre-filter (type: Racor)

057 250 73

8194
Screwdriver insert
with hexagonal socket (size 4 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)

057 250 75

8196
Open end wrench adapter
Size 13,
for torque wrench
Tightening of lock nut of the valve clearance setting
screw

057 250 71

708 BOMAG 008 914 20

Special tools, Deutz engine (TCD 2012 2V) 14.26

TCD 2012 2V Standard tools

8198
Pricker
Removing rotary shaft lip seal

057 250 76

8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)

057 250 77

9017
Assembly lever
Example: Removing and installing the valves

057 250 78

008 914 20 BOMAG 709

14.26 Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V Special tools

100 190
Connection piece
(in conjunction with compression pressure tester 8005)

057 250 79

100 320
Turning gear
flywheel side

057 250 80

100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper

079 947 19

3/12

710 BOMAG 008 914 20

Special tools, Deutz engine (TCD 2012 2V) 14.26

Special tools TCD 2012 2V

100 400
Dial gauge with fixing wheel
Measuring range 0 -10mm / 0.01mm

057 250 81

100 410
Digital gauge
Measuring range 0 -30 mm / 0.01 mm

057 250 82

100 750
Measuring apparatus
Measuring bar with two spacing washers
(in conjunction with 100 400 or 100 410)
Checking valve lag dimension
Checking piston projection

057 250 83

008 914 20 BOMAG 711

14.26 Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V Special tools

103 050
Socket wrench insert
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)

057 250 84

103 220
Special pliers
for removing the roller tappet

057 250 85

110 500
Special wrench
Size 17
Removing and installing high-pressure lines

057 250 86

712 BOMAG 008 914 20

Special tools, Deutz engine (TCD 2012 2V) 14.26

Special tools TCD 2012 2V

110 700
Socket wrench insert
long
Assembling/disassembling pressure sensors
(rail pressure, oil pressure, fuel pressure)

057 250 87

110 900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three assembly sleeves
with guide:
- High pressure pump (Ø 36), 110 902
- Injector, 2V motor (Ø 16), 110 903
- Injector, 4V motor (Ø 23), 110 904
Disassembling/assembling O-rings

057 250 88
© 43208-0

120 430
Assembly tool
Removing and installing the heating plugs

057 250 89

008 914 20 BOMAG 713

14.26 Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V Special tools

120 900
Support bracket
pivoting
Clamping cylinder head

057 250 90

120 910
Base plate for support bracket
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)

057 250 91

121 410
Assembly tool
Assembling valve stem gaskets

057 250 92

714 BOMAG 008 914 20

Special tools, Deutz engine (TCD 2012 2V) 14.26

Special tools TCD 2012 2V

121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket

057 250 93

130 300
Universal piston ring pliers
Removing and installing the piston rings

057 250 94

130 440
Trapezoidal groove wear gauge
for piston diameter 101 mm
Check piston ring groove

057 250 95

008 914 20 BOMAG 715

14.26 Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V Special tools

130 450
Trapezoidal groove wear gauge
for piston diameter 98 mm
Check piston ring groove

057 250 96

130 660
Piston ring tensioning band
Piston diameter 98 mm

057 250 97

130 670
Piston ring tensioning band
Piston diameter 101 mm

057 250 98

716 BOMAG 008 914 20

Special tools, Deutz engine (TCD 2012 2V) 14.26

Special tools TCD 2012 2V

142 670
Assembly tool
Assembling crankshaft sealing ring
(opposite side to flywheel)

079 947 26

142 830
Assembly tool
for crankshaft (flywheel side)

079 947 27

144 800
Counter support
Torsional vibration damper

057 250 99

008 914 20 BOMAG 717

14.26 Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V Special tools

170 050
Special wrench
Unscrew the filter cartridges

079 947 28

170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

079 947 29

6066
Assembly block
Engine clamping, double-sided

079 947 30

718 BOMAG 008 914 20

Special tools, Deutz engine (TCD 2012 2V) 14.26

Special tools TCD 2012 2V

6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided

079 947 31

008 914 20 BOMAG 719

14.26 Special tools, Deutz engine (TCD 2012 2V)

720 BOMAG 008 914 20

15 Air conditioning system

008 914 20 BOMAG 721

15.1 Physical basics

15.1 Physical basics A - heat absorption

In order to understand the working principle of an air B- Heat dissipation

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.

1. gaseous (invisible)

2. vaporous

3. liquid

4. solid

Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.

Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.

722 BOMAG 008 914 20

Physical basics 15.1
Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
l Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
l Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
l Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.

Fig. 4 Pressure - Temperature Diagram

In the pressure - temperature diagram for the refriger-
ant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direc-
tion of the arrow.
The characters A, B, C, D stand for:
Fig. 3 Steam pressure curve A - compression
Steam pressure curve for refrigerant R134a B- condensation
The steam pressure curve is a means for explaining C- relaxation
the operation principle of an air conditioning system. D- evaporation.
A- liquid Excerpt from the wet steam table * R134a
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).
* This table is used for the determination of evaporation and con-
3. Condensing gas dissipates a lot of heat energy.
densation temperature.

008 914 20 BOMAG 723

15.1 Physical basics

Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar

reading Pe in bar) P in bar)
-20 0,33 1,33
-10 1,01 2,01
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72

724 BOMAG 008 914 20

Refrigerant R134a 15.2
15.2 Refrigerant R134a Characteristics of the refrigerant R134a:
Refrigerant R134a is currently available under the fol-
General lowing trade marks.
The evaporation and condensation process is the H-FKW 134a 
method commonly used in mobile air conditioning sys- SUVA 134a 
tems. The system in this case works with a substance KLEA 134a
that boils at low temperature, a substance referred to
a refrigerant. The refrigerant used is tetrafluoroethane
R134a, which boils at a temperature of -26.5°C and Colour:
under a steam pressure of 1 bar. Refrigerant in form of vapour or liquid is colourless as
Although the refrigerant circuit is a hermetically closed water. The gas is invisible. Only the bordering layer
loop, the system loses approx. 100g of refrigerant between gas and liquid is visible. (Fluid level in rising
over the course of 1 year by diffusion through hoses, pipe of filling cylinder or bubbles in inspection glass).
pipes and seals, even though the system is free of In the inspection glass the liquid refrigerant R134a
leaks. If too much refrigerant is lost the cooling power may appear coloured (milky). This turbidity results
of the system will drop. from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Physical data of the refrigerant R134a

Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous
CH2F-CF3 or CF3-CH2F refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
Chemical designation: sure and is frequently referred to as steam pressure.
Tetrafluoroethane The steam pressure is independent from the temper-
ature.

Boiling point at 1 bar:

- 26.5 °C Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
Solidification point: tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
-101.6 °C
ation oils, e.g. PAG-oils (polyalkylene glycol oils).

Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.

Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the

008 914 20 BOMAG 725

15.3 Compressor oil / refrigeration oil

liquid container has absorbed approx. 8 gr. of water, 15.3 Compressor oil / refrigeration
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle oil
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
Inflammability: until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul- Compressor oil (the oil quantity should be 10 % of the
traviolet light also cracks refrigerant (caused by refrigerant weight) mixes with the refrigerant and cir-
electric welding). This results in toxic fission products, culates permanently through the system.
these must not be inhaled. However, irritation of the In connection with R134a- air conditioning systems
mucous membranes is an early and in-time warning. special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
Filling factor: from this, the materials in the R134a air conditioning
In a container there must be a steam space above the system may be attacked when the mixture is flowing
liquid space. The liquid expands with increasing tem- through the refrigerant circuit under high pressure and
perature. The steam filled space becomes smaller. at high temperatures or if the lubrication film in the
From a certain time on the container will be filled with compressor tears off. The use of non-permitted oils
just liquid. After this only a minor temperature in- can cause damage to the air conditioning system, you
crease is enough to generate very high pressures in should therefore only used the approved oils.
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to Properties of compressor oil / refrigeration oil:
avoid overfilling of a container the pressure gas direc- The most important properties are high solvency in
tive clearly specifies how many kilograms of refriger- connection with refrigerants, good lubrication charac-
ant may be filled into the container per litre volume. teristics, that they are free of acids and their low water
Multiplied with the internal volume this "filling factor" content. For this purpose only certain oils can be
determines the permissible filling capacity For refrig- used. PAG-oils suitable for use with refrigerant R134a
erants used in motor vehicles it is 1.15 kg/l. are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
The contribution of R134a to the greenhouse effect is gressive against metals.
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.

726 BOMAG 008 914 20

Working principle of the air conditioning system 15.4
15.4 Working principle of the air 15.5 Monitoring devices
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en- Pressure switch
vironment. Everybody knows the effect: if a sweating
The pressure switch (8) is used as monitoring feature
body is exposed to wind it will cool down, because
for too high and too low pressures. The switching con-
heat is extracted. For this purpose a refrigerant circu-
tacts (4 and 5) effect the magnetic clutch of the com-
lates in a closed circuit inside the vehicle. This refrig-
pressor via a relay (6).
erant thereby continuously changes its physical state
between liquid and gaseous. If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
Fig. 1 Principle sketch of an air conditioning system
is set to approx. 1.5 bar to avoid icing. The switch on
An engine driven compressor (1) draws in gaseous re- pressure is 0.5 to 2 bar higher than the shut-off pres-
frigerant from the evaporator (5) and compresses it. sure (depending on system, see description of com-
During this process the temperature of the refrigerant ponents.)
increases tremendously.
Thermostat
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front A frost protection thermostat (3) protects the evapora-
of the vehicle radiator, so that a sufficient air flow is as- tor against icing. Similar to the pressure switch, the
sured. In the condenser (2) the gas is cooled down thermostat activates or deactivates the magnetic
and consequently liquefied. clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
In the dryer / liquid container (3) the refrigerant is then
tween the fins of the evaporator or attached to the
collected and freed of moisture and contaminants.
evaporator outlet (suction side). With fixed tempera-
The expansion valve (4) regulates the flow rate from ture controls the control switches the compressor off
the dryer / liquid container (3) back to the evaporator at about 1 °C and back on again at about 2.5°C to 5.5
(5) and the circuit starts again. °C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.

008 914 20 BOMAG 727

15.6 Description of components

Monitoring chain 15.6 Description of components

Compressor

Fig. 2 Monitoring chain consisting of:

l 1 Switch
l 2 Fuse
l 3 Thermostat
l 4 Low pressure switch contact Fig. 1
l 5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
l
6 Relay
the function of the system. Coupling and decoupling is
l
7 Connection for magnetic clutch accomplished by an electromagnetically controlled
l
8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.

Compressor data
Displacement: 155 cm²
Weight: 6.9 kg
max. rpm: 6000
Sense of rotation: clockwise
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)

! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil / refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.

Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.

728 BOMAG 008 914 20

Description of components 15.6
Reason of oil loss Amount of oil lost Condenser
Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve

! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1
To avoid excessive oil in the A/C-system and thus The condenser is located in front of the the radiator for
a poor cooling effect, the oil level in the A/C-sys- the machine. It emits heat energy from the system into
tem must be adjusted accordingly. the surrounding air and liquefies the gaseous refriger-
The quantity depends on the amount of oil that ant.
may have been lost in connection with the possi-
ble replacement of other components.
i Note
The compressor oil quantity must be 10% of the The fins must be free of dirt and damage.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re- ! Caution
quires a compressor oil / refrigerant oil filling of
100 gr. When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
Procedure: changing the components, must be replaced with
Drain and measure the compressor oil from the fresh oil.
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.

i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.

008 914 20 BOMAG 729

15.6 Description of components

Dryer / filter / fluid container / inspection Pressure relief valve

glass

Fig. 2

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

Response pressure 32 +/- 4 bar
Dryer / filter
Tightening torque 10 - 15 Nm
The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve. Inspection glass
Moisture that has entered during assembly of the re-
frigerant circuit is absorbed by a dryer in the fluid con-
tainer.
At evaporation temperatures below zero the refriger-
ant will deposit previously absorbed moisture on the
expansion valve, where this water turns into ice and
thus adversely affects the controllability of the expan-
sion valve. Moreover, moisture in the refrigerant cir-
cuit causes corrosion, forms acids and enters into
chemical compositions.
Inside the refrigerant container the heavy liquid refrig-
erant collects in the lower part of the container, flows
through a rising pipe to the outlet marked "A" and thus
ensures bubble free operation of the expansion valve.
Fig. 3
i Note During operation the refrigerant must flow through the
Since the absorbing capacity of this filter/dryer is lim- inspection glass without air bubbles. In most cases
ited, it must be changed within certain service inter- the presence of air bubbles is a sign for a too low re-
vals. We recommend to replace it 1 x per years, frigerant level in the system. Apart from this, the refrig-
before the start of the season. erant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
! Caution down to a level, at which gaseous refrigerant could
The filter/dryer must generally be replaced when- flow through the rising tube to the inspection glass.
ever opening the refrigerant circuit, because This results in abnormally high temperatures in and on
moisture will enter in such a case. the fluid lines (between refrigerant container and ex-
This requires emptying the air conditioning sys- pansion valve), as well as very high pressures in the
tem! pressure side.

Installation position: However, incorrect evacuation or filling may also be

the reason for air entering into the system and since
The arrow marks on the filter/dryer must point in air cannot be condensed, one will not be able to get
flow direction, i.e. towards the expansion valve. rid of these bubbles by topping up refrigerant. In this
Filter/dryer cannot be treated for further use! case the air conditioning system needs to be evacuat-
ed and refilled.

730 BOMAG 008 914 20

Description of components 15.6
i Note Expansion valve
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.

! Danger

In case of mechanical damage or corrosion on

this pressure container this collector unit must be
replaced, to avoid bursting and further damage. Fig. 1
The expansion valve is mounted inside the HKL-mod-
ule in the cabin. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup-
plied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.

i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+

008 914 20 BOMAG 731

15.6 Description of components

Evaporator Thermostat
Thermostat with fixed setting

Fig. 1
The evaporator is mounted inside the HKL-module in
Fig. 1
the cabin. It consists of a heat exchanger (inside air -
refrigerant), with refrigerant flowing to a pipe system The feeler of a defroster thermostat to switch off the
with cooling flanges. magnetic clutch in case of icing up or to switch the
clutch back on after defrosting, is mounted on the
As with the condenser, correct operation of all fans evaporator.
and cleanliness of the fins must be assured.
With fixed temperature controls the control switches
Air conditioning systems have a circulation air filter the compressor off at about +1 °C and back on again
mounted in the air flow in front of the evaporator, at about +2.5°C to +5.5 °C.
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. Adjustable thermostat
A condensation water filter is mounted in the air flow With adjustable temperature regulators the switching
after the evaporator. This filter has the function to col- point can be changed so that the compressor is al-
lect the water that has condensed from the air in the ready shut down at higher temperatures. This enables
evaporator block and to discharge this water into the regulation of the air temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.

! Caution
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.

Fig. 2 adjustable temperature controller

i Note
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on.

732 BOMAG 008 914 20

Description of components 15.6
Pressure switch Pipes and hoses
Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
Fig. 1
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure Recommended tightening torques for O-ring
side, the pressure switch will switch of the magnetic sealed fittings
clutch of the compressor, thus to avoid destruction of
system components by excessive pressure or draw- Thread Spanner width Torque
ing in external gases and foreign matter as a result of 5/8“ 17 or 19 13,6 - 20,3 Nm
too low pressure. 3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
Working pressure:
1 1/16“ 32 40,7 - 47,5 Nm
Low pressure off: 1,5 ±0,5 bar M30X2 36 105,0 - 115,0
Low pressure on: 3.5 bar Nm
M36X2 41 165,0 - 175,0
Overpressure off: 25,0 ±1,5 bar
Nm
Overpressure on: 18,0 ±1,5 bar
Bending radii for air conditioning hoses

Hose type Nominal width Bending radius

GH 134 NW8 min. 50 mm
GH 134 NW10 min. 65 mm
GH 134 NW12 min. 75 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm

008 914 20 BOMAG 733

15.7 Measuring the compressor oil level

15.7 Measuring the compressor oil 15.8 Checking the magnetic clutch
level l Measure the voltage.

!Caution i Note
The compressor oil level must be checked after Nominal value = vehicle voltage
replacing a system component or if a leak in the l
Check the magnetic coil locking ring for secure fit.
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404). l
Check the current consumption.
l Run the compressor for 10 minutes at engine idle
speed.
l remove the refrigerant from the air conditioning sys-
tem.

Fig. 1

Fig. 1 i Note
l
Turn the compressor, as shown in (Fig. 1), if neces- at 12 Volt vehicle voltage approx. 3.5 Amp.
sary remove V-belt and hoses.
at 24 Volt vehicle voltage approx. 1.75 Amp.
l
Remove the oil plug.
Overcurrent indicates a short circuit inside the mag-
netic coil.
i Note No current indicates an interrupted electric circuit.
The oil level must reach the bottom edge of the bore,
top up or drain off oil if necessary.
l
Close the oil plug again.

!Caution
The contact area must be clean and should be free
of damage.
Tightening torque 15 to 25 Nm
l Refill the air conditioning system.

Fig. 2 Measuring the air gap

l Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).

734 BOMAG 008 914 20

Inspection and maintenance work 15.9
i Note 15.9 Inspection and maintenance
The gap should be 0.4 to 0.8 mm. work
l
Take off the drive V-belt and rotate the V-belt pulley l Visual inspection of the complete system for dam-
by hand while the magnetic clutch is disengaged. age.
l Check the compressor mounting bracket on the ve-
i Note hicle engine for tight fit and damage.
In case of excessive flatness faults or deviations the l Check the condition, alignment and tightness of the
magnetic clutch needs to be replaced. V-belt.
l
Check the routing of refrigerant hoses and cables in
Cross-section of magnetic clutch
the area of the vehicle engine and transmission, as
Fig. 3 shows a cross-section of the magnetic clutch. If well as on the chassis for chafing and rectify any de-
the coil (7) is not supplied with operating voltage, tected faults. Ensure sufficient clearance to hot
there is no contact between the front plate of the parts, such as the exhaust; install a protective
clutch (1) and the V-belt pulley (2). A spring presses shield, if necessary.
the front plate away from the belt pulley. The V-belt l Check the routing of hoses and hoses on the at-
pulley rotates with the bearing (3) in idle speed, the
tachment box or in the cabin.
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is l Check all hose and screw fittings for leaks.
generated and pulls the front plate of the clutch. Both l Check the fastening of the condenser unit.
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works. l
Clean the condenser fins, replace the condenser
block if damaged fins are found.
l
Check the fastening of the evaporator unit.
l
Check the function of evaporator and condenser
fans.
l
Check the electric control panel. If discolorations on
conductors are found, these should be replaced
and possibly also the corresponding relays.
l
Switch on the cooling system and check the refrig-
erant level.
l
Filter/dryer and filter/dryer/fluid container combina-
tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
l Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
Fig. 3 Cross-section of magnetic clutch out air temperature - The temperature difference
should be at least 8-10 K.
l
Measuring the pressure in the refrigerant circuit

008 914 20 BOMAG 735

15.10 Checking, replacing the refrigerant compressor V-belt

15.10Checking, replacing the refrig- l Press the compressor in direction of arrow, until the
correct V-belt tension is reached.
erant compressor V-belt* l Retighten all fastening screws.

Danger
! Changing the V-belt
Danger of injury! l Slightly slacken the fastening screws 1, 2 and 3.
Work on the V-belt must only be performed with l Press the compressor against the direction of arrow
the engine shut down. completely against the engine.
Wear safety goggles. l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
Check the V-belt
l Tension the V-belt as previously described.

Caution
!

Check the V-belt tension after a running time of 30

minutes.

Fig. 4
l
Inspect the entire circumference of the V-belt (Fig.
4) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
l Check with thumb pressure whether the V-belt can
be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
essary.

Tighten the V-belt.

Fig. 5
l
Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).

* Optional equipment

736 BOMAG 008 914 20

Air conditioning service (old design) 15.11
15.11Air conditioning* service (old
design)

Clean the condenser

Caution
!

A soiled condenser results in a considerable re-

duction of air conditioning power.
Under extremely dusty conditions it may be nec-
essary to clean the condenser several times per
day.
Fig. 7
If, during operation of the air conditioning system, l Switch the air conditioning (Fig. 7) on.
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
ment.

! Danger

Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 8
l Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 8) in the blue section.
l
Open the air outlet nozzles.
l
Check, whether the out flowing air is noticeably
cooler.

i Note
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on.
l Open the hood.
Fig. 6
l
Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
l
Clean the condenser fins on front and back with
compressed air or cold water .

Checking the refrigerant level

l
Start the engine.

* Optional equipment

008 914 20 BOMAG 737

15.11 Air conditioning service (old design)

Checking the moisture level of the drying

agent

Fig. 9
l Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
at the top. Fig. 11
l Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
i Note
The refrigerant level is correct. orange = drying agent o.k.
colourless= moisture level of drying agent too high.
l Inform the service department. Replace drier/col-
lector unit, check air conditioning system.

Caution
!

Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.

Checking the condition of the drier/col-

lector unit

Fig. 10 !Caution
l
If the white float (Fig. 10) inside the inspection glass According to the regulation for pressure reser-
of the drier/collector unit floats at the bottom, inform voirs all pressure reservoirs must be repeatedly
the service department. inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
i Note
with this inspection the drier/collector unit must
The refrigerant level is not correct.
be visually examined twice every year. During
l Refrigerant must be filled up, if necessary check the these inspections special attention must be paid
air conditioning system for leaks. to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.

! Danger

Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.

738 BOMAG 008 914 20

Service the air conditioning 15.12
15.12Service the air conditioning*

Clean the condenser

! Danger

Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 12
l Check the drier/collector unit (Fig. 12) for mechani-
! Caution
cal damage or rust.
A soiled condenser results in a considerable re-
duction of air conditioning power.
Under extremely dusty conditions it may be nec-
essary to clean the condenser several times per
day.
If, during operation of the air conditioning system,
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
ment.

Fig. 13
l Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
l
Clean the condenser fins on front and back with
compressed air or cold water .

Checking the refrigerant level

l
Start the engine.

* Optional equipment

008 914 20 BOMAG 739

15.12 Service the air conditioning

Fig. 14 Fig. 16
l Turn the rotary switch for the cab ventilator (Fig. 14) l Check whether the white float (Fig. 16) inside the in-
to position "1". spection glass of the drier/collector unit floats right
at the top.

i Note
The refrigerant level is correct.

Fig. 15
l Choose a cooling temperature with the rotary switch
for the air conditioning system (Fig. 15) in the blue
section.
l
Open the air outlet nozzles. Fig. 17
l
Check, whether the out flowing air is noticeably l
If the white float (Fig. 17) inside the inspection glass
cooler. of the drier/collector unit floats at the bottom, inform
the service department.
i Note
The adjusted temperature must be below the actual i Note
temperature inside the cabin, so that the compressor The refrigerant level is not correct.
will be switched on.
l Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.

740 BOMAG 008 914 20

Service the air conditioning 15.12
Checking the moisture level of the drying
agent

Fig. 19
l Check the drier/collector unit (Fig. 19) for mechani-
cal damage or rust.
Fig. 18
l Check the moisture indication pearl (Fig. 18) inside
the inspection glass of the drier/collector unit.
orange = Drying agent o.k.
colourless= moisture level of drying agent too high.
l Inform the service department. Replace drier/col-
lector unit, check air conditioning system.

Caution
!

Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.

Checking the condition of the drier/col-

lector unit

!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
with this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.

! Danger

Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.

008 914 20 BOMAG 741

15.13 Drying and evacuation

15.13Drying and evacuation 15.14Emptying in case of repair

Evacuation of air conditioning systems using R-type For repair work the air conditioning systems must very
refrigerants not only has the purpose of emptying the often be emptied of all refrigerant.
system of all air before filling in refrigerant, but also to Especially with expensive refrigerants and larger
verify the leak tightness over a longer lifetime in the amounts of oil it may be necessary to keep the refrig-
achieved vacuum. However, the most important factor erant for later use.
in this work step is the drying of the system.
For later use these refrigerants must be drawn out
Any water residues in the refrigerant circuit will com- with suitable equipment and intermediately stored in
bine with the refrigerant, which will lead to the previ- collecting containers.
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
Environment
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration Contaminated refrigerant must be disposed of en-
system. vironmentally
The refrigerant compressor is not suitable for the pur- Releasing refrigerant into the atmosphere is pro-
pose of evacuation, because it is not able to achieve hibited (see restrictive injunction concerning
a sufficient final vacuum and, apart from this, may be CFC, day of enforcement 01. 08. 1991, § 8)
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
! Danger
It is common practice to evacuate the refrigeration For draining refrigeration systems you should not
system to a final vacuum of 1 Torr, i.e. 1.33 mbar. simply use any delivery containers, but only ap-
An exact time for evacuation and drying cannot be propriate pressure bottles, which must be special-
predicted. It can only be determined by means of a ly marked and should comply with the pressure
vacuum meter. However, if there is no vacuum meter gas directive.
at hand it is generally better to evacuate 1 hour longer
When transferring refrigerant you must make sure
than 1 hour too less.
that the bottle does not contain more than the per-
Function drying: mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced, In order to reduce the evacuation period in case of
water will already evaporate, e.g. under a pressure of short repairs, you may fill the refrigerant circuit with
10 mbar, at an ambient temperature of almost 7°C, approx. 0.5 bar nitrogen when opening. This ensures
but the water will not evaporate all at once. Since it is that nitrogen will flow out of the refrigerant circuit while
very difficult to separate the steam from the vacuum in it is open and no air or moisture can enter. However,
the system, the evacuation process is supported by the necessity for vacuum generation and a dryer
the co-called vacuum breaking (filling the circuit with change remains.
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.

742 BOMAG 008 914 20

Leak test 15.15
15.15Leak test

! Caution
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.

Leak test with electronic leak tester

Fig. 1 Electronic leak tester

Small leaks with only very low amounts of refrigerant
escaping can be detected, e.g. with an electronic leak
tester. Such equipment is able to detect leaks of less
than 5 gr. per year.
The leak tester used must be specially designed for
the refrigerant composition in the air conditioning sys-
tem. For example, leak detectors for refrigerant R12
are not suitable for R134a, because the refrigerant
R134a is free of chlorine atoms, meaning that this leak
detector will not respond.

Leak test with soap bubbles

Fig. 2 Soap bubble test

Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.

008 914 20 BOMAG 743

15.16 Filling instructions

15.16Filling instructions

Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).

! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.

i Note
White frost on the suction line is no measure for as-
sessing the filling.

744 BOMAG 008 914 20

Filling instructions 15.16

Fig. 1 10 Filter dryer

1 High pressure - gaseous 11 Fluid container
2 High pressure - liquid 12 Condenser
3 Low pressure - gaseous 13 Manual shut-off valve (not used)
4 Compressor 14 Pressure switch with high and low pressure con-
5 Compressor pressure switch (not used) tacts
6 not used 15 Defroster thermostat
7 Evaporator 16 Vacuum meter
8 Expansion valve 17 Low pressure gauge
9 Inspection glass 18 High pressure gauge

008 914 20 BOMAG 745

15.16 Filling instructions

19 Pressure reducing valve 16 Switch off the vacuum pump, watch the pressure
20 Vacuum pump gauges to see whether the vacuum is maintained.
21 Nitrogen bottle 17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
22 Refrigerant bottle
gauge bar. Fill refrigerant into the system, until a
23 Pressure gauge bar pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
Filling instructions es).
1 Connect the service adapter with the blue hand 18 Close the red hand wheel.
wheel in the suction side. 19 Perform a leak test with the electronic leak detec-
2 Connect the service adapter with the red hand tor.
wheel in the pressure side (the hand wheels on 20 Start the engine and switch on the system.
the service adapters must be fully backed out - left 21 Open the blue hand wheel and continue filling in
hand stop) refrigerant until the inspection glass is free or air
3 Connect the blue suction hose below the blue bubbles (in fluid container/dryer combinations the
hand wheel on the pressure gauge bar to the blue white pearl should float in the upper third of the in-
service adapter. spection glass). Then close the refrigerant bottle.
4 Connect the red pressure hose below the red 22 Close the blue hand wheel on the pressure gauge
hand wheel on the pressure gauge bar to the red bar.
service adapter. 23 Preparing the test run: -Close windows and doors
5 Connect the yellow hose below the yellow hand -Fan on full speed stage -Mount measuring feel-
wheel on the manometer bar to the 2-stage vacu- ers to air discharge and air intake.
um pump. 24 Run the system for approx. 20 minutes with medi-
6 Connect the last hose below the black hand wheel um engine speed.
on the nitrogen bottle via the pressure reducing 25 The temperature difference between air discharge
valve. and air intake should be (depending on type of air
7 Check on the pressure gauge bar that all hand condition) 8-10°C. The ambient temperature
wheels are closed. thereby is approx. 20°C. (These data are only ref-
8 Turn the hand wheels on both service adapter erence values, which may be influenced by possi-
clockwise. This opens the valves (right hand ble insolation)
stop). 26 Switch off system and engine and check for leaks
9 Open the valve on the nitrogen bottle (only via again.
pressure reducer); pressure approx. 20 bar. 27 Turn out (left hand stop) and remove the hand
10 Open the black and red hand wheels on the pres- wheels on both service adapters.
sure gauge bar and fill nitrogen into the system, 28 Fit all valves with dust caps.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 29 Perform a leak test.
ed on the suction side.
30 Mark the system with the corresponding type
11 Then open the blue hand wheel and raise the plates and information decals, such as type of oil
pressure in the suction side (max. 10 bar). Check and refrigerant.
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.

746 BOMAG 008 914 20

Trouble shooting in refrigerant circuit, basic principles 15.17
15.17Trouble shooting in refriger-
ant circuit, basic principles

Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
l Expert knowledge
l technical equipment

Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
l
Service station
Filling the system with refrigerant causes an excess
l
Pressure gauge pressure of Pe = 3 bar.
l
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
l
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
l
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
l
Container for old oil
l
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
l
Hoses
l Scales
l Suction station
l Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.

Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.

Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)

008 914 20 BOMAG 747

15.17 Trouble shooting in refrigerant circuit, basic principles

Pressure gauge with saturation temperature scale If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.

Common overheating values

The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
Fig. 3 Absolute pressure gauge is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
Temperature scales on the pressure gauges always
ates within a range between 4 and 12 Kelvin. The in-
refer to the absolute pressures Pabs. Please note that
fluence of the ambient air on the suction line causes
it is not possible to measure a temperature directly
an additional overheating effect.
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper- Overheating is calculated as follows:
ature is assigned to the measured pressure.
 to2h = to2h - to
If the refrigerant is fluid, the temperature is below the
saturation temperature.  to2h, overheating at evaporator outlet in K
If the refrigerant is gaseous, the temperature is above to2h, temperature at evaporator outlet in °C
the saturation temperature. to, evaporation temperature in °C
Pressure gauges must indicate 0 bar when not con- „h“ represents "overheated"
nected to the system.
Low pressure gauges have a blue, high pressure Supercooling
gauges a red border.

Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause

748 BOMAG 008 914 20

Trouble shooting in refrigerant circuit, basic principles 15.17
a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.

Common supercooling values

In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.

Supercooling is calculated as follows:

 tc2u = tc - tc2u
 tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"

008 914 20 BOMAG 749

15.17 Trouble shooting in refrigerant circuit, basic principles

Fig. 1 Refrigerant circuit with t, h- diagram

1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion

750 BOMAG 008 914 20

Trouble shooting, refrigerant circuit diagram 15.18
15.18Trouble shooting, refrigerant
circuit diagram

Fig. 1 Refrigerant circuit diagram 13 Compressor

1 Cold air 14 Condenser
2 Evaporator 15 Cooling air
3 Thermostat 16 Pressure gauge, low pressure
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air

008 914 20 BOMAG 751

15.19 Trouble shooting procedure

15.19Trouble shooting procedure l Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
l The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
l Ambient temperature above 15 °C.
about the system design, the installed components l The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:

Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.

i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.

Test prerequisites
l Cooler and condenser are clean, clean if neces-
sary.
l The ribbed belt for compressor and generator is
correctly tightened.
l All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
l The engine has operating temperature.

752 BOMAG 008 914 20

Trouble shooting procedure 15.19
Measuring points and measurements

Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
l C, condenser measuring points tainer the inspection glass is most suitable to check
l E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
l O, evaporator measuring points
The hot gas temperature can be used to check wheth-
l V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
l a) Which measuring equipment is required?
can be used to derive the overheating of the evapora- l b) Where to measure with which size?
tor. Overheating is a clear indicator for the evaporator l c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is l
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- l e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „to2h“ ?
Pressure and temperature at the condenser outlet can l
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used

008 914 20 BOMAG 753

15.19 Trouble shooting procedure

Solution: be a defect in the expansion valve or problems in the

l a) Pressure gauge, thermometer, steam table oil recirculation.
l b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
l c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
l
d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
l e) to2h = to2h - to, „Overheating at evaporator out-
Ambient temperature in °C Excess pressure in bar
let = evaporator outlet temperature - evaporation
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
l f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
l a) Which measuring equipment is required?
l
b) Where to measure with which size?
l
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
l
d) How high is the condensing temperature "tc" ?
l
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "tc2u" ?
l
f) Evaluation of the measured supercooling.

Solution:
l
a) Pressure gauge, thermometer, steam table
l
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
l c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
l d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
l e) tc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
l f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.

Typical faults and possible causes

Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist. r Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also

754 BOMAG 008 914 20

Trouble shooting procedure 15.19
Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X

008 914 20 BOMAG 755

15.19 Trouble shooting procedure

Suction pressure too low (1), high pressure too

low to normal (2)

Fig. 3

Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspec- Check for leaks, refill
tion glass, high overheating, hoar-
frost on evaporator
Evaporator fins or air filter soiled Cooling power too low clean
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vac- Replace the valve
uum, because the valve has closed
Screen or nozzle in expansion valve high overheating clean
clogged
Filter dryer clogged Bubbles in inspection glass, high Change filter dryer
overheating, filter dryer cold
Heat power too low Frequent low pressure shut off, Check the control
thawing thermostat / rotary thermo-
stat switching too frequently

756 BOMAG 008 914 20

Trouble shooting procedure 15.19
Suction pressure normal (1), high pressure too
high (2)

Fig. 4

Cause Possible effect Remedy

Condenser dirty high hot gas temperature, low cool- clean
ing power
Condenser fan failed high hot gas temperature, high pres- repair
sure shut down
overfilled high hot gas temperature, low su- Correct the filling capacity
percooling, low cooling power
Leak gas (air) high hot gas temperature, low renew filling
measured supercooling, low cooling
power
Restriction between compressor and high hot gas temperature, low cool- Check lines and valves
condenser ing power

008 914 20 BOMAG 757

15.19 Trouble shooting procedure

Suction pressure too high (1), high pressure too

low to normal (2)

Fig. 5

Cause Possible effect Remedy

Compressor defective Cooling power too low Replace the compressor

758 BOMAG 008 914 20

Trouble shooting procedure 15.19
Suction pressure too high (1), high pressure too
high (2)

Fig. 6

Cause Possible effect Remedy

Expansion valve defective overheating too low, wet operation Replace the valve
of compressor

008 914 20 BOMAG 759

15.19 Trouble shooting procedure

Other faults

Symptom Cause Possible effect Remedy

Hot gas temperature too Lack of refrigeration oil increased compressor Refill refrigeration oil
high, the hot gas line be- wear
comes so hot that it cannot
be touched long with a
hand
Compressor does not start Pressure switch or any oth- System stopped Check the control units,
er safety feature has trig- check cause for switching
gered, electrical fault, and rectify
cylinder filled with liquid re-
frigerant
Compressor switches con- Switching difference too Cycling of compressor, in- Check the control units,
tinuously small, triggering of a creased wear, too low cool- check cause for switching
switching element (over- ing power and rectify
pressure switch, low pres-
sure switch), lack of
refrigerant, fan defective,
overfilled
Excessive overheating Expansion valve deadjust- low cooling power, hot gas Replace the expansion
ed or screen blocked, lack temperatures too high valve, clean the screen, fill
of refrigerant in refrigerant, leak test
Hoarfrost on inlet side of incorrectly working expan- too low infeed of refrigerant Check the expansion
evaporator sion valve, lack of refriger- into the evaporator valve, check the refrigerant
ant filling
Evaporator fully covered Load problem, too low air low cooling power of sys- Clean the evaporator,
with hoarfrost flow volume tem check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, low cooling power Eliminate the pressure
shows condensation filter dryer clogged drop, replace the filter dryer
Exceptionally cold pres- "Wet intake" of the com- low cooling power, exces- Clean the compressor, re-
sure lines pressor due to insufficient sive wear of compressor place if necessary, replace
overheating of evaporator the expansion valve if nec-
essary

Noise in system

Faults Possible cause Remedy

V-belt loose or excessively worn V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch loud Magnetic clutch runs until high pres- Repair or replace the magnetic
sure builds up, then the clutch starts clutch
to slip
Refrigerant compressor is loud Mounting bracket is loose, internal Repair the mounting bracket, re-
parts worn, low oil level in compres- place the compressor, renew the re-
sor frigeration oil
Fan is loud, fan motor excessively Replace the fan motor
worn
Whistling and rattling noise in opera- V-belt pulley and bearing worn Replace the bearing, check V-belt
tion, noticeable unevenness when pulley for wear
turning by hand
Rattling noise or vibration of high System overfilled Draw out refrigerant
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, refrigerant level in system too low Perform a leak test, fill up the system
on expansion valve, turbidity in in-
spection glass or ball does not float

760 BOMAG 008 914 20

Trouble shooting procedure 15.19
Inspection glass

Faults Possible cause Remedy

008 914 20 BOMAG 767

General safety regulations for assembly ! Caution
When installing the cabin to your machine you Paragraphs marked like this highlight possible
must strictly comply with the valid accident pre- dangers for machines or parts of the machine.
vention instructions or the country specific regu-
lations. However, dangers for persons and i Note
property may still arise, if:
Paragraphs marked like this contains technical infor-
l the lifting gear used has a too low bearing capacity mation and hints for optimal assembly.
l damaged or worn lifting tackle is used
l
unqualified personnel is entrusted with the installa- Environment
tion Paragraphs marked like this point out practices
l the safety instructions are not observed for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Each person involved in the installation of the
Strictly observe the national regulations for the
cabin must therefore read and comply with these
protection of the environment.
safety regulations. If necessary, the customer
must demand a written confirmation with signa-
ture. Information and safety stickers/decals on
Moreover, the following instructions and regulations
the cabin
must obviously also be complied with: Keep stickers/decals in good and legible condition
(see spare parts catalogue) and comply with their
l
applicable accident prevention instructions
meaning.
l
generally accepted safety and road traffic regula-
Replace damaged stickers/decals
tions
l
country specific safety regulations. It is the duty of Work on heating lines
the operator to be acquainted with these instruc-
tions and to apply these accordingly. This applies Before starting work on heating pipes relieve any
also for local regulations concerning different types pressure and let them cool down - danger of scalding!
of handling work. Should the recommendations in After completing work on the heating system of the
these instructions be different from the regulations machine check all connections and fittings for leaks.
valid in your country, you must comply with the
safety regulations valid in your country. Working on electric parts of the machine
Before starting to work on electric parts of the ma-
Changes and conversions to the cabin/ chine disconnect the battery and cover it with insulat-
machine ing material.
Unauthorized changes to the cabin are prohibited for Do not use fuses with higher ampere ratings and do
safety reasons. not repair fuses with a piece of wire. Fire hazard.
Original parts and accessories have been specially
designed for this machine. We wish to make explicitly
clear that we have not tested or approved any parts or
accessories not supplied by us. The installation and/
or use of such products may have an adverse effect
on the active and/or passive driving safety.
The manufacturer explicitly excludes any liability for
damage caused by the use of non-original parts or ac-
cessories.

Notes on safety in the assembly instruc-

tions

! Danger

Paragraphs marked like this highlight possible

dangers for persons.

768 BOMAG 008 914 20

Preparations 16.1
16.1 Preparations

! Danger

Danger of accident!
For transport purposes the driver's seat must be
tied down with cable straps thus to operate the
seat contact switch. Before resuming operation of
the machine these cable straps must strictly be re-
moved to ensure safe and reliable function of the
seat contact switch.
Check the 4 lifting eyes on the cabin roof for tight
fit. Fig. 8
Fasten the lifting gear to all four lifting eyes. l Fasten the lifting gear to the four lifting eyes 1 (Fig.
Use lifting gear (chains or ropes) of sufficient load 8).
bearing capacity. The minimum load bearing ca- l Loosen possible fastening on the transport pallet.
pacity of the crane must be 1000 kg.
l Slowly list the crane with a crane.
Do not stand or step under loads being lifted.

Danger
!

Danger of accident!
Do not stand or step under loads being lifted.

Fig. 7
l
Make sure that all fastening screws, washers, spac-
ers and nuts to fasten the cabin are available (Fig.
7).
l
Check whether rear rack, foot mat, step plate and
fastening kit are available.

008 914 20 BOMAG 769

16.2 Cabin assembly

16.2 Cabin assembly i Note

Mount the cabin immediately after sticking on the
! Danger
sealing tape, because the sealing tape will swell.
Danger of accident!
Use lifting gear (chains or ropes) of sufficient load
bearing capacity. The minimum load bearing ca-
pacity of the crane must be 1000 kg.
Do not stand or step under loads being lifted.
l Clean the operator's stand of dirt, oil and moisture.

Fig. 11
l Spray the sealing tape with soapsuds (Fig. 11), to
be able to slide the cabin on the operator's stand.

Fig. 9
l
Stick the supplied sealing tape 1 (Fig. 9) along the
edge of the operator's stand.

!Caution
Only unroll and stick the sealing tape on just be-
fore mounting the cab to the operator's stand. The
sealing tape will swell a few minutes after being
unrolled. In this case the cabin can no longer be
Fig. 12
mounted!
l Slowly lower the cabin vertically to the operator's
stand (Fig. 12).

Caution
!

The cabine must be lowered vertically onto the op-

erator's stand.

Fig. 10
l Stick the sealing tape 1 (Fig. 10) all around the op-
erator's stand.
l Do not run the sealing tape across the front recess
in the operator's stand (2), since this is the air inlet
for the cabin ventilation.

770 BOMAG 008 914 20

Cabin assembly 16.2

Fig. 13 Fig. 16
l Tighten the bottom fastening screw on the access
Caution
! side (Fig. 16) with 578 Nm.
Take care that none of the hoses and electric ca-
bles become squashed (Fig. 13).
l Run cables and hoses from inside the cabin through
the operator's stand to the outside.

Fig. 17
l Loosen both fastening screws (Fig. 17) at the rear
of the cabin again.

Fig. 14 i Note
l Turn both fastening screws (Fig. 14) at the rear of The cabin will now slide into final assembly position.
the cabin in handtight. l Tighten both fastening screws (Fig. 17) at the rear
of the cabin with 578 Nm.

Fig. 15

Fig. 18
i Note l
Tighten the rear lateral fastening screw on the left
If the bores do not match the cabin can be moved into hand side with 578 Nm (Fig. 18).
position by means of a crow bar (Fig. 15).

008 914 20 BOMAG 771

16.2 Cabin assembly

Fig. 19 Fig. 22
l Tighten the rear lateral fastening screw on the right l Tighten the front lateral fastening screw on the right
hand side with 578 Nm (Fig. 19). hand side with 578 Nm (Fig. 22).

Fig. 20 Fig. 23
l Tighten the rear inside fastening screw on the right l Tighten the front lateral fastening screw on the left
hand side with 578 Nm (Fig. 20). hand side with 578 Nm (Fig. 23).

Fig. 21 Fig. 24
l Turn nuts with washers onto both studs and tighten l Cover all lateral fastening screws with plastic caps
with 200 Nm (Fig. 21). (Fig. 24).

772 BOMAG 008 914 20

Cabin assembly 16.2

Fig. 25 Fig. 28
l Insert the foot mat 1 (Fig. 25). l Insert the rear rack and knock both plastic fasteners
carefully into the bores with a hammer (Fig. 28).

Fig. 26
Fig. 29
l Attach the step plate 1 (Fig. 26) and tighten the
three fastening screws (2). l Connect the feed 1 (Fig. 29) and the return flow (2)
for the air conditioning system with quick release
couplings.
l Connect the feed (4) and the return flow (3) of the
heating. (Observe the marks on the hoses).

i Note
Run the connecting lines for the heating parallel to
each other (do not cross).

i Note
Check the function of air conditioning and heating
within the scope of the function test.
Fig. 27 Observe identical hose diameters when connecting.
l Insert the dashboard and fasten it with four fasten-
ing screws (Fig. 27).

008 914 20 BOMAG 773

16.2 Cabin assembly

Danger
!

Before starting to work on electric parts of the ma-

chine disconnect the battery and cover it with in-
sulating material.

Fig. 30
l Plug on both connecting plugs for the washing wa-
ter pumps (Fig. 30).

Fig. 33
l Connect the plug connection of the air conditioning
system (Fig. 33).

Fig. 31
l Plug on the hoses for the washing water supply to
front and rear windscreens 1 (Fig. 31).

i Note
Check the function of the washing water system within
the scope of the function test.

Fig. 32
l
Insert the plug 1 (Fig. 32) into the socket (2).
l
Close the bayonet catch by turning the corrugated
cap nut in clockwise direction against the stop.

774 BOMAG 008 914 20

Final function tests and checks 16.3
16.3 Final function tests and
checks

Caution
!

Make sure that all screws have been tightened

with the specified torque.

i Note
After the cabin assembly the following tests must be
performed to assure that all cables and lines are cor-
rectly connected.
l Insert the ignition key and turn clockwise to position
"1".
l Operate the switches for headlights, direction indi-
cators and interior light to check their function.
l Operate the switches for front and rear windscreen
washer system and check their correct function.

i Note
If the function of the windscreen washer system is re-
versed, the two washing water hoses must be inter-
changed.
l
Start the engine.
l Switch the air conditioning on by the switch. After a
five minute operation the cabin must become no-
ticeably cooler.
l
Switch the air heater on by the switch. After a five
minute operation the cabin must become noticeably
warmer.
l
Function of the seat contact switch.

!Caution
The machine must not be operated if the seat con-
tact switch is not functioning correctly.

008 914 20 BOMAG 775

16.3 Final function tests and checks

776 BOMAG 008 914 20

17 Replacing the cab window panes

008 914 20 BOMAG 777

17.1 Assembly of window panes

Fig. 1

1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap

778 BOMAG 008 914 20

Special tools, cabin windows 17.2
17.2 Special tools, cabin windows
1. Locking handle for fastening element

BOMAG part-no.: 055 705 84

Fig. 1
2. Suction lifter

commercial

Fig. 2
3. Cutter

Commercial

Fig. 3

008 914 20 BOMAG 779

17.3 Auxiliary materials

Safety gloves
4. Cutter

Commercial

Fig. 1
5. Window glass bonding agent

BOMAG part-no.: 009 780 32

Fig. 2
6. Activator

BOMAG part-no.: 009 780 33

Fig. 3

780 BOMAG 008 914 20

Auxiliary materials 17.3
7. Silicone sealant

BOMAG part-no.: 009 700 36

Fig. 4

008 914 20 BOMAG 781

17.4 Removing and installing the window pane

17.4 Removing and installing the window

pane
Environment
Environmental damage
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.

! Danger

Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).

Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.

Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).

Fig. 3

782 BOMAG 008 914 20

Removing and installing the window pane 17.4
6. Turn the fixing and spacer washer hand-tight onto
the thread of the fastening element (Fig. 4).

i Note
Do not overtighten the thread.

Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).

i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.

Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.

Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).

i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.

Fig. 7

008 914 20 BOMAG 783

17.4 Removing and installing the window pane

14. Remove the suction lifter (Fig. 8).

Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).

i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.

Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).

Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).

Fig. 11

784 BOMAG 008 914 20

Removing and installing the window pane 17.4
19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).

Fig. 12
20. Treat the inside joint (Fig. 13)

Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.

i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.

Fig. 14

008 914 20 BOMAG 785

17.4 Removing and installing the window pane

786 BOMAG 008 914 20

18 Drum

008 914 20 BOMAG 787

18.1 Repair overview for drum

O-ring

Fig. 1 Drum + drum drive

788 BOMAG 008 914 20

Repair overview for drum 18.1

1 Vibration motor 5 Exciter unit

2 Swivel motor 6 Drum shell
3 Travel motor 7 Rubber buffer
4 Travel gear

Fig. 2 Exciter shafts and eccentric weights

1 Eccentric weights, outer 5 Exciter shaft, middle

2 Eccentric weight, middle 6 Coupling shaft
3 Exciter shaft, left 7 Additional weight only BW226
4 Exciter shaft, right

008 914 20 BOMAG 789

790
2 X crosswise
tighten
18.1

Fig. 3 Exciter unit

2 X crosswise
tighten

BOMAG
M27X1,5 = 1263 Nm M27X1,5 = 1263 Nm M27X1,5 = 1263 Nm
M22X1,5 = 785 Nm M22X1,5 = 785 Nm M22X1,5 = 785 Nm
Repair overview for drum

008 914 20
Repair overview for drum 18.1

1 Exciter housing left 5 Exciter housing middle

2 Eccentric weights 6 Drive shaft
3 Coupling shaft 7 Vibrator shaft
4 Exciter housing right

Fig. 4 Pinion

1 Inner bearing race 8 Circlip (outer)

2 Pinion 9 Outer bearing race with rolls, bearing flange
3 Circlip (outer) 10 Bearing flange
4 Feather key 11 Circlip (inner)
5 Gear 12 Circlip (inner)
6 Circlip (outer) 13 Outer bearing race with rolls
7 Inner bearing race, bearing flange 14 Circlip (inner)

008 914 20 BOMAG 791

18.1 Repair overview for drum

Fig. 5 Exciter housing right

1 Radial seal 8 Inner race

2 Outer bearing race with rolls 9 O-ring
3 Circlip (inner) 10 Outer bearing race with rolls
4 Inner bearing race 11 Circlips (inner)
5 Inner bearing race 12 Gear
6 Exciter shaft (right) 13 Socket head cap screws
7 Circlips (outer)

792 BOMAG 008 914 20

Repair overview for drum 18.1

Fig. 6 Exciter housing left

1 not used 7 Circlips (outer)

2 Outer bearing race with rolls 8 not used
3 Circlip (inner) 9 not used
4 Inner bearing race 10 Outer bearing race with rolls
5 Inner bearing race 11 Circlips (inner)
6 Exciter shaft (left)

008 914 20 BOMAG 793

18.1 Repair overview for drum

Fig. 7 Flanged hub

1 Flanged hub 11 Tapered roller bearing set, inner bearing

race with rolls
2 Side plate
12 Tapered roller bearing set, two matching in-
3 Outer bearing race with rolls
termediate rings
4 Inner bearing race
13 Tapered roller bearing set, outer bearing
5 Circlip (outer) race
6 Circlip (inner) 14 Tapered roller bearing set, inner bearing
7 Radial seal race with rolls

8 Mechanical seal 15 Spacer ring

9 O-ring 16 Circlip (inner)

10 Tapered roller bearing set, outer bearing 17 Clamping ring

race 18 Socket head cap screws

794 BOMAG 008 914 20

Repair overview for drum 18.1

Fig. 8 Flanged hub with side plate

008 914 20 BOMAG 795

18.1 Repair overview for drum

O-rings
O-ring

Sealed with
Hylomar SQ32M
Fig. 9 Side plate and cover

Coat gear box from inside with grease (AUTOL TOP 2000).

1 Drive shaft 4 Vibration motor

2 Acceleration transducer, B62 5 Potentiometer, B97
3 Speed sensor, B59 6 Swivel motor

796 BOMAG 008 914 20

Repair overview for drum 18.1

Fig. 10

008 914 20 BOMAG 797

18.2 Removing and installing the drum

i Note
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (Fig. 1).

Fig. 1

i Note
However, the drum can also be removed without
having to disassemble the side plate, if it is lifted
up and out of the frame (Fig. 2).

Fig. 2
Removing the drum

i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.
1. Unscrew the fastening screws and remove the
protection hood (Fig. 3).

Fig. 3

798 BOMAG 008 914 20

Removing and installing the drum 18.2
2. Open the hose brackets (Fig. 4) on both sides of
the drum.

Fig. 4

Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
3. Mark the hydraulic hoses on the vibration motor
(Fig. 5) and disconnect them from the ports.
4. Close all hydraulic hoses and vibration motor
ports with suitable plugs.

Fig. 5
5. Mark the hydraulic hoses on the slewing motor
(Fig. 6) and disconnect them from the ports.
6. Close all hydraulic hoses and slewing motor ports
with suitable plugs.

Fig. 6
7. Mark the hydraulic hoses on the control valve
block (Fig. 7) and disconnect them from the ports.
8. Close all hydraulic hoses and control valve ports
with suitable plugs.
9. Pull off both plugs (2) from the solenoid valve.
10. Disassemble the protection hood (1) for the plug
of the wiring loom.

Fig. 7

008 914 20 BOMAG 799

18.2 Removing and installing the drum

11. Disconnect all plugs (Fig. 8).

Fig. 8
12. Mark the hydraulic hoses (Fig. 9) on the travel
motor and disconnect them from the ports.
13. Close all hydraulic hoses and travel motor ports
with suitable plugs.
14. Disassemble the guard plates for speed range
selection solenoid valve (1) and speed sensor
(2).

Fig. 9
15. Disconnect the plug from the speed sensor sole-
noid valve (Fig. 10).
16. Close the connections with plugs.

Fig. 10
17. Disassemble the front scraper 1 (Fig. 11).
18. Disassemble the rear scraper (2).

Fig. 11

800 BOMAG 008 914 20

Removing and installing the drum 18.2
! Danger

Danger of accident!
Do not start or run the engine during repair
work.
19. Support the front cross-member safely (Fig. 12).

Fig. 12
20. Properly support the rear cross-member on both
sides (Fig. 13).

Fig. 13
21. Attach the lifting tackle to the side plate (Fig. 14).
22. Unscrew the front and rear fastening screws from
the side plate.

Fig. 14
23. Unscrew the fastening screws (Fig. 15) from the
spacer block on the vibration motor.

! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
24. Take off the side plate and lay it down.

Fig. 15

008 914 20 BOMAG 801

18.2 Removing and installing the drum

25. Unscrew the fastening screws on the travel motor

side (Fig. 16).

Fig. 16
26. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 17).

! Danger

Danger of squashing! Do not stand or step

under loads being loaded.

Fig. 17
27. Examine all rubber buffers on the travel motor
side (Fig. 18) for wear, replace if necessary.
28. Check the rectangular rubber buffers on the vi-
bration motor side, replace if necessary.

Fig. 18

802 BOMAG 008 914 20

Removing and installing the drum 18.2
Installing the drum
! Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
1. Place the drum into the frame and align it parallel
to the frame (Fig. 1).

Fig. 1
Assemble the side plate
2. Attach the lifting tackle and assemble the side
plate (Fig. 2).

i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
3. Turn in the front and rear fastening screws and
tighten with 463 Nm.

Fig. 2
4. Turn in and tighten the fastening screws on the
travel motor side (Fig. 3).

Fig. 3
Adjust the pretension of the rubber buffers.
5. On the vibration motor side measure the distance
„X“ between spacer block 1 (Fig. 4) and side
plate.
6. Calculate the thickness of the compensation
plates.

Nominal value:
Distance „X“ + 2 mm
7. Turn in one screw (3) into each welded nut (2) on
the spacer blocks and provide sufficient space to
insert the compensation plates.
Fig. 4

008 914 20 BOMAG 803

18.2 Removing and installing the drum

8. Insert the compensation plates (Fig. 5).

9. Turn in the fastening screws.
10. Unscrew the screws from the welded nuts.
11. Tighten the fastening screws.

Fig. 5
Connecting the travel motor side
12. Connect hydraulic hoses to the travel motor ports
according to the marks made during disassembly
(Fig. 6).
13. Connect the plugs (Solenoid valve for travel
speed range selection and speed sensor) and re-
assemble the guard plates (1) and (2).

Fig. 6
Connecting the vibration motor side
14. Connect the hydraulic hoses to the ports on the
vibration motor according to the marking (Fig. 7).

Fig. 7
15. Connect hydraulic hoses to the slewing motor
ports according to the marks made during disas-
sembly (Fig. 8).

Fig. 8

804 BOMAG 008 914 20

Removing and installing the drum 18.2
16. Connect all cable plugs and reassemble the pro-
tection hood 1 (Fig. 9).

! Caution
Ensure correct routing of the wiring harness-
es!
17. Connect the hydraulic hoses to the ports on the
control valve block according to the marking.
18. Plug in both plugs (2) on the solenoid valve.

Fig. 9
19. Fasten the brackets (Fig. 10) for the hydraulic
hoses on both sides.

Fig. 10
Adjusting the scrapers
20. Assemble the front scraper 1 (Fig. 11).
21. Assemble the rear scraper (2).

i Note
Observe the adjustment measurement 30-35
mm.

Fig. 11
22. Assemble the protection hood (Fig. 12).

! Caution
Check the hydraulic system for function and
leak tightness before putting the machine
back into service.
Adjust the potentiometer (see Technical Man-
ual VC).
Adjust the slewing motor (see Technical Man-
ual VC).

Fig. 12

008 914 20 BOMAG 805

18.3 Dismantling the drum

i Note
The oil drain plug must be positioned vertically
below the drum center, if necessary move the
drum as required.
1. Unscrew the oil drain plug with the seal ring (1
(Fig. 1)).
2. Drain the oil off into a suitable container.

Environment
Dispose of oil according to applicable envi-
ronmental regulations.
Fig. 1 3. Screw the oil plug with seal ring back in.

Left drum side

4. Attach the lifting tackle to the spacer block (Fig.
2).

i Note
BW213 = 4 Rectangular rubber buffers.
BW226 = 8 Rectangular rubber buffers.

Fig. 2

! Danger
Attach a support on the opposite side of the
side plate (Fig. 3).

Fig. 3

806 BOMAG 008 914 20

Dismantling the drum 18.3
5. Loosen the screw connections 1 (Fig. 4).
6. Lift the longitudinal rubber element with spacer
block off the side plate and lay it down safely.

Fig. 4
7. Attach the lifting tackle to the second spacer
block .
8. Loosen the screw connections 1 (Fig. 5).
9. Lift the longitudinal rubber element with spacer
block off the side plate and lay it down safely.

Fig. 5
10. Attach the lifting tackle to the exciter unit (Fig. 6).

Fig. 6
11. Unscrew the fastening screws for the flanged hub
(Fig. 7).
12. Unscrew the dummy plug (1) from the flanged
hub and screw in fastening screws (forcing
screws).
13. Press the exciter unit out of the drum with forcing
screws.

Fig. 7

008 914 20 BOMAG 807

18.3 Dismantling the drum

14. Lift the exciter unit carefully out of the drum (Fig.
8) and lay it down safely.

Fig. 8

Right drum side

15. Attach lifting tackle to the drive disc with gearbox,
travel motor and gearbox holder (Fig. 9).

Fig. 9
16. Disassemble nuts and washers (Fig. 10).

Fig. 10
17. Pull the drive unit out of the drum (Fig. 11) and lay
it down safely.

Fig. 11

808 BOMAG 008 914 20

Dismantling the drum 18.3
18. Check the rubber buffers, replace if necessary
(Fig. 12).

Fig. 12
19. Unscrew the fastening screws from the bearing
flange (Fig. 13).
20. Turn in two guide bolts (2) (M20).
21. Unscrew the dummy plug (1) from the bearing
flange and screw in fastening screws (forcing
screws).
22. Force the bearing flange off the drum using two
forcing screws.

Fig. 13
23. Attach the lifting tackle to the bearing flange and
lift it off the drum (Fig. 14).

Fig. 14
24. Check cylinder roller bearing 1 (Fig. 15) and radi-
al seal, replace if necessary.

Fig. 15

008 914 20 BOMAG 809

18.4 Assembling the vibrator unit

i Note
Explorer bearings represent an entirely new per-
formance class in the range of cylinder roller
bearings with considerably improved perform-
ance parameters with respect to endurance, ro-
tating characteristics and dynamic loading
capacity.

! Caution
Inner and outer bearing races are matched to
each other and must not be mixed up by mis-
take.
Fig. 1 Mark inner (A) (Fig. 1) and outer bearing races
(B) with a marker pen to prevent mixing up by
mistake during later assembly.
Ensure strict cleanliness.

Assembling the exciter shaft (middle)

Vibration motor side 1 Outer bearing race with rolls, travel motor
side
2 Circlip (inner)
3 Exciter shaft (middle)
4 Inner bearing race, travel motor side
5 Inner bearing race, vibration motor side
6 Circlips (outer)
7 Outer bearing race with rolls, vibration motor
side

Travel motor side 8 Circlip (inner)

Fig. 2 Sectional drawing
1. Clean the exciter housing and blow it out with
Travel motor side
compressed air (Fig. 3).

i Note
Lubricate the bearing seat area.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.
2. Cool down the outer bearing race (1) to -25°C.
3. Press the outer bearing race (1) (Fig. 2) and (Fig.
Fig. 3 3) into the exciter housing against the end stop.

Caution
!

Wipe off any ice!

4. Insert the circlip (2) into the groove (arrow) in the
exciter housing.

810 BOMAG 008 914 20

Assembling the vibrator unit 18.4
Vibration motor side i Note
Lubricate the bearing seat areas.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.

! Danger
Danger of burning!
Wear safety gloves.
Travel motor side
5. Heat both inner bearing races (4) and (5) (Fig. 4)
Fig. 4
up to 80°C and slide them over the exciter shaft
(3) against the shoulder.
6. Insert the circlips (6) into the grooves (arrow) in
the exciter shaft.

i Note
Oil the inner bearing races.
7. Turn the exciter housing by 180°.
8. Attach suitable lifting tackle to the pre-assembled
exciter shaft and move it carefully into the exciter
housing (Fig. 5).

Vibration motor side

Fig. 5
9. Remove the lifting gear (Fig. 6).

! Caution
Check the bearings.

Fig. 6

008 914 20 BOMAG 811

18.4 Assembling the vibrator unit

i Note
Lubricate the bearing seat area.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.
10. Cool down the outer bearing race (7) to -25°C.
11. Press the outer bearing race (7) (Fig. 7) (see also
(Fig. 2)) into the exciter housing against the end
stop.
12. Insert the circlip (8) into the groove (arrow) in the
Fig. 7 exciter housing.

! Caution
Wipe off ice and check the bearings (Fig. 8).

Fig. 8

812 BOMAG 008 914 20

Assembling the vibrator unit 18.4
Assembling the wheel set
i Note
Lubricate the bearing seat area.
13. Cool down the outer bearing race 13 (Fig. 9) (see
also (Fig. 16)) to -25°C.
14. Press the outer bearing race (13) into the exciter
housing against the end stop.

Caution
!

Wipe off any ice!

15. Insert circlip (14) (Fig. 9) (see also (Fig. 16)) into
the groove in the exciter housing .
Fig. 9
Assemble the intermediate gear (Fig. 10)
1 Stub axle
2 Circlip (inner)
3 Intermediate gear
4 Inner bearing race
5 Spacer ring
6 Bearing race
7 Outer bearing race with rolls

Fig. 10 Sectional drawing

16. Insert the spacer ring (5) (Fig. 11).
17. Assemble the bearing race (6).

Fig. 11

i
Note
Oil the intermediate gear.
18. Cool down the outer bearing race 7 (Fig. 12) to -
25°C.
19. Press the outer bearing race (7) into the interme-
diate gear (3) against the end stop.

! Caution
Wipe off any ice!
20. Insert the circlip (2) into the groove in the interme-
diate gear (3).
Fig. 12

008 914 20 BOMAG 813

18.4 Assembling the vibrator unit

21. Push in the pre-assembled intermediate gear (3)

(Fig. 13).

Fig. 13

i Note
Oil the stub axle.

! Danger
Danger of burning!
Wear safety gloves.
22. Heat the inner bearing race 4 (Fig. 14) up to 80°C
and slide it over the stub axle (1) against the
shoulder.

i Note
Fig. 14 Oil the inner bearing race.
23. Assemble the pre-assembled stub axle (Fig. 15).
24. Turn in the socket head cap screws (8).

i Note
Do not yet tighten the socket head cap screws.
25. Check the bearings.

! Caution
The intermediate gear should be light to turn.

Fig. 15

814 BOMAG 008 914 20

Assembling the vibrator unit 18.4
Assembling the pinion
1 Inner bearing race
2 Pinion
3 Circlip (outer)
4 Feather key
5 Gear
6 Circlip (outer)
7 Inner bearing race, bearing flange
8 Circlip (outer)
9 Outer bearing race with rolls, bearing flange
10 Bearing flange
Fig. 16 Sectional drawing
11 Circlip (inner)
12 Circlip (inner)
13 Outer bearing race with rolls, see also (Fig. 9)
14 Circlip (inner), see also (Fig. 9)

i Note
Lubricate the bearing seat area.

Danger
!

Danger of burning!
Wear safety gloves.
26. Heat the inner bearing race 1 (Fig. 17) up to 80°C
and slide it over the pinion (2) against the shoul-
der.
27. Insert the circlip (3) into the groove in the pinion
(2).
Fig. 17
28. Insert the feather key (4) (Fig. 18).
29. Push on gear (5).

Fig. 18

008 914 20 BOMAG 815

18.4 Assembling the vibrator unit

30. Insert the circlip (6) into the groove in the pinion
(2) (Fig. 19).

Fig. 19

i Note
Lubricate the bearing seat area.

!Danger
Danger of burning!
Wear safety gloves.
31. Heat the inner bearing race 7 (Fig. 20) up to 80°C
and slide it over the pinion (2) against the shoul-
der.
32. Insert the circlip (8) into the groove in the pinion
(2).
Fig. 20

i Note
Oil the inner bearing races.
33. Assemble the pre-assembled pinion (Fig. 21).

Fig. 21
34. Insert the circlip (11) into the groove in the bear-
ing flange (10) (Fig. 22).

i Note
Lubricate the bearing seat area.
35. Cool down the outer bearing race (9) to -25°C.
36. Press the outer bearing race (9) into the bearing
flange (10) against the end stop.

! Caution
Wipe off any ice!
Fig. 22 37. Insert the circlip (12) into the groove in the bear-
ing flange (10).

816 BOMAG 008 914 20

Assembling the vibrator unit 18.4
38. Mount the pre-assembled bearing flange (Fig. 23)
(see also (Fig. 16)).
39. Turn in the socket head cap screws (1).

i Note
Do not yet tighten the socket head cap screws.

! Caution
Check the bearings.
Intermediate gear and pinion should be light
to turn.
Fig. 23
40. Assemble the gear (1), turn in the socket head
cap screws (2) (Fig. 24).

i Note
Do not yet tighten the socket head cap screws.
41. Check the bearings.

! Caution
Intermediate gear, pinion and exciter shaft
should be light to turn.

Fig. 24
42. Turn the guide bolt M27X500 into the exciter
shaft (Fig. 25).

Fig. 25
43. Tighten all socket head cap screws (1) (Fig. 26).

i Note
Tightening torque 75Nm.

Fig. 26

008 914 20 BOMAG 817

18.4 Assembling the vibrator unit

44. Turn in three guide bolts M18X1,5X 300 mm (Fig.

27).

Fig. 27

818 BOMAG 008 914 20

Assembling the vibrator unit 18.4
Assembling the (right) exciter hous-
ing
1 Radial seal
2 Outer bearing race with rolls
3 Circlip (inner)
4 Inner bearing race
5 Inner bearing race
6 Exciter shaft (right)
7 Circlips (outer)
8 Inner race
9 O-ring, assembly see (Fig. 129)
10 Outer bearing race with rolls
Fig. 28 Sectional drawing
11 Circlips (inner)
12 Gear
13 Socket head cap screws
45. Clean the exciter housing and blow it out with
compressed air (Fig. 29).

Fig. 29
46. Drive the radial seal (1) (Fig. 30) (see also (Fig.
28)) in againt the end stop using a suitable as-
sembly mandrel.

i
Note
Sealing lips pointing up.

Fig. 30

008 914 20 BOMAG 819

18.4 Assembling the vibrator unit

i Note
Lubricate the bearing seat area.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.
47. Cool down the outer bearing race (2) to -25°C.
48. Press the outer bearing race (2) (Fig. 31) (see
also (Fig. 28)) into the exciter housing against the
end stop.

Fig. 31 ! Caution
Wipe off any ice!
49. Insert circlip (3) into the groove in the exciter
housing.

i Note
Lubricate the bearing seat areas.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.

!Danger
Danger of burning!
Wear safety gloves.
50. Heat the inner bearing races 4 (Fig. 32) and (5)
Fig. 32
up to 80°C and slide it over the exciter shaft (6)
against the shoulder.
51. Heat the inner bearing race (8) up to 80°C and
slide it over the exciter shaft (6) against the shoul-
der.
52. Insert the circlips (7) into the grooves in the excit-
er shaft.
53. Grease the splined shaft and the grease cham-
bers with Optipit (Fig. 33).

i Note
Oil the inner bearing races.

Fig. 33

820 BOMAG 008 914 20

Assembling the vibrator unit 18.4
54. Insert the pre-assembled exciter shaft carefully
into the exciter housing (Fig. 34).
55. Check the bearings.

Fig. 34

i Note
Lubricate the bearing seat area.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.
56. Insert circlip (11.1) into the groove in the exciter
housing (Fig. 35).
57. Cool down the outer bearing race (10) to -25°C.
58. Press the outer bearing race (10) (see also (Fig.
28)) into the exciter housing against the end stop.
Fig. 35
59. Insert circlip (11.2) into the groove in the exciter
housing.

! Caution
Wipe off any ice!
60. Check the bearings.

Fig. 36
61. Assemble the gear (12), turn in the socket head
cap screws (13) (Fig. 37).

Fig. 37

008 914 20 BOMAG 821

18.4 Assembling the vibrator unit

62. Turn the guide bolt M27X500 into the exciter

shaft (Fig. 38).
63. Tighten the socket head cap screws (13).

i Note
Tightening torque 75Nm.
64. Turn in eye bolt (A).

Fig. 38
65. Turn the exciter housing by 180°and attach suita-
ble lifting tackle (Fig. 39).

Fig. 39
66. Carefully Join the pre-assembled exciter units to-
gether (Fig. 40).

! Caution
The guide bolts (1) must be in line.
67. Remove the lifting gear.
68. Unscrew the guide bolts (2) and turn in the socket
head cap screws with washers (3).

! Caution
Tighten the socket head cap screws 2X cross-
Fig. 40 wise.

i Note
Tightening torque 466 Nm

822 BOMAG 008 914 20

Assembling the vibrator unit 18.4
69. Insert the feather key (1) (Fig. 41).

Fig. 41

008 914 20 BOMAG 823

18.4 Assembling the vibrator unit

Assembling the (left) exciter housing

1 not used
2 Outer bearing race with rolls
3 Circlip (inner)
4 Inner bearing race
5 Inner bearing race
6 Exciter shaft (left)
7 Circlips (outer)
8 not used
9 not used
10 Outer bearing race with rolls
Fig. 42 Sectional drawing
11 Circlips (inner)
70. Clean the exciter housing and blow it out with
compressed air (Fig. 43).

Fig. 43

i Note
Lubricate the bearing seat area.

Caution
!

Inner and outer bearing races must not be

mixed up by mistake.
71. Cool down the outer bearing race (2) to -25°C.
72. Press the outer bearing race (2) (Fig. 44) (see
also (Fig. 42)) into the exciter housing against the
end stop.

Fig. 44 Caution
!

Wipe off any ice!

73. Insert circlip (3) into the groove in the exciter
housing.

824 BOMAG 008 914 20

Assembling the vibrator unit 18.4
i Note
Lubricate the bearing seat areas.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.

!Danger
Danger of burning!
Wear safety gloves.
74. Heat the inner bearing races (4) and (5) (Fig.
Fig. 45
45)up to 80°C and slide it over the exciter shaft
(6) against the shoulder.
75. Insert the circlips (7) into the grooves in the excit-
er shaft.
76. Grease the splined shaft and the grease cham-
bers with Optipit (Fig. 46).

i Note
Oil the inner bearing races.

Fig. 46
77. Insert the pre-assembled exciter shaft carefully
into the exciter housing (Fig. 47).
78. Check the bearings.

Fig. 47

008 914 20 BOMAG 825

18.4 Assembling the vibrator unit

i Note
Lubricate the bearing seat area.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.
79. Insert circlip (11.2) into the groove in the exciter
housing (Fig. 48).
80. Cool down the outer bearing race (10) to -25°C.
81. Press the outer bearing race (10) (see also (Fig.
42)) into the exciter housing against the end stop.
Fig. 48
82. Insert circlip (11.1) into the groove in the exciter
housing.
83. Check the bearings (Fig. 49).

! Caution
Wipe off any ice!

Fig. 49
84. Turn the guide bolt M27X500 into the exciter
shaft (Fig. 50).
85. Turn in eye bolt (A).

Fig. 50
86. Turn the exciter housing by 180°and attach suita-
ble lifting tackle (Fig. 51).

Fig. 51

826 BOMAG 008 914 20

Assembling the vibrator unit 18.4
87. Oil and insert the coupling shaft (1) (Fig. 52).
88. Turn in three guide bolts M18X1,5X 300 mm.

Fig. 52
89. Carefully join the pre-assembled exciter units to-
gether (Fig. 53).

! Caution
The guide bolts (1) must be in line.
90. Remove the lifting gear.
91. Unscrew the guide bolts (2) and turn in the socket
head cap screws with washers (3).

! Caution
Tighten the socket head cap screws 2X cross-
Fig. 53 wise.

i Note
Tightening torque 466 Nm

008 914 20 BOMAG 827

18.4 Assembling the vibrator unit

Assembling the weights

1 Eccentric weights, outer
2 Eccentric weight, middle
3 Additional weight only BW226

Fig. 54
92. Turn in the eye bolt (A) and attach lifting gear to
the eccentric weight (outer) (Fig. 55).

Fig. 55

! Danger

Danger of squashing!
93. Insert both eccentric weights (outer) over guide
bolts, one after the other (Fig. 56).

Danger
!

Do not yet unscrew the eye bolts (A)!

The eye bolts prevent the eccentric weights
from swinging over.
94. Remove the guide bolt (1) and replace it with
socket head cap screw and washer.
Fig. 56
95. Remove the guide bolt (2) and replace it with
socket head cap screw and washer.

828 BOMAG 008 914 20

Assembling the vibrator unit 18.4
96. Turn in the eye bolt (B) and attach lifting gear to
the eccentric weight (inner) (Fig. 57).

Fig. 57
97. Insert the (inner) eccentric weight over guide
bolts (1) (Fig. 58).
98. Unscrew the guide bolts (1), turn in two socket
head cap screws with washers.

! Danger
Do not yet unscrew the eye bolt (B) (Fig. 58)
and (Fig. 59)!
The eye bolt prevents the eccentric weight
from swinging over.

Fig. 58
99. Attach a manual screwer (1) (Fig. 59) und tighten
the socket head cap screws on all eccentric
weights.

i Note
The manual screwer is equipped with a ratchet.
Short ratchet movements allow very effective
working.

Fig. 59
100. Turn the exciter housing around (Fig. 60).
101. Unscrew all eye bolts.
102. Assemble six additional weights with screws and
washers.

i Note
Additional weight only BW 226.

Fig. 60

008 914 20 BOMAG 829

18.4 Assembling the vibrator unit

103. Assemble spacer blocks (1) with socket head cap

screws and washers (2) (Fig. 61).

i Note
Tightening torque 466Nm.

Fig. 61

830 BOMAG 008 914 20

Assembling the vibrator unit 18.4
Bearing flange
i Note
Lubricate the bearing seat areas.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.

! Danger

Danger of burning!
Wear safety gloves.
104. Heat inner bearing race (Fig. 62) up to 80 °C and
Fig. 62
slide it on against the stop.
105. Insert the circlip (Fig. 63) into the groove.

Fig. 63

i Note
Lubricate the bearing seat area.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.
106. Cool down the outer bearing race to -25°C.
107. Press the outer bearing race (3) into the bearing
flange against the end stop (Fig. 64).

Fig. 64

008 914 20 BOMAG 831

18.4 Assembling the vibrator unit

108. Insert the circlip (6) (Fig. 65) into the groove.

! Caution
Wipe off any ice!

Fig. 65
109. Attach the radial seal (7) (Fig. 66).

i Note
Sealing lips pointing up.

Fig. 66
110. Press the radial seal in until it bottoms (Fig. 67).

Fig. 67

i Note
Grease the O-ring.
111. Assemble the O-ring (9) (Fig. 68).

Fig. 68

832 BOMAG 008 914 20

Assembling the vibrator unit 18.4
112. Fill the bearing with grease (Fig. 69).

Fig. 69

008 914 20 BOMAG 833

18.4 Assembling the vibrator unit

Flanged hub and side plate

1 Flanged hub
2 Side plate
3 Outer bearing race with rolls
4 Inner bearing race
5 Circlip (outer)
6 Circlip (inner)
7 Radial seal
8 Mechanical seal
9 O-ring
10 Tapered roller bearing set, outer bearing race
Fig. 70
11 Tapered roller bearing set, inner bearing race
with rolls
12 Tapered roller bearing set, two matching in-
termediate rings
13 Tapered roller bearing set, outer bearing race
14 Tapered roller bearing set, inner bearing race
with rolls
15 Spacer ring
16 Circlip (inner)
17 Clamping ring
18 Socket head cap screws

! Caution
The tapered roller bearing set must only be
assembled with the associated intermediate
rings (C) (Fig. 71) (12)(Fig. 70).
Replacement of individual bearings or inter-
mediate rings (C) is not permitted!
Inner bearing races with rolls (8) and outer
bearing races (A) must not be mixed up by
mistake.

Fig. 71 Tapered roller bearing set

i
Note
Lubricate the bearing seat areas.

Caution
!

Inner and outer bearing races must not be

mixed up by mistake.

Danger
!

Danger of burning!
Wear safety gloves.
113. Heat inner bearing race (4) (Fig. 72) up to 80 °C
Fig. 72
and slide it on against the stop.

834 BOMAG 008 914 20

Assembling the vibrator unit 18.4
114. Insert the circlip (5) (Fig. 73) into the groove.

Fig. 73

i Note
Lubricate the bearing seat area.

! Caution
Inner and outer bearing races must not be
mixed up by mistake.
115. Cool down the outer bearing race to -25°C.
116. Press the outer bearing race (3) into the bearing
flange against the end stop (Fig. 74).

Fig. 74
117. Insert the circlip (6) (Fig. 75) into the groove.

! Caution
Wipe off any ice!

Fig. 75
118. Attach the radial seal (7) (Fig. 76).

i Note
Sealing lips pointing up.

Fig. 76

008 914 20 BOMAG 835

18.4 Assembling the vibrator unit

119. Press the radial seal in until it bottoms (Fig. 77).

Fig. 77

i Note
Grease the O-ring.
120. Assemble the O-ring (9) (Fig. 78).

Fig. 78
121. Fill the bearing with grease (Fig. 79).

Fig. 79
122. Turn the flanged hub.
123. Assemble the magnetic plugs with seal rings (A)
(Fig. 80).
124. Turn in dummy plugs.

Fig. 80

836 BOMAG 008 914 20

Assembling the vibrator unit 18.4
125. Assemble the assembly rings (Fig. 81).

Fig. 81
126. Attach the mechanical seal (8.1) to the assembly
tool. (Fig. 82)

Fig. 82
127. Insert the mechanical seal (8.1) into the flanged
hub (Fig. 83).

Fig. 83
128. Remove the assembly tool and check the me-
chanical seal for correct fit (Fig. 84).

Fig. 84

008 914 20 BOMAG 837

18.4 Assembling the vibrator unit

129. Grease the mechanical seal ring and fill the

space between mechanical seal and flanged hub
with grease (Fig. 85).

Fig. 85

i Note
Lubricate the bearing seat area.
130. Cool down the outer bearing race to -25°C.
131. Press the outer bearing race (B) into the bearing
plate (Fig. 86) against the end stop.

! Caution
Wipe off any ice!
132. Assemble plug (A).

Fig. 86
133. Mark the side plate with a center punch to secure
the outer bearing race (B) against moving. (Fig.
87)

Fig. 87
134. Attach the mechanical seal (8.2) to the assembly
tool (Fig. 88).

Fig. 88

838 BOMAG 008 914 20

Assembling the vibrator unit 18.4
135. Insert the mechanical seal (8.2) into the sdie plate
(Fig. 89).
136. Remove the assembly tool and check the me-
chanical seal for correct fit .

Fig. 89
137. Attach the lifting tackle to the side plate (2) (Fig.
90).
138. Slide the side plate over the flanged hub (1).

Fig. 90
139. Brush some grease on the collar of the side plate
(Fig. 91).

Fig. 91

! Caution
Inner and outer bearing races must not be
mixed up by mistake.

!Danger
Danger of burning!
Wear safety gloves.
140. Heat the inner bearing race (11) of the tapered
roller bearing set up to 80 °C and slide it on
against the stop (Fig. 92).
141. Fill the space between inner race and side plate
Fig. 92 collar with grease.

008 914 20 BOMAG 839

18.4 Assembling the vibrator unit

! Caution
Inner and outer bearing races must not be
mixed up by mistake.
142. Cool down the outer bearing race (10) of the ta-
pered roller bearing set up to -25 °C and press it
in against the stop. (Fig. 93).

! Caution
Wipe off any ice!

Fig. 93
143. Insert the two matching intermediate rings (12) of
the tapered roller bearing set (Fig. 94).
144. Fill the chambers with grease.

Fig. 94

! Caution
Inner and outer bearing races must not be
mixed up by mistake.
145. Cool down the outer bearing race (13) of the ta-
pered roller bearing set up to -25 °C and press it
in against the stop (Fig. 95).

! Caution
Wipe off any ice!

Fig. 95
146. Insert the spacer ring (15) (Fig. 96).

Fig. 96

840 BOMAG 008 914 20

Assembling the vibrator unit 18.4
147. Remove the assembly rings (Fig. 97).

! Caution
During assembly rotate the side plate only to
one direction.

Fig. 97

! Caution
Inner and outer bearing races must not be
mixed up by mistake.

! Danger
Danger of burning!
Wear safety gloves.
148. Heat the inner bearing race (14) of the tapered
roller bearing set up to 80 °C and slide it on
against the stop (Fig. 98).

Fig. 98
149. Insert the circlip (16) into the groove (Fig. 99).

Fig. 99
150. Fasten the clamping ring (17) with socket head
cap screws (18) (Fig. 100).

! Caution
Follow the procedure described next to tight-
en the screws:
During assembly rotate the side plate only to
one direction.
1) Tighten the socket head cap screws (18)
crosswise with 80 Nm, then rotate the side
plate three times.
2) Retighten the socket head cap screws (18)
Fig. 100
crosswise with 100 Nm, rotate the side plate
three times.

008 914 20 BOMAG 841

18.4 Assembling the vibrator unit

3) Retighten the socket head cap screws (18)

crosswise with 120 Nm, rotate the side plate
three times.
4) Mark the position of the socket head cap
screws (18) to the clamping ring, then loosen
one socket head cap screw at a time, screw it
back in with Loctite 2701 and tighten it to the
mark.
5) Control: There must be clearance between
clamping ring and flanged hub, check with a
feeler gauge.
151. Lubricate with grease (Fig. 101).

Fig. 101
152. Attach the lifting tackle to the pre-assembled unit
(Fig. 102).

Fig. 102
153. Lubricate with grease (Fig. 103).

Fig. 103

842 BOMAG 008 914 20

Assembling the vibrator unit 18.4
154. Insert the pre-assembled unit into the exciter
housing (Fig. 104).

Fig. 104
155. Lubricate the exciter housing with oil (Fig. 105).

Fig. 105

! Danger
Danger of burning!
Wear safety gloves.
156. Heat the gear up to 80 °C and slide it over the ex-
citer housing. (Fig. 106).

i Note
Mind the feather key (A) (Fig. 105).

Fig. 106
157. Insert the circlip (Fig. 107) into the groove.

Fig. 107

008 914 20 BOMAG 843

18.4 Assembling the vibrator unit

158. Screw in the mechanical lock (Fig. 108).

i Note
Mechanical lock, vertical amplitude.

Fig. 108
159. Assemble rubber bushing (1) and bolt (2) into
gear (3) (Fig. 109).

Fig. 109

! Danger
Danger of burning!
Wear safety gloves.
160. Heat the inner bearing races up to 80°C and slide
over the gear against the shoulder. (Fig. 110).

Fig. 110
161. Attach the protection ring for assembling the gear
(Fig. 111).

Fig. 111

844 BOMAG 008 914 20

Assembling the vibrator unit 18.4
162. Insert the gear carefully into the bearing in the
side plate (Fig. 112).

Fig. 112

! Caution
Offset the gear by 9 teeth (Fig. 113).
(9 teeth
i Note
Tooth gap a) Mark on swashing motor
b) Middle of tooth on swashing motor = zero po-
sition
Tooth gap
Feather keywa

Fig. 113
163. Press the gear in until it bottoms (Fig. 114).

Fig. 114
164. Remove the protection ring (Fig. 115).

Fig. 115

008 914 20 BOMAG 845

18.4 Assembling the vibrator unit

165. Assemble the locking disc (1) with socket head

cap screws (2) (Fig. 116).

i Note
Tightening torque 35Nm.

Fig. 116
166. Assemble the cover with a new O-ring (1) (Fig.
117).

i Note
Assemble the O-ring with some grease.

Fig. 117
167. Assemble both acceleration transducers (Fig.
118).

Fig. 118
168. Turn in two guide bolts (1) (Fig. 119).
169. Assemble the new O-ring (2).

i Note
Assemble the O-ring with some grease.
170. Fill the side plate with grease.

Fig. 119

846 BOMAG 008 914 20

Assembling the vibrator unit 18.4
171. Cool down the outer bearing race (1) to -25°C
and press it into the gear cover until it bottoms
(Fig. 120).
172. Assemble circlip (2).

! Caution
Wipe off any ice!

Fig. 120
173. Use an appropriate assembly mandrel tp knock
the seal ring into the gear cover until it bottoms
(Fig. 121).

Fig. 121
174. Assemble the gear cover (1) with hexagon
screws and washers (2) (Fig. 122).
175. Remove the guide bolts (2).

Fig. 122
176. Fill the splined shaft with Optipit (Fig. 123).

Fig. 123

008 914 20 BOMAG 847

18.4 Assembling the vibrator unit

177. Turn the swashing motor againet the left stop

(Fig. 124).
178. Unscrew the socket (3).
179. Screw in the locking screw (1).
180. Lubricate the splined shaft with Optipit.
181. Assemble the new O-ring (2) with grease.

Fig. 124
182. Assemble the swashing motor with radial seal
(Fig. 125).

Fig. 125
183. Fasten the swashing motor with screws and
washers (Fig. 126).

i Note
Install the screws with Loctite 243 .
1. Unscrew the locking screw (1) and turn in the hy-
draulic socket.

Fig. 126
2. Fill the gear with grease, until grease starts to run
out from the bore hole (1) (Fig. 127).
3. Turn in the magnetic plugs (2 and 3) with new
seal rings.

Fig. 127

848 BOMAG 008 914 20

Assembling the vibrator unit 18.4
4. Unscrew the mechanical lock from the side plates
(Fig. 128).
5. Screw the magnetic plug back in with a new seal
ring.

Fig. 128
6. Insert circlip (1) into the groove in the drive shaft
(Fig. 129).
7. Fill the drive shaft with Optipit.
8. Lay the new O-ring (9) into the groove in the drive
shaft (see also (Fig. 28).
9. Lubricate the splined shaft with Optipit.

Fig. 129
10. Insert the drive shaft (Fig. 130).

Fig. 130
11. Cover the motor flange with Hylomar (Fig. 131).

i Note
1) BW 226
2) BW 213

Fig. 131

008 914 20 BOMAG 849

18.4 Assembling the vibrator unit

i Note
(Fig. 132) BW 213
12. Assemble the motor flange with socket head cap
screws and washers (Fig. 132).
13. Screw in the bleeding screw (1).
14. Turn in twplugs (2).

Fig. 132 BW 213

i Note
(Fig. 133) BW 226
15. Assemble the motor flange with socket head cap
screws and washers (Fig. 132).
16. Screw in the bleeding screw (1).

Fig. 133 BW 226

17. Assemble the seal ring (1) (Fig. 134).
18. Lubricate the splined shaft with Optipit.

i Note
(Fig. 134) shows vibration motor BW 226

Fig. 134
19. Assemble the vibration motor with hexagon
screws (1), ball socket (3) and bevelled washers
(2) (Fig. 135).

i Note
(Fig. 135) shows vibration motor BW 226

Fig. 135

850 BOMAG 008 914 20

Installing the exciter unit 18.5
18.5 Installing the exciter unit
! Caution
Fitting and contact surfaces of the connection
between exciter housing and drum must be
absolutely dry and free of grease, oil, paint
and conserving agent.
The tapped bores 2 (Fig. 1) must be free of
grease, oil, paint and conserving agents.
1. Clean the tapped bores (2) on both sides of the
drum and blow them out with compressed air.
2. Clean the contact faces (1) between bearing
flange and drum on both sides.

Fig. 1 3. Clean the inner tube in the drum.

Right drum side

4. Check cylinder roller bearing 1 (Fig. 2) and radial
seal, replace if necessary.
5. Fill the bearing with grease "AUTOL TOP 2000
high temp".
6. Grease the new O-ring and insert it into the bear-
ing housing.
7. Clean the contact face (2).

Fig. 2
8. Attach the lifting tackle to the bearing flange.
9. Turn in two guide bolts (M20) (Fig. 3).

Fig. 3

008 914 20 BOMAG 851

18.5 Installing the exciter unit

! Caution
Oil drain plug and marking on drum (Fig. 4)
must be in line.
10. Insert the bearing flange into the drum.

Fig. 4
11. Assemble the fastening screws (Fig. 5) with
"Loctite blue 243".
12. Unscrew the guide bolt and replace it with a fas-
tening screw.
13. Tighten the screws with washers evenly cross-
wise.

Fig. 5
14. Check the rubber buffers, replace if necessary
(Fig. 6).

Fig. 6
15. Close free tapped bores (only BW213) with
screws and washers (Fig. 7).

Fig. 7

852 BOMAG 008 914 20

Installing the exciter unit 18.5
16. Attach lifting tackle to the drive disc with gearbox,
travel motor and gearbox holder (Fig. 8).

Fig. 8
17. Attach the drive unit to the rubber buffers (Fig. 9).

Fig. 9
18. Fasten the drive unit with nuts and washers (Fig.
10).
19. Remove the lifting tackle.

Fig. 10

008 914 20 BOMAG 853

18.5 Installing the exciter unit

Left drum side

20. Attach the lifting tackle to the exciter unit (Fig. 11).

Fig. 11
21. Grease the new O-ring 1 (Fig. 12) and insert it
into the flanged hub.
22. Clean the contact face (2).

Fig. 12
23. Fill the inner bearing race with grease "AUTOL
TOP 2000 high temp" (Fig. 13).

Fig. 13
24. Insert the vibrator unit into the drum (Fig. 14).

Fig. 14

854 BOMAG 008 914 20

Installing the exciter unit 18.5
! Caution
Oil filler opening and marking on drum (Fig.
15) must be in line.

Fig. 15
25. Assemble the fastening screws (Fig. 16) with
"Loctite blue 243".
26. Remove the lifting tackle.
27. Tighten the screws with washers evenly cross-
wise.

Fig. 16
28. Keep turning the side plate to both directions and
check for resistances while turning (Fig. 17).

! Caution
Replace the bearings if they do not perform
correctly

Fig. 17
29. Unscrew the oil filler plug 1 (Fig. 18) from the
flange.
30. Fill in oil up to the max. capacity .

i Note
For quality and quantity of oil refer to the table of
"fuels, lubricants and filling capacities".
31. Turn the oil filler plug into the flange.

Fig. 18

008 914 20 BOMAG 855

18.5 Installing the exciter unit

32. Attach the lifting tackle to the spacer block with

longitudinal rubber elements (Fig. 19).

!Caution
Observe the assembly direction, arrow up.

i Note
BW213 = 4 Rectangular rubber buffers.
BW226 = 8 Rectangular rubber buffers.

Fig. 19
33. Assemble the rectangular rubber buffer unit to the
side plate with screws, washers and nuts (Fig.
20) (travel direction front).
34. Tighten the screws (1) hand-tight.

Fig. 20

! Danger
Assemble the support.
35. Remove the lifting tackle.

Fig. 21
36. Attach the lifting tackle to the second spacer
block with longitudinal rubber elements (Fig. 22).

!Caution
Observe the assembly direction, arrow up.

i Note
BW213 = 4 Rectangular rubber buffers.
BW226 = 8 Rectangular rubber buffers.

Fig. 22

856 BOMAG 008 914 20

Installing the exciter unit 18.5
37. Assemble the rectangular rubber buffer unit to the
side plate with screws, washers and nuts (Fig.
23) (travel direction rear).
38. Tighten the screws (1) hand-tight.
39. Remove the lifting tackle.
40. Remove the support again.

Fig. 23
41. Assemble the tool to block the rectangular rubber
buffers (Fig. 24).

Fig. 24
42. Tighten the fastening screws (Fig. 25) for the rec-
tangular rubber buffers.
43. Disassemble the tool to block the rectangular rub-
ber buffers.

Fig. 25

008 914 20 BOMAG 857

18.6 Changing the rubber buffers and adjusting the pretension

18.6 Changing the rubber buffers and ad-

justing the pretension
Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buff-
ers and rectangular buffers are relieved of any
load (Fig. 1).
2. Loosen all fastening screws.

Fig. 1
3. Turn one screw each into the welded nuts (Fig. 2)
on the spacer blocks.

Fig. 2
4. Remove the compensation shims (Fig. 3).

Fig. 3

858 BOMAG 008 914 20

Changing the rubber buffers and adjusting the pretension 18.6
5. Unscrew the screws (Fig. 4) from the welded
nuts.

Fig. 4

iNote
Check the rectangular rubber buffers, replace if
necessary.
Observe the assembly direction, arrow up.

Fig. 5
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. 6
Adjusting the pre-load
12. Measure distance "X" between spacer piece and
side plate (Fig. 7).
13. Calculate the thickness of the compensation
plates.

Nominal value:
Distance "X" + 2 mm

Fig. 7

008 914 20 BOMAG 859

18.6 Changing the rubber buffers and adjusting the pretension

14. Turn in screws into each welded nut and provide

sufficient space to insert the compensation plates
(Fig. 8).

Fig. 8
15. Assemble the compensation shims (Fig. 9).

Fig. 9
16. Unscrew the screws (Fig. 10) from the welded
nuts.

Fig. 10
17. Tighten the fastening screws (Fig. 11).
18. Lower the frame again.

Fig. 11

860 BOMAG 008 914 20

Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 18.7
18.7 Special tools, drum BW 213/226 DH-4
BVC and Variocontrol
1. Guide bolt for bearing flange M20 x 200 mm.

Fig. 1
2. Tool to block the rectangular rubber buffers.

Fig. 2
3. Tool to the drive disc with gearbox, travel motor
and gearbox holder.

Fig. 3

008 914 20 BOMAG 861

18.7 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol

4. Tool to take up the exciter unit.

Fig. 4
5. Mechanical fixation, assembly of gearbox cover
with weights pointing downward (vertical ampli-
tude) .

BOMAG part-no.: 955 822 11

Fig. 5
6. Mechanical fixation, adjustment of potentiometer
for horizontal amplitude.

BOMAG part-no.: 955 821 69

Fig. 6
7. Mechanical lock for swashing motor

Fig. 7

862 BOMAG 008 914 20

Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 18.7
8. Auxiliary assembly rings, side plate.

BOMAG part-no.: 972 051 73

Fig. 8
9. Assembly device, radial seal.

Fig. 9
10. Pressing tool, inner races of tapered roller bear-
ings

BOMAG part-no.: 972 051 76

Fig. 10
11. Pressing tool, outer races of tapered roller bear-
ings

BOMAG part-no.: 972 051 75

Fig. 11

008 914 20 BOMAG 863

18.7 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol

12. 3X guide bolts for exciter shaft M27 X 500 mm.

Fig. 12
13. 3X guide bolts for installation of exciter housing
M18X1,5X 300 mm.

Fig. 13
14. Assembly mandrel for radial seal in exciter hous-
ing

Fig. 14
15. Manual screwer

i Note
The manual screwer is equipped with a ratchet.
Short ratchet movements allow very effective
working.

Fig. 15

864 BOMAG 008 914 20

Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 18.7
16. Assembly mandrel for radial seal in bearing
flange

Fig. 16
17. Protection cap for assembling the gear

Fig. 17
18. Puller to disassemble the exciter shaft, exciter
housing right

Fig. 18
19. Puller to disassemble the outer bearing race, ex-
citer housing right

Fig. 19

008 914 20 BOMAG 865

18.7 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol

866 BOMAG 008 914 20

19 Oscillating articulated joint

008 914 20 BOMAG 867

19.1 Special tools

1. Assembly mandrel for rocker bearings (console
of articulated joint).

BOMAG part-no.: 007 211 55

Fig. 1
2. Assembly mandrel for rocker bearings (steering
cylinders).

BOMAG part-no.: 007 211 56

Fig. 2

868 BOMAG 008 914 20

Special tools 19.1

008 914 20 BOMAG 869

19.2 Repair overview oscillating articulated joint

Fig. 1 Oscillating articulated joint

870 BOMAG 008 914 20

Repair overview oscillating articulated joint 19.2

Fig. 2 Cross-sectional drawing 5 Console, rear

1 Four-point bearing 6 Self-aligning bearing
2 Console, front 7 Spacer ring
3 Centring disc 8 Washer
4 O-ring 9 Bolt

008 914 20 BOMAG 871

19.2 Repair overview oscillating articulated joint

Fig. 3 2) Clean the grease nipples and lubricate with

1) Assemble with sliding agent OKS 571 approx. 10 shots from the grease gun.
00970026 (Fig. 3). 3) Slightly oil the bearing seat

872 BOMAG 008 914 20

Repair overview oscillating articulated joint 19.2

Fig. 4 electric steering 3) Roll pin

Assembly of steering angle sensor for elec- 4) Control lever
tric steering (BVC machines) (Fig. 4). 5) Adapter plate
a) Align the marks for assembly.
b) The marks must face in travel direction for- i Note
ward (± 15°) After assembly perform teaching of the end
1) Mounting plate stops for the steering angle sensor (see
electrics of the machine).
2) Steering angle sensor

008 914 20 BOMAG 873

19.3 Removing and installing the oscillating articulated joint

19.3 Removing and installing the oscillat-

ing articulated joint
1. Jack the back of the frame (Fig. 1) up and secure
it with trestles or wooden blocks.
2. Jack the front frame up and secure it with trestles
or wooden blocks.
3. Block drums and wheels with suitable chocks .

Fig. 1
4. Unscrew fastening screws 1 (Fig. 2) and take off
axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).

Fig. 2

! 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. 3).

Fig. 3

874 BOMAG 008 914 20

Removing and installing the oscillating articulated joint 19.3
9. Unscrew fastening screws 1 (Fig. 4).
10. Pull out the oscillating articulated joint.

Fig. 4
Note on assembly
11. Insert the bolt for the steering cylinder so that
groove 2 (Fig. 5) is in line with tapped bores (1).

Fig. 5

008 914 20 BOMAG 875

19.4 Dismantling the oscillating articulated joint

19.4 Dismantling the oscillating articulated

joint
1. Unscrew fastening screws 1 (Fig. 1) and take off
axle holder (2).

! Danger

Danger of squashing!
2. Take out bolt (3).

Fig. 1
3. Unscrew fastening screws 1 (Fig. 2) and take off
axle holder (2).

Fig. 2

! Danger
Danger of squashing!
4. Turn out bolt 1 (Fig. 3) and separate consoles (2
and 3).

Fig. 3

876 BOMAG 008 914 20

Dismantling the oscillating articulated joint 19.4
5. Take spacer ring 1 (Fig. 2) out of the centring
disc.

Fig. 4
6. Unscrew fastening screws 1 (Fig. 3) and take off
the centring disc (2).

Fig. 5
7. Take the O-ring out of the rocker bearing (Fig. 4).

Fig. 6
8. Knock both rocker bearings 1 (Fig. 5) out of con-
sole (2).

Fig. 7

008 914 20 BOMAG 877

19.4 Dismantling the oscillating articulated joint

9. Knock rocker bearings 1 (Fig. 8) out of the steer-

ing cylinder receptacles.

Fig. 8
10. Unscrew fastening screws 1 (Fig. 9) and lift the
front console (2) off the four point bearing (3).
11. Check four point bearing for wear , replace if nec-
essary.

Fig. 9

878 BOMAG 008 914 20

Assembling the oscillating articulated joint 19.5
19.5 Assembling the oscillating articulated
joint
1. Lay the four point bearing 3 (Fig. 1) on a level sur-
face, insert console (2) and fasten with screws (1)
and washers.

Fig. 1
2. Spray the rocker bearings 1 (Fig. 2) with sliding
lacquer OKS 571 and knock them into the corre-
sponding boreholes in the steering cylinder.

Special tools:
Assembly mandrel for rocker bearings (steering
cylinders).

Fig. 2
3. Slightly lubricate the bearings seats and knock
rocker bearings 1 (Fig. 3) into console (2).

Special tools:
Assembly mandrel for rocker bearings (console
of articulated joint).

Fig. 3

008 914 20 BOMAG 879

19.5 Assembling the oscillating articulated joint

4. Grease the new O-rings and insert them into the

rocker bearings (Fig. 2).

Fig. 4
5. Fasten centring discs 2 (Fig. 3) with screws (1).

Fig. 5
6. Insert spacer ring 1 (Fig. 4) into one of the cen-
tring discs.

Fig. 6
7. Spray pin 1 (Fig. 5) with sliding agent OKS 571.

! Caution
Bolt (1) must be knocked in on the side with
spacer ring 1 (Fig. 4).
8. Join both consoles (2 and 3) together and knock
in bolt (1).

Fig. 7

880 BOMAG 008 914 20

Assembling the oscillating articulated joint 19.5
9. Assemble disc 2 (Fig. 8) with screws (1) and
washers.

Fig. 8
10. Spray bolt 3 (Fig. 9) with sliding lacquer OKS 571
and insert it so that groove (2) is in line with
tapped bores (1).

Fig. 9
11. Secure bolt 3 (Fig. 10) with axle holder (2),
screws (1) and washers.

Fig. 10

008 914 20 BOMAG 881

19.5 Assembling the oscillating articulated joint

882 BOMAG 008 914 20

20 Suppliers documentation

008 914 20 BOMAG 883

884 BOMAG 008 914 20
20.1 Travel and vibration pump

008 914 20 BOMAG 885

20.1 Travel and vibration pump

886 BOMAG 008 914 20

Travel and vibration pump 20.1

Series 90 Pumps

Service Manual

008 914 20 BOMAG 887

20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
2EVISIONS

HISTORY OF REVISIONS Table of Revisions

Date Page Changed Rev.

!PRIL 70 4ORQUE FOR ' ' ' ' " " " " CHANGED !"
TO .M ; LBFsFT=
3EPTEMBER - &IRST PRINTING REPLACES ",. !!

¹ 3AUER $ANFOSS !LL RIGHTS RESERVED

3AUER $ANFOSS ACCEPTS NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGS BROCHURES AND OTHER PRINTED MATERIAL
3AUER $ANFOSS RESERVES THE RIGHT TO ALTER ITS PRODUCTS WITHOUT PRIOR NOTICE4HIS ALSO APPLIES TO PRODUCTS
ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS ARENT IN CONmICT WITH AGREED SPECIlCATIONS !LL TRADEMARKS IN
THIS MATERIAL ARE PROPERTIES OF THEIR RESPECTIVE OWNERS 3AUER $ANFOSS AND THE 3AUER $ANFOSS LOGOTYPE ARE
TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP
&RONT COVER ILLUSTRATIONS & & &

2 520L0818 s 2EV !" s !PRIL 2008

888 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
#ONTENTS

INTRODUCTION /VERVIEW

7ARRANTY
'ENERAL INSTRUCTIONS
3AFETY PRECAUTIONS 7
5NINTENDED MACHINE MOVEMENT 7
&LAMMABLE CLEANING SOLVENTS 7
&LUID UNDER PRESSURE 7
0ERSONAL SAFETY 7
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE 8
$ESIGN 9
4HE SYSTEM CIRCUIT0

OPERATION #HARGE PUMP2

#HARGE RELIEF VALVE2
-ULTI FUNCTION VALVES 2
0RESSURE LIMITER AND HIGH PRESSURE RELIEF VALVES
3YSTEM CHECK VALVES
"YPASS VALVES
3PEED SENSORS
&ILTRATION OPTIONS
0RESSURE OVERRIDE 0/2 n FRAME SIZE ONLY
-ANUAL DISPLACEMENT CONTROL -$#
.ON LINEAR -$#
3OLENOID OVERRIDE VALVE FOR -$#
.EUTRAL START SWITCH .33
(YDRAULIC DISPLACEMENT CONTROL ($#
%LECTRIC DISPLACEMENT CONTROL %$#
!UTOMOTIVE CONTROL &"! )) "
0OSITION &.2 ELECTRIC CONTROL

OPERATING /VERVIEW

PARAMETERS )NPUT SPEED
3YSTEM PRESSURE
#HARGE PRESSURE7
#HARGE INLET PRESSURE7
#ASE PRESSURE7
4EMPERATURE AND VISCOSITY8
4EMPERATURE 8
6ISCOSITY8
&LUID AND lLTER RECOMMENDATIONS9

TECHNICAL /VERVIEW 20

SPECIFICATIONS &EATURES AND OPTIONS 20
/PERATING PARAMETERS 20
&LUID SPECIlCATIONS 20

520L0818 s 2EV !" s !PRIL 2008 3

008 914 20 BOMAG 889
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
#ONTENTS

INITIAL STARTUP 'ENERAL 2

PROCEDURES 3TART UP PROCEDURE 2

PRESSURE 2EQUIRED TOOLS 2

MEASUREMENTS 0ORT LOCATIONS AND GAUGE INSTALLATION2

TROUBLESHOOTING /VERVIEW 2

.EUTRAL DIFlCULT OR IMPOSSIBLE TO lND2
3YSTEM OPERATING HOT 2
4RANSMISSION OPERATES NORMALLY IN ONE DIRECTION ONLY 27
3YSTEM WILL NOT OPERATE IN EITHER DIRECTION27
,OW MOTOR OUTPUT TORQUE 28
)MPROPER MOTOR OUTPUT SPEED28
3YSTEM NOISE OR VIBRATION28
3YSTEM RESPONSE IS SLUGGISH29

ADJUSTMENTS 3TANDARD PROCEDURES INSPECTIONS AND ADJUSTMENTS 0

!DJUSTMENTS
#HARGE PRESSURE RELIEF VALVE ADJUSTMENT
-ULTI FUNCTION VALVE PRESSURE ADJUSTMENT
%NGAGING THE BYPASS FUNCTION
0RESSURE OVERRIDE 0/2 VALVE PRESSURE ADJUSTMENT OPTION FOR FRAME SIZE
$ISPLACEMENT LIMITER ADJUSTMENT7
3TANDARD MANUAL DISPLACEMENT CONTROL -$# ADJUSTMENT7
.ON LINEAR MANUAL DISPLACEMENT CONTROL -$# 8
-$# NEUTRAL START SWITCH .33 ADJUSTMENTS 9
.EUTRAL START SWITCH ECCENTRIC PLUG ADJUSTMENT CONDITION I
.33 DEADBAND ADJUSTMENT CONDITIONS II III 2
#HECKING SWITCH CONTINUITY
(YDRAULIC DISPLACEMENT CONTROL ($# AND ELECTRIC DISPLACEMENT CONTROL %$#
ADJUSTMENT
3PEED SENSOR ADJUSTMENT

4 520L0818 s 2EV !" s !PRIL 2008

890 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
#ONTENTS

MINOR REPAIR 3TANDARD PROCEDURES 7

3HAFT SEAL AND SHAFT REPLACEMENT8
-ULTI FUNCTION VALVE CARTRIDGES0
-ULTI FUNCTION VALVE CARTRIDGES PRE 2
0RESSURE OVERRIDE VALVE OPTION FOR FRAME SIZE
#HARGE PRESSURE RELIEF VALVE
!UXILIARY PAD
#HARGE PUMP
!DDING AN !UXILIARY PAD TO A PUMP PREVIOUSLY WITHOUT ONE8
)NTEGRAL CHARGE PRESSURE lLTER REPLACEMENT 9
0UMP CONTROL COVER PLATE0
$ISPLACEMENT CONTROL ORIlCES
$ISPLACEMENT CONTROL ORIlCE CHECK VALVE
$ISPLACEMENT CONTROL ADAPTER PLATE EARLY PRODUCTION PUMPS ONLY
-ANUAL DISPLACEMENT CONTROL -$# 2
3OLENOID OVERRIDE VALVE FOR -$#
3OLENOID OVERRIDE VALVE FOR -$# WITH PRESSURE RELEASED BRAKE
(YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS
0RESSURE CONTROL PILOT 0#0 FOR ELECTRIC DISPLACEMENT CONTROL %$#
0OSITION &.2 ELECTRIC CONTROL 7
$ISPLACEMENT CONTROL lLTER SCREENS8
3PEED SENSOR8

TORQUE CHART &ASTENER SIZE AND TORQUE CHART 9

0LUG SIZE AND TORQUE CHART 70
&ASTENERS AND PLUGS70

520L0818 s 2EV !" s !PRIL 2008 5

008 914 20 BOMAG 891
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

OVERVIEW 4HIS MANUAL INCLUDES INFORMATION FOR THE INSTALLATION MAINTENANCE AND MINOR REPAIR OF
3ERIES AXIAL PISTON CLOSED CIRCUIT PUMPS )T INCLUDES A DESCRIPTION OF THE UNIT AND ITS
INDIVIDUAL COMPONENTS TROUBLESHOOTING INFORMATION AND MINOR REPAIR PROCEDURES

0ERFORMING MINOR REPAIRS REQUIRES YOU REMOVE THE UNIT FROM THE VEHICLEMACHINE
4HOROUGHLY CLEAN THE UNIT BEFORE BEGINNING MAINTENANCE OR REPAIR ACTIVITIES 3INCE DIRT
AND CONTAMINATION ARE THE GREATEST ENEMIES OF ANY TYPE OF HYDRAULIC EQUIPMENT FOLLOW
CLEANLINESS REQUIREMENTS STRICTLY4HIS IS ESPECIALLY IMPORTANT WHEN CHANGING THE SYSTEM
lLTER AND WHEN REMOVING HOSES OR PLUMBING

! WORLDWIDE NETWORK OF 3AUER $ANFOSS 'LOBAL 3ERVICE 0ARTNERS '30S IS AVAILABLE FOR
MAJOR REPAIRS 3AUER $ANFOSS TRAINS '30S AND CERTIlES THEIR FACILITIES ON A REGULAR BASIS
9OU CAN LOCATE YOUR NEAREST !3# USING THE DISTRIBUTOR LOCATOR AT WWWSAUER DANFOSSCOM
#LICK ON THE Sales and Service LINK

WARRANTY 0ERFORMING INSTALLATION MAINTENANCE AND MINOR REPAIRS ACCORDING TO THE PROCEDURES IN
THIS MANUAL WILL NOT AFFECT YOUR WARRANTY -AJOR REPAIRS REQUIRING THE REMOVAL OF A UNITS
REAR OR SIDE COVER VOIDS THE WARRANTY UNLESS DONE BY A 3AUER $ANFOSS !UTHORIZED 3ERVICE
#ENTER

GENERAL INSTRUCTIONS &OLLOW THESE GENERAL PROCEDURES WHEN REPAIRING 3ERIES VARIABLE DISPLACEMENT CLOSED
CIRCUIT PUMPS

w Remove the unit

0RIOR TO PERFORMING MAJOR REPAIRS REMOVE THE UNIT FROM THE VEHICLEMACHINE #HOCK
THE WHEELS ON THE VEHICLE OR LOCK THE MECHANISM TO INHIBIT MOVEMENT "E AWARE THAT
HYDRAULIC mUID MAY BE UNDER HIGH PRESSURE ANDOR HOT )NSPECT THE OUTSIDE OF THE PUMP
AND lTTINGS FOR DAMAGE #AP HOSES AFTER REMOVAL TO PREVENT CONTAMINATION

e Keep it clean
#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY PUMP LIFE ON EITHER NEW OR
REPAIRED UNITS #LEAN THE OUTSIDE OF THE PUMP THOROUGHLY BEFORE DISASSEMBLY4AKE CARE
TO AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS BY USING A CLEAN SOLVENT WASH
AND AIR DRYING IS USUALLY ADEQUATE

!S WITH ANY PRECISION EQUIPMENT KEEP ALL PARTS FREE OF FOREIGN MATERIALS AND CHEMICALS
0ROTECT ALL EXPOSED SEALING SURFACES AND OPEN CAVITIES FROM DAMAGE AND FOREIGN MATERIAL
)F LEFT UNATTENDED COVER THE PUMP WITH A PROTECTIVE LAYER OF PLASTIC

d Replace all O-rings and gaskets

5SE NEW / RINGS AND GASKETS DURING REASSEMBLY ,IGHTLY LUBRICATE ALL / RINGS WITH CLEAN
PETROLEUM JELLY PRIOR TO ASSEMBLY

t Secure the unit

&OR REPAIR PLACE THE UNIT IN A STABLE POSITION WITH THE SHAFT POINTING DOWNWARD )T WILL BE
NECESSARY TO SECURE THE PUMP WHILE REMOVING AND TORQUING END COVERS CONTROLS AND
VALVES

6 520L0818 s 2EV !" s !PRIL 2008

892 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

SAFETY PRECAUTIONS !LWAYS CONSIDER SAFETY PRECAUTIONS BEFORE BEGINNING A SERVICE PROCEDURE 0ROTECT
YOURSELF AND OTHERS FROM INJURY4AKE THE FOLLOWING GENERAL PRECAUTIONS WHENEVER SERVICING A
HYDRAULIC SYSTEM

Unintended machine movement

W Warning
5NINTENDED MOVEMENT OF THE MACHINE OR MECHANISM MAY CAUSE INJURY TO THE TECHNICIAN
OR BYSTANDERS4O PROTECT AGAINST UNINTENDED MOVEMENT SECURE THE MACHINE OR DISABLE
DISCONNECT THE MECHANISM WHILE SERVICING

Flammable cleaning solvents

W Warning
3OME CLEANING SOLVENTS ARE mAMMABLE4O AVOID POSSIBLE lRE DO NOT USE CLEANING
SOLVENTS IN AN AREA WHERE A SOURCE OF IGNITION MAY BE PRESENT

Fluid under pressure

W Warning
%SCAPING HYDRAULIC mUID UNDER PRESSURE CAN HAVE SUFlCIENT FORCE TO PENETRATE YOUR SKIN
CAUSING SERIOUS INJURY ANDOR INFECTION4HIS mUID MAY ALSO BE HOT ENOUGH TO CAUSE BURNS
5SE CAUTION WHEN DEALING WITH HYDRAULIC mUID UNDER PRESSURE 2ELIEVE PRESSURE IN THE
SYSTEM BEFORE REMOVING HOSES lTTINGS GAUGES OR COMPONENTS .EVER USE YOUR HAND
OR ANY OTHER BODY PART TO CHECK FOR LEAKS IN A PRESSURIZED LINE 3EEK MEDICAL ATTENTION
IMMEDIATELY IF YOU ARE CUT BY HYDRAULIC mUID

Personal safety
W Warning
0ROTECT YOURSELF FROM INJURY 5SE PROPER SAFETY EQUIPMENT INCLUDING SAFETY GLASSES AT ALL
TIMES

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20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

SYMBOLS USED IN  7!2.).' MAY RESULT IN INJURY  4IP HELPFUL SUGGESTION

SAUER-DANFOSS
LITERATURE  #!54)/. MAY RESULT IN DAMAGE TO  ,UBRICATE WITH CLEAN HYDRAULIC mUID
PRODUCT OR PROPERTY
 !PPLY GREASEPETROLEUM JELLY
 2EUSABLE PART
 !PPLY LOCKING COMPOUND
 .ON REUSABLE PART USE A NEW PART
 )NSPECT FOR WEAR OR DAMAGE
 .ON REMOVABLE ITEM
 #LEAN AREA OR PART
 /PTION n EITHER PART MAY EXIST
 "E CAREFUL NOT TO SCRATCH OR DAMAGE
 3UPERSEDED n PARTS ARE NOT
INTERCHANGEABLE  .OTE CORRECT ORIENTATION

 -EASUREMENT REQUIRED  -ARK ORIENTATION FOR REINSTALLATION

 &LATNESS SPECIlCATION  4ORQUE SPECIlCATION

 0ARALLELISM SPECIlCATION  0RESS IN n PRESS lT

 %XTERNAL HEX HEAD  0ULL OUT WITH TOOL n PRESS lT

 )NTERNAL HEX HEAD  #OVER SPLINES WITH INSTALLATION

sleeve
 4ORX HEAD
 0RESSURE MEASUREMENTGAUGE
 / RING BOSS PORT LOCATION OR SPECIlCATION

4HE SYMBOLS ABOVE APPEAR IN THE ILLUSTRATIONS AND TEXT OF THIS MANUAL4HEY ARE INTENDED
TO COMMUNICATE HELPFUL INFORMATION AT THE POINT WHERE IT IS MOST USEFUL TO THE READER
)N MOST INSTANCES THE APPEARANCE OF THE SYMBOL ITSELF DENOTES ITS MEANING4HE LEGEND
ABOVE DElNES EACH SYMBOL AND EXPLAINS ITS PURPOSE

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Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

DESIGN 3AUER $ANFOSS 3ERIES CLOSED CIRCUIT PISTON PUMPS CONVERT INPUT TORQUE INTO HYDRAULIC
POWER4HE INPUT SHAFT TRANSMITS ROTATIONAL FORCE TO THE CYLINDER BLOCK "EARINGS SUPPORT
THE INPUT SHAFT AT THE FRONT AND REAR OF THE PUMP4HE SHAFT IS SPLINED INTO THE CYLINDER
BLOCK ! LIP SEAL AT THE FRONT END OF THE PUMP PREVENTS LEAKAGE WHERE THE SHAFT EXITS
THE PUMP HOUSING4HE SPINNING CYLINDER BLOCK CONTAINS NINE RECIPROCATING PISTONS !
BALL JOINT AT ONE END CONNECTS EACH PISTON TO A BRASS SLIPPER &IXED CLEARANCE HOLD DOWN
BRACKETS KEEP THE SLIPPERS IN CONTACT WITH THE SWASHPLATE4HE RECIPROCATING MOVEMENT
OF THE PISTONS OCCURS AS THE SLIPPERS SLIDE AGAINST THE INCLINED SWASHPLATE DURING ROTATION
4HE VALVE PLATE CONNECTS ONE HALF OF THE CYLINDER BLOCK TO LOW PRESSURE AND THE OTHER
HALF TO HIGH PRESSURE !S EACH PISTON CYCLES IN AND OUT OF ITS BORE mUID IS DRAWN FROM THE
INLET AND DISPLACED TO THE OUTLET THEREBY IMPARTING HYDRAULIC POWER INTO THE SYSTEM !
SMALL AMOUNT OF mUID mOWS FROM THE CYLINDER BLOCKVALVE PLATE AND SLIPPERSWASHPLATE
INTERFACES FOR LUBRICATION AND COOLING #ASE DRAIN PORTS RETURN THIS mUID TO THE RESERVOIR

4HE ANGLE OF THE SWASHPLATE CONTROLS THE VOLUME OF mUID DISPLACED INTO THE SYSTEM4HE
SERVO PISTON FORCES THE SWASHPLATE INTO AN INCLINED POSITION4HE PUMP CONTROL ACTING
ON INPUT FROM THE OPERATOR BY MODULATING PRESSURE BALANCE ACROSS THE SERVO PISTON SETS
DISPLACEMENT IN THE SYSTEM CIRCUIT

Cross section
Piston
Slipper
Displacement control
Slider block Servo arm
Servo piston

Feedback linkage

Cradle bearing
Bushing

Cylinder block Roller bearing

Shaft
Valve plate seal

Rear
bushing

Input shaft

Charge pump Swashplate Cradle guide P106 648E

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20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

THE SYSTEM CIRCUIT The basic closed circuit Basic closed circuit diagram
(YDRAULIC LINES CONNECT THE MAIN PORTS
OF THE PUMP TO THE MAIN PORTS OF THE
MOTOR &LUID mOWS IN EITHER DIRECTION
FROM THE PUMP TO THE MOTOR THEN BACK
Reservoir
TO THE PUMP IN THIS CLOSED CIRCUIT %ITHER
OF THE HYDRAULIC LINES CAN BE UNDER HIGH Input PV MF Output
PRESSURE )N PUMPING MODE THE POSITION
OF THE PUMP SWASHPLATE DETERMINES
WHICH LINE IS HIGH PRESSURE AS WELL AS THE
DIRECTION OF mUID mOW
Flow (Bi-directional)

Case drain line

P104 120E

Case drain and heat exchanger

4HE PUMP AND MOTOR REQUIRE CASE DRAIN LINES TO REMOVE HOT mUID FROM THE SYSTEM
4HE TOPMOST PORT DRAINS THE MOTOR TO ENSURE THE CASE REMAINS FULL OF mUID &LUID ROUTES
THROUGH THE LOWER DRAIN PORT ON THE PUMP AND OUT THE TOPMOST PORT TO THE RESERVOIR
! HEAT EXCHANGER WITH A BYPASS VALVE COOLS THE CASE DRAIN mUID BEFORE IT RETURNS TO THE
RESERVOIR

System circuit diagram

Control handle Displacement control valve

Heat exchanger bypass valve

Reservoir
Orificed check
valve Vacuum gauge

Heat exchanger
Purge relief valve
Charge pressure relief valve P102 000

Reversible variable Servo control cylinder Multi-function valve Fixed displacement motor
displacement pump

To
pump
case
Servo
pressure
relief valves

Charge pump
Input shaft Output shaft
Multi-function valve Motor swashplate
Pump swashplate
Servo control cylinder Loop flushing valve

Pump Motor

Working loop (high pressure) Working loop (low pressure) Suction line Control fluid Case drain fluid

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3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

THE SYSTEM CIRCUIT

(continued)

Pump schematic

X5
A

M5
M4

L1 S L2

P104 126E

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20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATION

CHARGE PUMP 4HE CHARGE PUMP IS NECESSARY TO SUPPLY Pump charge system
COOL mUID TO THE SYSTEM TO MAINTAIN
Case
POSITIVE PRESSURE IN THE MAIN SYSTEM drain Charge relief valve
line
LOOP TO PROVIDE PRESSURE TO OPERATE System
check
THE CONTROL SYSTEM AND TO MAKE UP FOR valves
INTERNAL LEAKAGE #HARGE PRESSURE MUST Input PV PF
BE AT ITS SPECIlED PRESSURE UNDER ALL Charge
pump
CONDITIONS TO PREVENT DAMAGE TO THE
TRANSMISSION
4HE CHARGE PUMP IS A lXED
DISPLACEMENT GEROTOR TYPE PUMP DRIVEN Inlet filter
OFF THE MAIN PUMP SHAFT4HE CHARGE Tank P104 121E
RELIEF VALVE LIMITS CHARGE PRESSURE

CHARGE RELIEF VALVE 4HE CHARGE RELIEF VALVE ON THE PUMP Charge pressure relief valve
MAINTAINS CHARGE PRESSURE AT A
DESIGNATED LEVEL ! DIRECT ACTING
POPPET VALVE RELIEVES mUID WHEN CHARGE
PRESSURE REACHES A CERTAIN LEVEL4HIS
LEVEL IS NOMINALLY SET REFERENCING CASE
PRESSURE AT RPM4HIS NOMINAL
SETTING ASSUMES THE PUMP IS IN NEUTRAL
ZERO mOW )N FORWARD OR REVERSE CHARGE
PRESSURE IS LOWER4HE PUMP MODEL CODE
SPECIlES THE CHARGE RELIEF VALVE SETTING
Charge pressure P106 157E

MULTI-FUNCTION VALVES 4HE MULTI FUNCTION VALVE INCORPORATES Multi-function valve

THE SYSTEM CHECK VALVE THE PRESSURE
LIMITER VALVE THE HIGH PRESSURE RELIEF High pressure
Pressure limiter housing relief / check Check valve
VALVE AND THE BYPASS VALVE IN A Pressure limiter valve poppet poppet
REPLACEABLE CARTRIDGE4HESE FUNCTIONS lock nut

ARE DESCRIBED SEPARATELY4HERE ARE TWO Pressure limiter

MULTI FUNCTION VALVE CARTRIDGES IN EACH adjustment screw

3ERIES PUMP TO HANDLE FUNCTIONS

Bypass
IN EITHER DIRECTION 3EE CORRESPONDING actuator Pressure limiter
Bypass
P104 122E
SECTIONS FOR ADJUSTMENTS AND REPAIRS valve poppet

3OME MULTI FUNCTION VALVES DO NOT INCLUDE A PRESSURE LIMITER VALVE

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3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATION

PRESSURE LIMITER AND 3ERIES PUMPS HAVE A SEQUENCED Circuit diagram showing pressure
HIGH PRESSURE RELIEF PRESSURE LIMITING SYSTEM AND HIGH control mechanism
VALVES PRESSURE RELIEF VALVES7HEN THE SYSTEM
To control
PRESSURE REACHES THE PRESET THE PRESSURE
LIMITER SYSTEM RAPIDLY DE STROKES THE Multi-function valve
PUMP TO LIMIT SYSTEM PRESSURE &OR
UNUSUALLY RAPID LOAD APPLICATION THE Servo piston Bypass
adjustment
HIGH PRESSURE RELIEF VALVE IMMEDIATELY Port "A"
LIMITS SYSTEM PRESSURE BY CROSS PORTING Servo Pres.
Relief Valve
SYSTEM mOW4HE PRESSURE LIMITER VALVE
Port "B"
ACTS AS THE PILOT FOR THE HIGH PRESSURE
Servo piston Charge
RELIEF VALVE SPOOL4HE HIGH PRESSURE pressure
RELIEF VALVE IS SEQUENCED TO OPERATE AT relief valve

APPROXIMATELY BAR PSI ABOVE THE Multi-function valve

LEVEL THAT INITIATES THE PRESSURE LIMITER P104 123E

VALVE

&OR SOME APPLICATIONS SUCH AS DUAL PATH VEHICLES THE PRESSURE LIMITER FUNCTION MAY BE
DEFEATED SO THAT ONLY THE HIGH PRESSURE RELIEF VALVE FUNCTION REMAINS

SYSTEM CHECK VALVES 4HE SYSTEM CHECK VALVES ALLOW PRESSURIZED mOW FROM THE CHARGE PUMP TO ENTER THE LOW
PRESSURE SIDE OF THE LOOP4HIS IS NEEDED AS THE PUMP GENERALLY LOSES SYSTEM PRESSURE
DUE TO LUBRICATIONCOOLING mOW AND OTHER FACTORS 3INCE THE PUMP OPERATES IN EITHER
DIRECTION THE SYSTEM USES TWO CHECK VALVES TO DIRECT THE CHARGE SUPPLY INTO THE LOW
PRESSURE LINES4HE SYSTEM CHECK VALVES ARE PART OF THE MULTI FUNCTION VALVE ASSEMBLY

BYPASS VALVES 9OU CAN OPERATE THE BYPASS VALVES TO MOVE THE VEHICLE OR MECHANICAL FUNCTION WHEN THE
PUMP IS NOT RUNNING -ANUALLY RESETTING THE VALVE POSITION OPENS THE VALVE4HE BYPASS
VALVES ARE BUILT INTO THE MULTI FUNCTION VALVES

SPEED SENSORS !N OPTIONAL SPEED SENSOR CAN PROVIDE UNIT SPEED INFORMATION4HE SENSOR READS A
MAGNETIC RING ON THE UNITS CYLINDER BLOCK 3EE THE CORRESPONDING SECTION TO LOCATE
INSTALL AND ADJUST THE SPEED SENSOR

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20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATION

FILTRATION OPTIONS 3ERIES PUMPS MAY HAVE EITHER SUCTION Suction ﬁltration
OR CHARGE PRESSURE lLTRATION TO lLTER THE # !

mUID ENTERING THE CIRCUIT

Suction ﬁltration – option S

4HE SUCTION lLTER IS IN THE CIRCUIT BETWEEN
THE RESERVOIR AND THE INLET TO THE CHARGE
" !!
PUMP AS SHOWN BELOW4HE USE OF A lLTER

CONTAMINATION MONITOR IS RECOMMENDED

Charge pressure ﬁltration – option R, Charge pressure ﬁltration

T, P, and L Screen
4HE PRESSURE lLTER CAN BE MOUNTED
ON THE PUMP OR REMOTELY FOR EASE OF Hydraulic fluid reservoir
Adjustable
SERVICING9OU WILL TYPICALLY lND A charge pressure
relief valve
M MESH SCREEN IN THE RESERVOIR OR
Charge pump
THE CHARGE INLET4HIS SYSTEM REQUIRES A
lLTER CAPABLE OF WITHSTANDING CHARGE Filter
To low To pump case
PRESSURE REFERENCE TO ATMOSPHERE ADD pressure
CASE PRESSURE side and
P102 004E
control

PRESSURE OVERRIDE 4HE 0RESSURE /VER2IDE VALVE 0/2 POR-Valve (180 frame size only)
(POR) – 180 FRAME SIZE MODULATES CONTROL PRESSURE TO MAINTAIN To control
ONLY A PUMP DISPLACEMENT WHICH PRODUCES A
SYSTEM PRESSURE LEVEL LESS THAN OR EQUAL
TO THE 0/2 SETTING &OR UNUSUALLY RAPID Multi-function valve

LOAD APPLICATION THE HIGH PRESSURE RELIEF Pressure

Bypass
VALVE FUNCTION OF THE MULTI FUNCTION override control valve
adjustment
VALVES IS AVAILABLE TO ALSO LIMIT THE Port "A"

PRESSURE LEVEL Shuttle

valve
Port "B"

4HE PRESSURE OVERRIDE CONSISTS OF A THREE

WAY NORMALLY OPEN VALVE WHICH OPERATES
IN SERIES WITH THE PUMP DISPLACEMENT Multi-function valve
Charge pressure
CONTROL #ONTROL SUPPLY PRESSURE NORMALLY relief valve
PORTS THROUGH THE 0/2 VALVE TO THE P104 124E
DISPLACEMENT CONTROL VALVE )F THE SYSTEM
DEMANDS A PRESSURE ABOVE THE OVERRIDE
SETTING THE 0/2 VALVE OVERRIDES THE
CONTROL BY REDUCING THE PRESSURE TO THE DISPLACEMENT CONTROL !S THE CONTROL PRESSURE
REDUCES THE INTERNAL FORCES ROTATING THE SWASHPLATE OVERCOME THE FORCE OF THE SERVO
PISTONS AND DECREASES THE PUMPS DISPLACEMENT

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3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATION

MANUAL DISPLACEMENT 4HE MANUAL DISPLACEMENT CONTROL CONVERTS A MECHANICAL INPUT SIGNAL TO A HYDRAULIC
CONTROL (MDC) SIGNAL USING A SPRING CENTERED FOUR WAY SERVO VALVE4HIS VALVE PORTS HYDRAULIC PRESSURE
TO EITHER SIDE OF A DUAL ACTING SERVO PISTON4HE SERVO PISTON ROTATES THE CRADLE
SWASHPLATE THROUGH AN ANGULAR ROTATION OF ¼² VARYING THE PUMPS DISPLACEMENT FROM
FULL IN ONE DIRECTION TO FULL IN THE OPPOSITE DIRECTION4HE ANGULAR POSITION OF THE PUMP
SWASHPLATE IS PROPORTIONAL TO THE ROTATION OF THE CONTROL INPUT SHAFT

NON-LINEAR MDC 4HE NON LINEAR MANUAL DISPLACEMENT CONTROL OPERATES IN THE SAME MANNER EXCEPT THAT IT
IS DESIGNED SO THE CHANGE IN THE ANGULAR POSITION OF THE PUMP SWASHPLATE PROGRESSIVELY
INCREASES AS THE CONTROL INPUT SHAFT IS ROTATED TOWARD ITS MAXIMUM DISPLACEMENT POSITION

SOLENOID OVERRIDE ! SOLENOID OVERRIDE VALVE OPTION IS AVAILABLE FOR THE -$#4HIS SAFETY FEATURE RETURNS THE
VALVE FOR MDC SWASHPLATE TO ZERO DISPLACEMENT )T IS AVAILABLE IN NORMALLY OPEN ACTIVATE TO ALLOW OR
NORMALLY CLOSED ACTIVATE TO DISALLOW OPTIONS

NEUTRAL START SWITCH 4HE NEUTRAL START SWITCH IS AN OPTIONAL FEATURE AVAILABLE WITH THE -$#7HEN CONNECTED
(NSS) PROPERLY WITH THE VEHICLES ELECTRICAL SYSTEM THE NEUTRAL START SWITCH ENSURES THAT THE
PRIME MOVER CAN START ONLY WHEN THE CONTROL IS IN NEUTRAL POSITION

HYDRAULIC 4HE HYDRAULIC DISPLACEMENT CONTROL USES A HYDRAULIC INPUT SIGNAL TO OPERATE A SPRING
DISPLACEMENT CENTERED FOUR WAY SERVO VALVE4HIS VALVE PORTS HYDRAULIC PRESSURE TO EITHER SIDE OF A
CONTROL (HDC) DUAL ACTING SERVO PISTON4HE SERVO PISTON ROTATES THE CRADLE SWASHPLATE THROUGH AN
ANGULAR ROTATION OF ¼² THUS VARYING THE PUMPS DISPLACEMENT FROM FULL DISPLACEMENT IN
ONE DIRECTION TO FULL DISPLACEMENT IN THE OPPOSITE DIRECTION4HE ANGULAR POSITION OF THE
PUMP SWASHPLATE IS PROPORTIONAL TO INPUT PRESSURE

ELECTRIC DISPLACEMENT 4HE ELECTRIC DISPLACEMENT CONTROL USES A 0RESSURE #ONTROL 0ILOT 0#0 VALVE TO MODULATE
CONTROL (EDC) PRESSURE BALANCE ACROSS THE SPRING CENTERED FOUR WAY SERVO VALVE4HE 0#0 VALVE
CONVERTS A $# ELECTRICAL INPUT SIGNAL TO A HYDRAULIC SIGNAL4HE SERVO VALVE PORTS HYDRAULIC
PRESSURE TO EITHER SIDE OF A DUAL ACTING SERVO PISTON4HE SERVO PISTON ROTATES THE
SWASHPLATE THROUGH AN ANGULAR ROTATION OF ¼² VARYING THE PUMPS DISPLACEMENT4HE
ANGULAR POSITION OF THE SWASHPLATE IS PROPORTIONAL TO THE %$# INPUT

AUTOMOTIVE CONTROL 4HE AUTOMOTIVE CONTROL ALLOWS THE OPERATOR TO DRIVE A VEHICLE SIMILAR TO AN AUTOMOBILE
(FBA II B) WITH AN AUTOMATIC TRANSMISSION4HE AUTOMOTIVE CONTROL INCLUDES A THREE POSITION
ELECTRIC CONTROL TO PROVIDE DIRECTION CONTROL

3-POSITION (FNR) 4HIS CONTROL UTILIZES A OR 6DC ELECTRICALLY OPERATED SPOOL VALVE TO PORT PRESSURE TO
ELECTRIC CONTROL EITHER SIDE OF THE PUMP SERVO PISTON %NERGIZING ONE OF THE SOLENOIDS CAUSES THE PUMP
TO GO TO ITS MAXIMUM DISPLACEMENT IN THE CORRESPONDING DIRECTION !LL FUNCTIONS OF THE
THREE POSITION &.2 ELECTRIC CONTROL ARE PRESET AT THE FACTORY

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20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATING PARAMETERS

OVERVIEW 4HIS SECTION DElNES THE OPERATING PARAMETERS AND LIMITATIONS FOR 3ERIES PUMPS WITH
REGARD TO INPUT SPEEDS AND PRESSURES &OR ACTUAL PARAMETERS REFER TO THE OPERATING
PARAMETERS FOR EACH DISPLACEMENT

INPUT SPEED Minimum speed IS THE LOWEST INPUT SPEED RECOMMENDED DURING ENGINE IDLE CONDITION
/PERATING BELOW MINIMUM SPEED LIMITS THE PUMPS ABILITY TO MAINTAIN ADEQUATE mOW FOR
LUBRICATION AND POWER TRANSMISSION

Continuous speed IS THE HIGHEST INPUT SPEED RECOMMENDED AT FULL POWER CONDITION
/PERATING AT OR BELOW THIS SPEED SHOULD YIELD SATISFACTORY PRODUCT LIFE

Maximum speed IS THE HIGHEST OPERATING SPEED PERMITTED %XCEEDING MAXIMUM SPEED
REDUCES PRODUCT LIFE AND CAN CAUSE LOSS OF HYDROSTATIC POWER AND BRAKING CAPACITY .EVER
EXCEED THE MAXIMUM SPEED LIMIT UNDER ANY OPERATING CONDITIONS

7HEN DETERMINING SPEED LIMITS FOR A PARTICULAR APPLICATION SEE 3AUER $ANFOSS
PUBLICATION BLN-9884 Pressure and speed limits

W7ARNING
Unintended vehicle or machine movement hazard
%XCEEDING MAXIMUM SPEED MAY CAUSE A LOSS OF HYDROSTATIC DRIVE LINE POWER AND BRAKING
CAPACITY9OU MUST PROVIDE A BRAKING SYSTEM REDUNDANT TO THE HYDROSTATIC TRANSMISSION
SUFlCIENT TO STOP AND HOLD THE VEHICLE OR MACHINE IN THE EVENT OF HYDROSTATIC DRIVE POWER
LOSS

SYSTEM PRESSURE System pressure IS THE DIFFERENTIAL PRESSURE BETWEEN SYSTEM PORTS ! AND " )T IS THE
DOMINANT OPERATING VARIABLE AFFECTING HYDRAULIC UNIT LIFE (IGH SYSTEM PRESSURE WHICH
RESULTS FROM HIGH LOAD REDUCES EXPECTED LIFE 3YSTEM PRESSURE MUST REMAIN AT OR BELOW
CONTINUOUS PRESSURE DURING NORMAL OPERATION TO ACHIEVE EXPECTED LIFE

Continuous pressure IS THE AVERAGE REGULARLY OCCURRING OPERATING PRESSURE /PERATING

AT OR BELOW THIS PRESSURE SHOULD YIELD SATISFACTORY PRODUCT LIFE

Maximum pressure IS THE HIGHEST INTERMITTENT PRESSURE ALLOWED -AXIMUM MACHINE

LOAD SHOULD NEVER EXCEED THIS PRESSURE &OR ALL APPLICATIONS THE LOAD SHOULD MOVE BELOW
THIS PRESSURE

!LL PRESSURE LIMITS ARE DIFFERENTIAL PRESSURES REFERENCED TO LOW LOOP CHARGE PRESSURE
3UBTRACT LOW LOOP PRESSURE FROM GAUGE READINGS TO COMPUTE THE DIFFERENTIAL

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3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATING PARAMETERS

CHARGE PRESSURE !N INTERNAL CHARGE RELIEF VALVE REGULATES CHARGE PRESSURE4HE CHARGE PUMP SUPPLIES THE
CONTROL WITH PRESSURE TO OPERATE THE SWASHPLATE AND TO MAINTAIN A MINIMUM PRESSURE IN
THE LOW SIDE OF THE TRANSMISSION LOOP

Minimum charge pressure IS THE LOWEST PRESSURE ALLOWED TO MAINTAIN A SAFE WORKING
CONDITION IN THE LOW SIDE OF THE LOOP -INIMUM CONTROL PRESSURE REQUIREMENTS ARE A
FUNCTION OF SPEED PRESSURE AND SWASHPLATE ANGLE AND MAY BE HIGHER THAN THE MINIMUM
CHARGE PRESSURE SHOWN IN THE OPERATING PARAMETERS TABLE

Maximum charge pressure IS THE HIGHEST CHARGE PRESSURE ALLOWED BY THE CHARGE RELIEF
ADJUSTMENT AND PROVIDES NORMAL COMPONENT LIFE9OU CAN USE ELEVATED CHARGE PRESSURE
AS A SECONDARY MEANS TO REDUCE THE SWASHPLATE RESPONSE TIME

4HE CHARGE PRESSURE SETTING IN THE ORDER CODE IS THE SET PRESSURE OF THE CHARGE RELIEF
VALVE WITH THE PUMP IN NEUTRAL OPERATING AT MIN RPM AND WITH A mUID VISCOSITY
OF MM2SEC 353 4HE CHARGE PRESSURE SETTING IS REFERENCED TO CASE PRESSURE
#HARGE PRESSURE IS THE DIFFERENTIAL PRESSURE ABOVE CASE PRESSURE

CHARGE INLET PRESSURE !T NORMAL OPERATING TEMPERATURE CHARGE INLET PRESSURE MUST NOT FALL BELOW rated charge
inlet pressure

Minimum charge inlet pressure IS ONLY ALLOWED AT COLD START CONDITIONS )N SOME
APPLICATIONS IT MAY BE NECESSARY TO WARM UP THE mUID BY RUNNING THE ENGINE AT LIMITED
SPEED UNTIL THE SYSTEM mUID TEMPERATURE REACHES AN ACCEPTABLE LEVEL

5NDER NORMAL OPERATING CONDITIONS DO NOT EXCEED THE rated case pressure $URING COLD
CASE PRESSURE START MAINTAIN THE CASE PRESSURE BELOW MAXIMUM INTERMITTENT CASE PRESSURE

C#AUTION
Possible component damage or leakage
/PERATION WITH CASE PRESSURE IN EXCESS OF STATED LIMITS MAY DAMAGE SEALS GASKETS ANDOR
HOUSINGS CAUSING EXTERNAL LEAKAGE 0ERFORMANCE MAY ALSO BE AFFECTED SINCE CHARGE AND
SYSTEM PRESSURE ARE ADDITIVE TO CASE PRESSURE

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20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATING PARAMETERS

TEMPERATURE AND Temperature

VISCOSITY 4HE HIGH TEMPERATURE LIMITS APPLY AT THE HOTTEST POINT IN THE TRANSMISSION LOOP WHICH
IS NORMALLY THE MOTOR CASE DRAIN -AINTAIN SYSTEM TEMPERATURE BELOW THE QUOTED rated
temperature

.EVER EXCEED THE maximum intermittent temperature

#OLD OIL WILL GENERALLY NOT AFFECT THE DURABILITY OF THE TRANSMISSION COMPONENTS BUT IT
MAY AFFECT THE ABILITY OF OIL TO mOW AND TRANSMIT POWER THEREFORE TEMPERATURES SHOULD
REMAIN ²# ; ²&= ABOVE THE POUR POINT OF THE HYDRAULIC mUID
4HE minimum temperature RELATES TO THE PHYSICAL PROPERTIES OF COMPONENT MATERIALS
3IZE HEAT EXCHANGERS TO KEEP THE mUID WITHIN THESE LIMITS4EST HEAT EXCHANGERS TO VERIFY
THAT THESE TEMPERATURE LIMITS ARE NOT EXCEEDED

Viscosity
&OR MAXIMUM EFlCIENCY AND BEARING LIFE ENSURE THE mUID VISCOSITY REMAINS IN THE
recommended range

Minimum viscosity SHOULD BE ENCOUNTERED ONLY DURING BRIEF OCCASIONS OF MAXIMUM

AMBIENT TEMPERATURE AND SEVERE DUTY CYCLE OPERATION

Maximum viscosity SHOULD BE ENCOUNTERED ONLY AT COLD START

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3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATING PARAMETERS

FLUID AND FILTER 4O ENSURE OPTIMUM PUMP LIFE PERFORM REGULAR MAINTENANCE OF THE mUID AND lLTER
RECOMMENDATIONS #ONTAMINATED mUID IS THE MAIN CAUSE OF UNIT FAILURE -AINTAIN mUID CLEANLINESS WHEN
SERVICING

#HECK THE RESERVOIR DAILY FOR PROPER mUID LEVEL THE PRESENCE OF WATER AND RANCID mUID
ODOR &LUID CONTAMINATED BY WATER MAY APPEAR CLOUDY OR MILKY OR FREE WATER MAY
SETTLE IN THE BOTTOM OF THE RESERVOIR 2ANCID ODOR INDICATES THE mUID HAS BEEN EXPOSED
TO EXCESSIVE HEAT #HANGE THE mUID IMMEDIATELY IF THESE CONDITIONS OCCUR #ORRECT THE
PROBLEM IMMEDIATELY

)NSPECT VEHICLE FOR LEAKS DAILY

Fluid and ﬁlter change interval
#HANGE THE mUID AND lLTER PER THE Reservoir type Max oil change interval
VEHICLEMACHINE MANUFACTURERS 3EALED HOURS
RECOMMENDATIONS OR AT THE INTERVALS "REATHER HOURS
SHOWN IN THE TABLE #HANGE mUID AFTER
lRST HOURS

C#AUTION
(IGH TEMPERATURES AND PRESSURES RESULT IN ACCELERATED mUID AGING #HANGE mUID MORE
FREQUENTLY IF OPERATING UNDER EXTREME CONDITIONS

#HANGE THE mUID MORE FREQUENTLY IF IT BECOMES CONTAMINATED WITH FOREIGN MATTER DIRT
WATER GREASE ETC OR IF THE mUID IS SUBJECTED TO TEMPERATURE LEVELS GREATER THAN THE
RECOMMENDED MAXIMUM

$ISPOSE OF USED HYDRAULIC mUID PROPERLY .EVER REUSE HYDRAULIC mUID

#HANGE lLTERS WHENEVER THE mUID IS CHANGED OR WHEN THE lLTER INDICATOR INDICATES A lLTER
CHANGE 2EPLACE ALL mUID LOST DURING lLTER CHANGE

&OR DETAILED lLTRATION INFORMATION SEE 3AUER $ANFOSS PUBLICATION 520L0463 Fluids
and Filtration &OR INFORMATION ON BIODEGRADABLE mUIDS SEE 3AUER $ANFOSS PUBLICATION
520L0465 Biodegradable Hydraulic Fluids

520L0818 s 2EV !" s !PRIL 2008 19

008 914 20 BOMAG 905
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ECHNICAL SPECIlCATIONS

OVERVIEW 3PECIlCATIONS AND OPERATING PARAMETERS FOR PUMPS APPEAR HERE FOR REFERENCE

FEATURES AND OPTIONS Model Series 90 Pumps

Mount 3!% " 3!% # AND % 3!% *
Pump type !XIAL PISTON TYPE
Rotation "IDIRECTIONAL
Installation position $ISCRETIONARY (OUSING MUST ALWAYS BE lLLED WITH HYDRAULIC mUID $O NOT INSTALL WITH
CONTROL ON BOTTOM
Input shafts 3PLINED
Control options -$# WITH OPTIONS %$# ($# &.2

OPERATING Parameter Unit Pressure

PARAMETERS 2ATED ;=
BAR
3YSTEM PRESSURE -AXIMUM ;=
;PSI=
-INIMUM LOW LOOP ;=
Minimum BAR ;=
#HARGE PRESSURE
-AXIMUM ;PSI= ;=
2ATED BAR ABSOLUTE ;=
#HARGE INLET PRESSURE
-INIMUM COLD START ;IN (G VACUUM= ;=
2ATED BAR ;=
#ASE PRESSURE
-AXIMUM ;PSI= ;=

Frame size
Parameter Unit
042 055 075 100 130 180 250
Displacement cm³
MAXIMUM ;INÃ= ;= ;= ;= ;= ;= ;= ;=
Minimum speed min-1 RPM
Rated speed min-1 RPM
Maximum speed min-1 RPM
Maximum attainable speed at
min-1 RPM
maximum displacement
.sMBAR
Theoretical torque at maximum
;LBFsIN
displacement ;= ;= ;= ;= ;= ;= ;=
PSI=
kg 88
Weight BASE UNIT ONLY
;LB= ;= ;= ;= ;= ;= ;= ;=

FLUID SPECIFICATIONS Parameter Unit Minimum Continuous Maximum

6ISCOSITY mm2SEC C3T 7
;353= ;= ; = ;=
2ATINGS AND DATA ARE BASED 4EMPERATURE ²# ;²&= ; = ;= ;=
ON OPERATION WITH PREMIUM #LEANLINESS )3/ #LASS OR BETTER
PETROLEUM BASED HYDRAULIC &ILTRATION EFlCIENCY SUCTION lLTRATION β β≥
mUIDS CONTAINING OXIDATION CHARGE lLTRATION β β≥
AND FOAM INHIBITORS

20 520L0818 s 2EV !" s !PRIL 2008

906 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NITIAL START UP PROCEDURE

GENERAL &OLLOW THIS PROCEDURE WHEN STARTING UP A NEW PUMP INSTALLATION OR WHEN RESTARTING AN
INSTALLATION IN WHICH THE PUMP WAS REMOVED

W 7ARNING
5NINTENDED MOVEMENT OF THE MACHINE OR MECHANISM MAY CAUSE INJURY TO THE TECHNICIAN
OR BYSTANDERS4O PROTECT AGAINST UNINTENDED MOVEMENT SECURE THE MACHINE OR DISABLE
DISCONNECT THE MECHANISM WHILE SERVICING

0RIOR TO INSTALLING THE PUMP INSPECT FOR SHIPPING DAMAGE

START-UP PROCEDURE %NSURE THAT THE HYDRAULIC mUID AND SYSTEM COMPONENTS RESERVOIR HOSES VALVES
lTTINGS AND HEAT EXCHANGER ARE CLEAN AND FREE OF CONTAMINATION

)NSTALL NEW SYSTEM lLTER ELEMENTS IF NECESSARY #HECK THAT INLET LINE lTTINGS ARE
PROPERLY TIGHTENED AND THERE ARE NO AIR LEAKS

)NSTALL THE PUMP )NSTALL A BAR ; PSI= GAUGE IN THE CHARGE PRESSURE GAUGE PORT
-

&ILL THE HOUSING BY ADDING lLTERED mUID IN THE UPPER CASE DRAIN PORT /PEN THE CASE
PLUG IN THE TOP OF THE CONTROL TO ASSIST WITH AIR BLEED

&ILL THE RESERVOIR WITH HYDRAULIC mUID OF THE RECOMMENDED TYPE AND VISCOSITY 5SE A
MICRON lLLER lLTER &ILL INLET LINE FROM RESERVOIR TO PUMP

$ISCONNECT THE PUMP CONTROL INPUT SIGNAL

!FTER START UP THE mUID LEVEL IN THE RESERVOIR MAY DROP DUE TO lLLING OF THE SYSTEM
COMPONENTS #HECK THE LEVEL IN THE RESERVOIR TO MAINTAIN A FULL mUID LEVEL THROUGHOUT THE
START UP PROCEDURE

C #AUTION
$AMAGE TO HYDRAULIC COMPONENTS MAY OCCUR FROM FAILURE TO MAINTAIN mUID SUPPLY

5SE A COMMON METHOD TO DISABLE THE ENGINE TO PREVENT THE ENGINE FROM STARTING
#RANK THE STARTER FOR SEVERAL SECONDS $O NOT TO EXCEED THE ENGINE MANUFACTURERS
RECOMMENDATION7AIT SECONDS AND THEN CRANK THE ENGINE A SECOND TIME
4HIS OPERATION HELPS REMOVE AIR FROM THE SYSTEM LINES 2ElLL THE RESERVOIR TO
RECOMMENDED FULL mUID LEVEL

520L0818 s 2EV !" s !PRIL 2008 21

008 914 20 BOMAG 907
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NITIAL START UP PROCEDURE

START-UP PROCEDURE 7HEN CHARGE PRESSURE REACHES BAR ; PSI= ENABLE AND START ENGINE ,ET THE
(continued) ENGINE RUN FOR A MINIMUM OF SECONDS AT LOW IDLE TO ALLOW THE AIR TO WORK ITSELF OUT
OF THE SYSTEM #HECK FOR LEAKS AT ALL LINE CONNECTIONS AND LISTEN FOR CAVITATION #HECK
FOR PROPER mUID LEVEL IN RESERVOIR

C#AUTION
!IR ENTRAPMENT IN mUID UNDER HIGH PRESSURE MAY DAMAGE HYDRAULIC COMPONENTS

C#AUTION
$O NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE OF AIR AND mUID HAS BEEN THOROUGHLY
lLTERED

7HEN ADEQUATE CHARGE PRESSURE IS ESTABLISHED AS SHOWN IN MODEL CODE INCREASE
ENGINE SPEED TO NORMAL OPERATING RPM TO FURTHER PURGE RESIDUAL AIR FROM THE SYSTEM

3HUT OFF THE ENGINE #ONNECT THE PUMP CONTROL SIGNAL 3TART THE ENGINE CHECKING TO
BE CERTAIN THE PUMP REMAINS IN NEUTRAL 2UN THE ENGINE AT NORMAL OPERATING SPEED
AND CAREFULLY CHECK FOR FORWARD AND REVERSE CONTROL OPERATION

#ONTINUE TO CYCLE BETWEEN FORWARD AND REVERSE FOR AT LEAST lVE MINUTES TO BLEED ALL
AIR AND mUSH SYSTEM CONTAMINANTS OUT OF LOOP

.ORMAL CHARGE PRESSURE mUCTUATION MAY OCCUR DURING FORWARD AND REVERSE OPERATION

#HECK THAT THE RESERVOIR IS FULL 2EMOVE CHARGE PRESSURE GAUGE4HE PUMP IS NOW
READY FOR OPERATION

22 520L0818 s 2EV !" s !PRIL 2008

908 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
0RESSURE MEASUREMENT

REQUIRED TOOLS 9OU CAN PERFORM THE SERVICE PROCEDURES DESCRIBED IN THIS MANUAL USING COMMON
MECHANICS TOOLS 3PECIAL TOOLS IF REQUIRED ARE SHOWN 5SE CALIBRATED PRESSURE GAUGES TO
ENSURE ACCURACY 5SE SNUBBERS TO PROTECT PRESSURE GAUGES

PORT LOCATIONS AND 4HE FOLLOWING SECTIONS LIST THE PORTS FOR EACH TYPE OF HYDRAULIC UNIT4HE lTTING SIZE AND
GAUGE INSTALLATION RECOMMENDED PRESSURE GAUGE ARE ALSO SPECIlED

4HE FOLLOWING TABLE AND DRAWINGS SHOW THE PORT LOCATIONS AND GAUGE SIZES NEEDED

Port information
Port identiﬁer Pressure obtained Gauge size Port size
M1, M2 3YSTEM PRESSURE BAR ; PSI=
M3 (M6) #HARGE PRESSURE BAR ; PSI=
M4, M5 3ERVO PRESSURE BAR ; PSI=
L1, L2 #ASE PRESSURE BAR ; PSI=

X1, X2 ($#%$# CONTROL PRESSURE BAR ; PSI= OR
X3 %XTERNAL CONTROL PRESSURE BAR ; PSI=
S #HARGE PUMP INLET 6ACUUM GAUGE
4EE INTO INLET LINE

3!% SPLIT mANGE

520L0818 s 2EV !" s !PRIL 2008 23

008 914 20 BOMAG 909
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
0RESSURE MEASUREMENT

PORT LOCATIONS AND

GAUGE INSTALLATION
(continued)

Pump with side port end cap and manual displacement control

Case drain Servo / displacement

port L1 cylinder pressure
gauge port M4

Servo / displacement
System pressure cylinder pressure
port B gauge port M5
External control pressure
System pressure supply port X3
gauge port M2
Speed sensor

Charge inlet pressure

(vacuum)

System pressure
gauge port M1

Carge pump
inlet port S System pressure
port A Case drain port L2 Charge pressure
gauge port M3 P106 158E

24 520L0818 s 2EV !" s !PRIL 2008

910 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
0RESSURE MEASUREMENT

PORT LOCATIONS AND

GAUGE INSTALLATION
(continued)

Pump with twin port end cap and manual displacement control
Servo / displacement
cylinder pressure
gauge port M4
Case drain
port L1

Servo / displacement
cylinder pressure
gauge port M5

System pressure
gauge port M2

System pressure
port B

Charge pump inlet

port S

System pressure
port A
System pressure
gauge port M1
Case drain port L2

P106 160E

Pump with side port end cap and remote pressure ﬁltration Pump with side port end cap and integral pressure
ﬁltration

Charge pressure
gauge port M6 Port E
(before the filter) (from filter)

Port D
(to filter)

Charge pressure
gauge port M3
Charge pressure (back side-after
gauge port M3 the filter)
(after the filter)

P106 163E

520L0818 s 2EV !" s !PRIL 2008 25

008 914 20 BOMAG 911
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ROUBLESHOOTING

OVERVIEW 4HIS SECTION PROVIDES GENERAL STEPS TO FOLLOW IF CERTAIN UNDESIRABLE SYSTEM CONDITIONS
OCCUR &OLLOW THE STEPS IN A SECTION UNTIL YOU SOLVE THE PROBLEM 3OME OF THE ITEMS
ARE SYSTEM SPECIlC &OR AREAS COVERED IN THIS MANUAL WE REFERENCE THE SECTION !LWAYS
OBSERVE THE SAFETY PRECAUTIONS LISTED IN THE Introduction SECTION PAGE AND THOSE
RELATING TO YOUR SPECIlC EQUIPMENT

NEUTRAL DIFFICULT OR
IMPOSSIBLE TO FIND

Item Description Action

)NPUT TO PUMP CONTROL )NPUT TO CONTROL MODULE IS OPERATING IMPROPERLY #HECK CONTROL INPUT AND REPAIR OR REPLACE AS NECESSARY
0UMP DISPLACEMENT CONTROL #ONTROL LINAGES ARE NOT SECURE CONTROL ORIlCES ARE !DJUST REPAIR OR REPLACE CONTROL MODULE AS NECESSARY
BLOCKED
-ULTIFUNCTION VALVE -ULTIFUNCTION VALVE IS LEAKING 3WAP MULTIFUNCTION VALVES )F SYSTEM CHANGES DIRECTION
REPLACE DEFECTIVE VALVE

SYSTEM OPERATING HOT

Item Description Action

/IL LEVEL IN RESERVOIR )NSUFlCIENT HYDRAULIC mUID WILL NOT MEET COOLING &ILL RESERVOIR TO PROPER LEVEL
DEMANDS OF SYSTEM
(EAT EXCHANGER (EAT EXCHANGER IS NOT SUFlCIENTLY COOLING THE #HECK AIR mOW AND INPUT AIR TEMPERATURE FOR HEAT
SYSTEM EXCHANGER #LEAN REPAIR OR REPLACE HEAT EXCHANGER
#HARGE PRESSURE ,OW CHARGE PRESSURE WILL OVERWORK SYSTEM -EASURE CHARGE PRESSURE )NSPECT AND ADJUST OR REPLACE
CHARGE RELIEF VALVE OR REPAIR LEAKY CHARGE PUMP
#HARGE PUMP INLET VACUUM (IGH INLET VACUUM WILL OVERWORK SYSTEM ! DIRTY #HECK CHARGE INLET VACUUM )F HIGH INSPECT INLET lLTER AND
lLTER WILL INCREASE THE INLET VACUUM )NADEQUATE LINE REPLACE AS NECESSARY #HECK FOR ADEQUATE LINE SIZE LENGTH
SIZE WILL RESTRICT mOW OR OTHER RESTRICTIONS
3YSTEM RELIEF PRESSURE SETTINGS )F THE SYSTEM RELIEF SETTINGS ARE TOO LOW THE RELIEF 6ERIFY SETTINGS OF PRESSURE LIMITERS AND HIGH PRESSURE
VALVES WILL BE OVERWORKED RELIEF VALVES AND ADJUST OR REPLACE MULTI FUNCTION VALVES
AS NECESSARY
&OR INTERNAL LEAKAGE IN MOTOR ,EAKAGE WILL REDUCE LOW SIDE SYSTEM PRESSURE AND -ONITOR MOTOR CASE mOW WITHOUT LOOP mUSHING IN THE
OVERWORK THE SYSTEM CIRCUIT USE DEFEAT SPOOL )F mOW IS EXCESSIVE REPLACE
MOTOR
3YSTEM PRESSURE (IGH SYSTEM PRESSURE WILL OVERHEAT SYSTEM -EASURE SYSTEM PRESSURE )F PRESSURE IS HIGH REDUCE LOADS

26 520L0818 s 2EV !" s !PRIL 2008

912 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ROUBLESHOOTING

3YSTEM PRESSURE AT MOTOR ,OW SYSTEM PRESSURE AT THE MOTOR WILL REDUCE TORQUE -EASURE SYSTEM PRESSURE AT MOTOR )F PRESSURE LIMITER
SETTING IS LOW INCREASE SETTING
6ARIABLE MOTOR STUCK AT -INIMUM MOTOR DISPLACEMENT YIELDS LOW OUTPUT #HECK CONTROL SUPPLY PRESSURE OR REPAIR DISPLACEMENT
MINIMUM DISPLACEMENT TORQUE CONTROL #HECK MOTOR CONTROL ORIlCES
)NTERNAL LEAKAGE )NTERNAL LEAKAGE WILL REDUCE SYSTEM PRESSURE #HECK FOR LEAKING / RINGS GASKETS AND OTHER lTTINGS
2EPAIR UNIT AS REQUIRED OR REPLACE LEAKING UNIT

IMPROPER MOTOR
OUTPUT SPEED

Item Description Action

/IL LEVEL IN RESERVOIR )NSUFlCIENT HYDRAULIC mUID WILL REDUCE MOTOR SPEED &ILL OIL TO PROPER LEVEL
0UMP OUTPUT mOW )NCORRECT OUTmOW WILL AFFECT OUTPUT SPEED )NCORRECT -EASURE PUMP OUTPUT AND CHECK FOR PROPER PUMP SPEED
OUTPUT mOW INDICATES THE SWASHPLATE IS OUT OF %NSURE THE PUMP IS IN FULL STROKE
POSITION
6ARIABLE MOTOR DISPLACEMENT )F VARIABLE MOTOR DISPLACEMENT CONTROL IS NOT 3EE IF VARIABLE MOTOR DISPLACEMENT CONTROL IS RESPONDING
CONTROL FUNCTIONING CORRECTLY VARIABLE MOTOR SWASHPLATE MAY )F NOT REPAIR OR REPLACE CONTROL
BE IN WRONG POSITION
)NTERNAL LEAKAGE )NTERNAL LEAKAGE WILL REDUCE SYSTEM PRESSURE #HECK FOR LEAKING / RINGS GASKETS AND OTHER lTTINGS
2EPAIR UNIT AS REQUIRED OR REPLACE LEAKY UNIT

SYSTEM NOISE OR
VIBRATION

Item Description Action

/IL IN RESERVOIR )NSUFlCIENT HYDRAULIC mUID WILL LEAD TO CAVITATION &ILL RESERVOIR TO PROPER LEVEL
!IR IN SYSTEM !IR BUBBLES WILL LEAD TO CAVITATION ,OOK FOR FOAM IN RESERVOIR #HECK FOR LEAKS ON INLET SIDE
SYSTEM LOOP AND REPAIR !FTERWARDS LET RESERVOIR SETTLE
UNTIL FOAM DISSIPATES 2UN SYSTEM AT LOW SPEED TO MOVE
SYSTEM mUID TO RESERVOIR 2EPEAT
0UMP INLET VACUUM (IGH INLET VACUUM CAUSES NOISE ! DIRTY lLTER WILL )NSPECT AND REPLACE lLTER AS NECESSARY #HECK FOR PROPER
INCREASE THE INLET VACUUM SUCTION LINE SIZE
3HAFT COUPLINGS ! LOOSE SHAFT COUPLING WILL CAUSE EXCESSIVE NOISE 2EPLACE LOOSE SHAFT COUPLING OR REPLACE PUMP OR MOTOR
3HAFT ALIGNMENT -ISALIGNED SHAFTS CAUSE NOISE !LIGN SHAFTS

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914 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ROUBLESHOOTING

SYSTEM RESPONSE IS
SLUGGISH

Item Description Action

/IL LEVEL IN RESERVOIR )NSUFlCIENT HYDRAULIC mUID CAUSES SLUGGISH RESPONSE &ILL RESERVOIR TO PROPER LEVEL
-ULTI FUNCTION VALVES PRESSURE )NCORRECT PRESSURE SETTINGS AFFECTS SYSTEM REACTION !DJUST OR REPLACE MULTI FUNCTION VALVES
SETTINGS TIME
0UMP INLET VACUUM (IGH PUMP INLET VACUUM REDUCES SYSTEM PRESSURE -EASURE CHARGE INLET VACUUM )F HIGH REPLACE INLET lLTER
0RIME MOVER SPEED ,OW ENGINE SPEED REDUCES SYSTEM PERFORMANCE !DJUST ENGINE SPEED
#HARGE AND CONTROL PRESSURES )NCORRECT CHARGE OR CONTROL PRESSURES AFFECTS SYSTEM -EASURE CHARGE AND CONTROL PRESSURES AND CORRECT IF
PERFORMANCE NECESSARY
3YSTEM INTERNAL LEAKAGE )NTERNAL LEAKAGE REDUCES SYSTEM PRESSURE #HECK FOR LEAKAGE IN / RINGS GASKETS AND OTHER lTTINGS

520L0818 s 2EV !" s !PRIL 2008 29

008 914 20 BOMAG 915
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

STANDARD
PROCEDURES, "EFORE WORKING ON THE PUMP CLEAN THE OUTSIDE OF THE PUMP
INSPECTIONS, AND
ADJUSTMENTS
CCaution
#ONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID YOUR WARRANTY4AKE
PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND REINSTALLING SYSTEM LINES

7ITH THE PRIME MOVER OFF THOROUGHLY CLEAN THE OUTSIDE OF THE PUMP

)F REMOVING THE PUMP TAG EACH HYDRAULIC LINE CONNECTED TO THE PUMP )F HYDRAULIC
LINES ARE DISCONNECTED PLUG EACH OPEN PORT WITH A CLEAN PLUG TO ENSURE THAT DIRT AND
CONTAMINATION DO NOT GET INTO THE PUMP

%NSURE THE SURROUNDING AREAS ARE CLEAN AND FREE OF CONTAMINANTS

)NSPECT THE SYSTEM FOR CONTAMINATION

6ISUALLY INSPECT THE HYDRAULIC mUID FOR SIGNS OF SYSTEM CONTAMINATION mUID
DISCOLORATION FOAM IN THE mUID SLUDGE OR SMALL METAL PARTICLES

)F THERE ARE SIGNS OF CONTAMINATION IN THE HYDRAULIC mUID REPLACE ALL lLTERS DRAIN AND
mUSH THE HYDRAULIC SYSTEM AND lLL WITH THE CORRECT lLTERED HYDRAULIC mUID

&LUSH THE LINES BEFORE REPLACING THE HYDRAULIC mUID

30 520L0818 s 2EV !" s !PRIL 2008

916 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

ADJUSTMENTS 4HIS SECTION OFFERS INSTRUCTION ON INSPECTION AND ADJUSTMENT OF PUMP COMPONENTS 2EAD
THROUGH THE ENTIRE RELATED SECTION BEFORE BEGINNING A SERVICE ACTIVITY 2EFER TO Pressure
measurements PAGES AND FOR LOCATION OF GAUGE PORTS AND SUGGESTED GAUGE
SIZES

CHARGE PRESSURE 4HE FOLLOWING PROCEDURE EXPLAINS HOW TO CHECK AND ADJUST THE CHARGE PRESSURE RELIEF
RELIEF VALVE VALVE
ADJUSTMENT
)NSTALL A BAR ; PSI= PRESSURE GAUGE IN THE PUMP CHARGE PRESSURE GAUGE PORT
W Warning - )NSTALL A BAR ; PSI= GAUGE TO MEASURE CASE PRESSURE TEE INTO , OR , OR
4HE FOLLOWING PROCEDURE USE SERVO GAUGE PORT - OR - /PERATE THE SYSTEM WITH THE PUMP IN NEUTRAL ZERO
MAY REQUIRE THE VEHICLE DISPLACEMENT WHEN MEASURING PUMP CHARGE PRESSURE
MACHINE TO BE DISABLED
WHEELS RAISED OFF THE 4HE TABLE SHOWS THE ACCEPTABLE PUMP CHARGE PRESSURE RANGE FOR SOME CHARGE RELIEF
GROUND WORK FUNCTION VALVE SETTINGS4HESE PRESSURES ASSUME MINÂ RPM AND A RESERVOIR TEMPERATURE
DISCONNECTED ETC IN ORDER OF ²# ;²&= AND ARE REFERENCED TO CASE PRESSURE
TO PREVENT INJURY TO THE
TECHNICIAN AND BYSTANDERS
4AKE NECESSARY SAFETY Charge pressure relief valve
#ASE DRAIN PORT ,
PRECAUTIONS BEFORE MOVING
THE VEHICLEMACHINE - G BAR ; PSI=
K90 B
!DJUSTING SCREW t .sM ; LBFsFT=
+ -
,OCK NUT
.sM ; LBFsFT=

#HARGE PRESSURE GAUGE PORT -

G BAR ; PSI=
B
t .sM ; LBFsFT=

3EE APPROPRIATE TABLE 0 %

,ISTED PRESSURES ASSUME A PUMP SPEED Charge pressure ranges

OF MIN RPM !T HIGHER PUMP Model code Measured charge pressure*
INPUT SPEEDS WITH HIGHER CHARGE mOWS n BAR
20
THE CHARGE PRESSURE WILL RISE OVER THE ; n PSI=
RATED SETTING n BAR

; n PSI=
n BAR
28
; n PSI=
4HIS IS THE ACTUAL CHARGE PRESSURE PORT GAUGE
READING MINUS THE CASE PRESSURE PORT GAUGE
READING

520L0818 s 2EV !" s !PRIL 2008 31

008 914 20 BOMAG 917
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

CHARGE PRESSURE %ARLIER PRODUCTION 3ERIES PUMPS HAVE A SHIM ADJUSTABLE CHARGE PRESSURE RELIEF
RELIEF VALVE VALVE 3HIM KITS ARE AVAILABLE FROM 3AUER $ANFOSS 2EMOVE THE PLUG USING A IN HEX
ADJUSTMENT WRENCH AND EXCHANGE SHIMS BEHIND THE SPRING TO ADJUST CHARGE PRESSURE4ORQUE
(continued) PLUG TO .sM ; LBFsFT=

,ATER PRODUCTION 3ERIES PUMPS HAVE AN EXTERNAL SCREW ADJUSTABLE CHARGE

PRESSURE RELIEF VALVE ,OOSEN LOCKNUT + AND TURN THE ADJUSTING SCREW + USING A
SCREWDRIVER OR IN HEX WRENCH TO ADJUST CHARGE PRESSURE SETTING

Lock nut wrench size

Frame size Wrench size
n INCH
n INCH

#LOCKWISE ROTATION OF THE PLUG INCREASES THE SETTING AND COUNTERCLOCKWISE ROTATION
DECREASES THE SETTING AT A RATE OF APPROXIMATELY BAR ; PSI= PER TURN 4ORQUE
LOCK NUT TO .sM ; LBFsFT=

/NCE YOU ACHIEVE THE DESIRED CHARGE PRESSURE SETTING REMOVE THE GAUGES AND PLUG
THE PORTS

32 520L0818 s 2EV !" s !PRIL 2008

918 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

MULTI-FUNCTION VALVE 9OU ACCOMPLISH ADJUSTMENT OF THE PRESSURE LIMITER SETTING AND THE HIGH PRESSURE RELIEF
PRESSURE ADJUSTMENT VALVE (026 SETTING SIMULTANEOUSLY4HE (026 SETTING IS AUTOMATICALLY SET APPROXIMATELY
BAR ; PSI= ABOVE THE PRESSURE LIMITER SETTING

W7ARNING ,OCK THE MOTOR OUTPUT SHAFT BY LOCKING THE VEHICLES BRAKES OR RIGIDLY lXING THE WORK
4AKE NECESSARY PRECAUTIONS FUNCTION SO IT CANNOT ROTATE OR CAP THE SYSTEM PORTS W
THAT THE MOTOR SHAFT
REMAINS STATIONARY DURING
THE ADJUSTMENT PROCEDURE
Multi-function valve adjustment

#HARGE PRESSURE GAUGE PORT -

G BAR ; PSI=
B
t .sM ; LBFsFT=

I !DJUSTING SCREW
h ,OCK NUT SMALLER HEX NUT
t,OCK NUT TORQUE 3EE APPROPRIATE TABLE

3YSTEM PRESSURE GAUGE PORT M2

G BAR ; PSI=
B
t .sM ; LBFsFT=
3YSTEM PRESSURE GAUGE PORT -
G BAR ; PSI=
B
t .sM ; LBFsFT=
0 %

)NSTALL TWO BAR OR PSI PRESSURE GAUGES IN THE HIGH PRESSURE GAUGE
PORTS - AND - )NSTALL A BAR OR PSI PRESSURE GAUGE IN THE PUMP CHARGE
PRESSURE GAUGE PORT -

3TART THE PRIME MOVER AND OPERATE AT NORMAL SPEED

,OOSEN LOCKING NUT

)NSERT AN INTERNAL HEX WRENCH INTO THE PRESSURE ADJUSTING SCREW

! PLASTIC DUST PLUG IS INSTALLED IN THE ADJUSTING SCREW

520L0818 s 2EV !" s !PRIL 2008 33

008 914 20 BOMAG 919
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

MULTI-FUNCTION VALVE 4HE MODEL CODE SHOWS THE FACTORY PRESET PRESSURE LIMITER SETTING )T IS REFERENCED TO
PRESSURE ADJUSTMENT CHARGE PRESSURE SO THE PRESSURE LIMITER SETTING IS THE DIFFERENCE BETWEEN THE HIGH
(continued) AND LOW PRESSURE SIDES OF THE SYSTEM LOOP !CTIVATE OR MOVE THE CONTROL INPUT SO
THAT PRESSURE INCREASES IN THE HIGH PRESSURE SIDE OF THE CLOSED CIRCUIT TO THE PRESSURE
LIMITER PRESSURE SETTING4HE PRESSURE LIMITER SETTING IS REACHED WHEN THE PRESSURE
STOPS INCREASING AND REMAINS STEADY AT A GIVEN PRESSURE LEVEL AS SHOWN ON THE
GAUGES

2ETURN THE PUMP TO ITS NEUTRAL ZERO mOW POSITION AND ADJUST THE PRESSURE LIMITER
SETTING BY ROTATING THE PRESSURE ADJUSTING SCREW WITH AN INTERNAL HEX WRENCH

#LOCKWISE ROTATION OF THE PRESSURE ADJUSTMENT SCREW INCREASES THE PRESSURE SETTING
AND COUNTERCLOCKWISE ROTATION DECREASES THE PRESSURE SETTING %ACH COMPLETE
ROTATION OF THE PRESSURE ADJUSTING SCREW CHANGES THE PRESSURE AS SHOWN IN THE
FOLLOWING TABLE

Pressure limiter adjustment data

Frame size Lock nut wrench size and torque Adjusting Approximate pressure change
screw size per revolution of adjusting screw
EARLY MM .sM ; LBFsIN= MM BAR ; PSI=
MM .sM ; LBFsFT= MM BAR ; PSI=
EARLY MM .sM ; LBFsFT= MM BAR ; PSI=
MM .sM ; LBFsFT= 8 mm BAR ; PSI=

4O VERIFY THE ACTUAL PRESSURE SETTING ACTUATE OR MOVE THE CONTROL INPUT SO THAT THE
PUMP AGAIN DEVELOPS PRESSURE IN THE HIGH PRESSURE CIRCUIT TO THE NEWLY ADJUSTED
PRESSURE LIMITER PRESSURE SETTING THEN READ THE HIGH PRESSURE GAUGE !LLOW THE PUMP
TO RETURN TO ITS NEUTRAL POSITION4HE PRESSURE IN THE HIGH PRESSURE CIRCUIT SHOULD
RETURN TO THE CHARGE PRESSURE SETTING

7HILE HOLDING THE PRESSURE ADJUSTING SCREW STATIONARY TIGHTEN THE PRESSURE ADJUSTING
SCREW LOCK NUT4ORQUE AS SHOWN IN THE TABLE

$O NOT OVERTORQUE

3HUT DOWN THE PRIME MOVER REMOVE THE GAUGES AND INSTALL THE GAUGE PORT PLUGS
2EPLACE THE PLASTIC DUST PLUGS IF USED

5SE THE SAME PROCEDURE FOR SETTING THE PRESSURE LIMIT OF THE OTHER MULTI FUNCTION VALVE
-OVE OR ACTIVATE THE CONTROL INPUT SIGNAL IN THE OPPOSITE DIRECTION SO THAT HIGH PRESSURE
DEVELOPS IN THE OPPOSITE SIDE OF THE CLOSED CIRCUIT

34 520L0818 s 2EV !" s !PRIL 2008

920 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

ENGAGING THE BYPASS 4HE MULTI FUNCTION VALVE CARTRIDGES PERFORM THE BYPASS FUNCTION 3HUT DOWN THE PRIME
FUNCTION MOVER WHEN ENGAGING THE BYPASS FUNCTION /PEN BOTH THE BYPASS VALVES TO ENGAGE THE
BYPASS FUNCTION

C#AUTION LOOSEN THE BYPASS ACTUATOR THREE Bypass actuator wrench size
$AMAGE TO THE PUMP AND TURNS 2EFER TO TABLE FOR WRENCH SIZE Frame size Wrench size
MOTOR CAN RESULT FROM NEWER n INCH
ROTATING THESE COMPONENTS $O NOT ROTATE MORE THAN n INCH
WITHOUT CHARGE mOW FOR REVOLUTIONS AS ADDITIONAL ROTATION WILL
LUBRICATION "YPASS VALVES PERMIT EXTERNAL LEAKAGE Multi-Function Valve with Bypass
ARE INTENDED FOR MOVING Function Engaged
A MACHINE OR VEHICLE FOR &OR UNITS WITH AN -$# TYPE CONTROL Opening bypass valve
allows flow to circuit
VERY SHORT DISTANCES AT VERY PRIOR TO MOVING THE VEHICLE OR Bypass through multi-function valves
SLOW SPEEDS4HEY ARE NOT OTHERWISE CAUSING THE MOTOR SHAFT actuator

TOW VALVES TO TURN MOVE THE CONTROL HANDLE OF

THE MANUAL DISPLACEMENT CONTROL
ON THE PUMP TO THE MAXIMUM FULL
FORWARD POSITION (OLD THE HANDLE
IN THIS POSITION DURING BYPASS VALVE
OPERATION
P104 144E

4O CLOSE THE BYPASS VALVE TIGHTEN THE

BYPASS ACTUATOR 3EE TABLE PROVIDED Bypass actuator torque
FOR PROPER TORQUE Frame size Torque
NEWER n .sM ; LBFsFT=
n .sM ; LBFsFT=

520L0818 s 2EV !" s !PRIL 2008 35

008 914 20 BOMAG 921
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

PRESSURE OVERRIDE 0RESSURE OVERRIDE VALVE OPERATION IS Pressure override valve for 180 frame size
(POR) VALVE PRESSURE EXPLAINED IN THE Operation section
ADJUSTMENT (OPTION PAGE Pressure override valve Adjusting screw
FOR 180 FRAME SIZE) Lock nut
)NSTALL TWO BAR ; PSI=
PRESSURE GAUGES IN THE HIGH PRESSURE
GAUGE PORTS - AND - )NSTALL A
BAR ; PSI= PRESSURE GAUGE IN
W Warning THE PUMP CHARGE PRESSURE GAUGE
5NINTENDED MOVEMENT OF PORT -
THE MACHINE OR MECHANISM
MAY CAUSE INJURY TO THE 3TART THE PRIME MOVER AND OPERATE AT
TECHNICIAN OR BYSTANDERS NORMAL SPEED
4O PROTECT AGAINST P104 145E

UNINTENDED MOVEMENT 7ITH THE PUMP OPERATING AT

SECURE THE MACHINE APPROXIMATELY DISPLACEMENT
OR DISABLEDISCONNECT LOAD THE WORK FUNCTION AND NOTE THE PRESSURE AS THE 0/2 VALVE OPERATES PUMP
THE MECHANISM WHILE DISPLACEMENT REDUCES TO ZERO
SERVICING
!DJUST THE PRESSURE OVERRIDE SETTING BY LOOSENING THE LOCK NUT WITH A INCH HEX
WRENCH AND TURNING THE ADJUSTMENT SCREW WITH A INCH INTERNAL HEX WRENCH
3ET THE 0/2 SETTING TO AT LEAST BAR ; PSI= BELOW THE HIGH PRESSURE RELIEF VALVE
SETTING OF THE MULTI FUNCTION VALVES

4ORQUE THE LOCK NUT TO .sM ; LBFsFT=

3HUT DOWN THE PRIME MOVER AND REMOVE THE GAUGES AND INSTALL THE GAUGE PORT
PLUGS

36 520L0818 s 2EV !" s !PRIL 2008

922 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

DISPLACEMENT LIMITER 9OU CAN LIMIT THE MAXIMUM DISPLACEMENT IN EITHER DIRECTION
ADJUSTMENT
,OOSEN THE LOCK NUT & WHILE Displacement limiter adjustment
HOLDING THE ADJUSTING SCREW &
STEADY

2OTATE THE ADJUSTING SCREW SOME

C#AUTION AMOUNT USING INFORMATION IN THE
4AKE CARE IN ADJUSTING FOLLOWING TABLE C2OTATING THE
DISPLACEMENT LIMITERS TO ADJUSTING SCREW CLOCKWISE DECREASES
AVOID UNDESIRABLE mOW OR THE MAXIMUM DISPLACEMENT OF THE
SPEED CONDITIONS 2E PUMP WHILE ROTATING THE ADJUSTING
TORQUE LOCK NUT & SCREW COUNTERCLOCKWISE INCREASES
AFTER EVERY ADJUSTMENT TO THE MAXIMUM DISPLACEMENT
PREVENT AN UNEXPECTED
&
CHANGE IN OPERATING /NE TURN OF THE ADJUSTING SCREW I!DJUSTING SCREW
CONDITIONS AND TO PREVENT CHANGES THE MAXIMUM DISPLACEMENT
EXTERNAL LEAKAGE DURING AS SHOWN IN TABLE BELOW &
,OCK NUT
UNIT OPERATION
,OCK NUT TORQUE
!FTER ESTABLISHING THE DESIRED
MAXIMUM DISPLACEMENT SETTING
TORQUE THE LOCK NUT TO THE TORQUE 0 %

SHOWN IN TABLE BELOW

Frame size Lock nut wrench size and torque Adjusting Approximate displacement change
screw size per revolution of adjusting screw
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=

STANDARD MANUAL 4HERE ARE NO ADJUSTABLE ELEMENTS IN THE MANUAL DISPLACEMENT CONTROL #ENTERING SPRINGS
DISPLACEMENT AND WASHERS ON EACH END OF THE CONTROL SPOOL HOLD IT IN ITS NEUTRAL POSITION 3INCE THERE
CONTROL (MDC) IS NO CENTERING SPRING ON THE CONTROL INPUT SHAFT THE SHAFT AUTOMATICALLY ASSUMES THE
ADJUSTMENT APPROPRIATE POSITION WHEN THE CONTROL IS INSTALLED ON THE PUMP

520L0818 s 2EV !" s !PRIL 2008 37

008 914 20 BOMAG 923
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

NON-LINEAR MANUAL ! CENTERING SPRING LOCATED ON THE CONTROL INPUT SHAFT LOCATES THE CONTROL SHAFT IN ITS
DISPLACEMENT NEUTRAL POSITION ! BIAS SPRING ON THE CONTROL SPOOL MAINTAINS A FORCE ON THE SPOOL AND
CONTROL (MDC) THE CONTROL LINKAGE TO ELIMINATE FREE PLAY IN THE LINKAGE

.EUTRAL ADJUSTMENT IS THE ONLY ADJUSTMENT THAT CAN BE MADE ON THE NONLINEAR MANUAL
DISPLACEMENT CONTROL !LL OTHER FUNCTIONS ARE PRESET AT THE FACTORY 0ERFORM NEUTRAL
ADJUSTMENT ON A TEST STAND OR ON THE VEHICLEMACHINE WITH THE PRIME MOVER OPERATING

MDC neutral adjustment

SerVO PRESSURE GAUGE PORT -
BAR ; PSI=
ServO PRESSURE GAUGE PORT - 8
.sM ; LBFsFT=
G BAR ; PSI=
B 8 M72
t .sM ; LBFsFT= I MM

M90
MM
.sM ; LBFsFT=
0 %

)NSTALL A BAR ; PSI= GAUGE IN EACH OF THE TWO SERVO CYLINDER GAUGE PORTS -
AND - $ISCONNECT THE EXTERNAL CONTROL LINKAGE FROM THE CONTROL HANDLE AND MAKE
CERTAIN THE CONTROL SHAFT IS IN ITS NEUTRAL POSITION 3TART THE PRIME MOVER AND OPERATE
AT NORMAL SPEED

,OOSEN THE LOCK NUT - ON THE NEUTRAL ADJUSTING SCREW - WITH A MM HEX
WRENCH

5SING A MM INTERNAL HEX WRENCH ROTATE THE NEUTRAL ADJUSTING SCREW CLOCKWISE UNTIL
THE PRESSURE INCREASES ON ONE OF THE PRESSURE GAUGES .OTE THE ANGULAR POSITION OF
THE WRENCH4HEN ROTATE THE ADJUSTING SCREW COUNTERCLOCKWISE UNTIL THE PRESSURE
INCREASES BY AN EQUAL AMOUNT ON THE OTHER GAUGE .OTE THE ANGULAR POSITION OF THE
WRENCH

2OTATE THE ADJUSTING SCREW CLOCKWISE HALF THE DISTANCE BETWEEN THE LOCATIONS NOTED
ABOVE4HE GAUGES SHOULD READ THE SAME PRESSURE INDICATING THAT THE CONTROL IS IN ITS
NEUTRAL POSITION

38 520L0818 s 2EV !" s !PRIL 2008

924 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

NON-LINEAR MANUAL (OLD THE ADJUSTING SCREW STATIONARY AND TIGHTEN THE LOCK NUT TO .sM ; LBFsFT=
DISPLACEMENT $O NOT OVERTORQUE THE NUT
CONTROL (MDC)
(continued) /NCE THE NEUTRAL POSITION IS SET STOP THE PRIME MOVER REMOVE THE GAUGES AND INSTALL
THE GAUGE PORT PLUGS 2ECONNECT THE EXTERNAL CONTROL LINKAGE

MDC NEUTRAL 4HE .EUTRAL 3TART 3WITCH .33 PROVIDES MDC with neutral start switch
START SWITCH (NSS) A MEANS TO PREVENT THE SYSTEM PRIME
A A
ADJUSTMENTS MOVER FROM STARTING WHILE THE PUMP
CONTROL HANDLE IS IN STROKE7HEN THE
Control shaft Switch cam
CONTROL INPUT SHAFT IS IN ITS NEUTRAL
POSITION THE SWITCH PIN ENGAGES A SLOT ON
THE ECCENTRIC CAM ATTACHED TO THE CONTROL Switch lock nut
SHAFT4HIS ALLOWS THE SPRING LOADED Neutral start switch
.33 TO CLOSE COMPLETING THE ELECTRICAL
Eccentric plug
STARTING CIRCUIT FOR THE PRIME MOVER
Switch pin
7HEN THE CONTROL INPUT SHAFT IS NOT IN ITS
Special lock nut
NEUTRAL POSITION THE ECCENTRIC CAM OPENS for eccentric plug
THE .33 SWITCH

4HE NEUTRAL START SWITCH IS THREADED INTO View at section A-A

THE SPECIAL LOCK NUT FOR THE ECCENTRIC
PLUG4URNING THE .33 CLOCKWISE #7
MOVES THE .33 CLOSER TO THE SWITCH
CAM ON THE CONTROL SHAFT AND NARROWS
THE .33 DEADBAND4URNING THE .33
Orifice check valve seat
COUNTERCLOCKWISE ##7 MOVES THE Control spool assembly
.33 FARTHER FROM THE SWITCH CAM ON Control link assembly
THE CONTROL SHAFT WIDENING THE .33 View A-A P104 146E
DEADBAND4HE SWITCH PIN IS LOCATED IN AN
ECCENTRIC PLUG WHICH IS TURNED TO MOVE
THE CENTER OF THE .33 DEADBAND

520L0818 s 2EV !" s !PRIL 2008 39

008 914 20 BOMAG 925
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

MDC NEUTRAL !DJUST THE .EUTRAL 3TART 3WITCH TO MEET Neutral start switch adjustment
START SWITCH (NSS) THE FOLLOWING THREE REQUIREMENTS requirements
ADJUSTMENTS NSS deadband Control shaft
(continued) I 4HE DISTANCE YOU CAN MOVE THE (switch closed, ON) (free-play)
CONTROL HANDLE WITHOUT OPENING Control deadband
(neutral)
THE .33 IS THE NSS deadband4HE
DISTANCE YOU CAN MOVE THE CONTROL Total control
HANDLE WITHOUT MOVING THE CONTROL shaft rotation

SPOOL ENOUGH TO PORT HYDRAULIC

mUID TO THE PUMP DISPLACEMENT Control shaft

CONTROL CYLINDERS IS THE control

deadband4HESE DEADBANDS MUST
BE CONCENTRIC

3INCE YOU CANNOT ADJUST THE POSITION

OF THE CONTROL DEADBAND YOU MUST
ADJUST THE POSITION OF THE .33
DEADBAND TO MATCH IT

II 4HE .33 DEADBAND MUST BE WIDE

ENOUGH SO THE .33 WILL NOT OPEN
WITHIN THE LOOSE AREA OF CONTROL
HANDLE MOVEMENT CAUSED BY NORMAL P104 147E
OPERATING CLEARANCES IN THE CONTROL
LINKAGE CONTROL SHAFT FREE PLAY

"Y SETTING THE .33 TO OPEN OUTSIDE THIS AREA THE CONTROL SPOOL SPRINGS OR CONTROL
SHAFT CENTERING SPRING CAN ALWAYS RETURN THE HANDLE TO NEUTRAL AND RE CLOSE THE .33

III 4HE .33 DEADBAND MUST BE NARROW ENOUGH SO THE .33 WILL OPEN BEFORE THE UNIT
BUILDS BAR ; PSI= DIFFERENTIAL SYSTEM PRESSURE IN EITHER DIRECTION

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926 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

MDC NEUTRAL Neutral start switch eccentric plug Eccentric plug adjustment tool
START SWITCH (NSS) adjustment (condition i)
12.7 9.14
ADJUSTMENTS #ENTER THE .33 DEADBAND AND THE [0.5] [0.36]
(continued) CONTROL DEADBAND IN RELATION TO EACH
OTHER 3INCE YOU CANNOT ADJUST THE
POSITION OF THE CONTROL DEADBAND YOU
MUST ADJUST THE POSITION OF THE .33 3.175 1.52
[0.125] [0.06]
DEADBAND TO MATCH IT4HE SWITCH PIN 25.4
IS LOCATED IN AN ECCENTRIC PLUG WHICH [1.0]

YOU TURN TO MOVE THE CENTER OF THE .33

P104 149E
DEADBAND %NSURE THE -$# IS INSTALLED
ON THE PUMP AND IN ITS NEUTRAL POSITION
WHEN ADJUSTING THE NEUTRAL START SWITCH NSS with eccentric plug
ECCENTRIC PLUG4HE ACCOMPANYING
DRAWING PROVIDES DIMENSIONS FOR AN
ECCENTRIC PLUG ADJUSTMENT TOOL

(OLD THE SWITCH AND ECCENTRIC PLUG

FROM TURNING AND USE A INCH
WRENCH TO LOOSEN THE LOCK NUT B

W 7ARNING 2EMOVE THE NEUTRAL START SWITCH W Switch

Eccentric plug lock nut
$O NOT START THE PRIME Switch pin
B
MOVER WHILE THE NEUTRAL .OTE THE SLOTS ON THE ECCENTRIC PLUG Special lock nut
START SWITCH IS REMOVED FOR THE ADJUSTMENT TOOL (OLD THE for eccentric plug Neutral start switch

FROM THE CONTROL #ASE ECCENTRIC PLUG IN PLACE WITH THE

PRESSURE WILL FORCE THE PIN ADJUSTMENT TOOL AND LOOSEN THE LOCK Special lock nut
for eccentric plug
OUT OF THE ECCENTRIC PLUG NUT WITH A INCH WRENCH
Eccentric plug
CAUSING OIL LOSS Control
mounting
0OSITION THE ECCENTRIC PLUG SO THE surface Switch pin
SWITCH PIN IS OFFSET TOWARD THE
View B-B
CONTROL MOUNTING SURFACE4HIS WILL (switch and lock nut removed)
PROVIDE THE BEST CONTACT BETWEEN P104 150E

THE PIN AND THE CAM ON THE CONTROL

SHAFT

520L0818 s 2EV !" s !PRIL 2008 41

008 914 20 BOMAG 927
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

MDC NEUTRAL (OLD THE CONTROL SHAFT IN ITS NEUTRAL Eccentric plug adjustment
START SWITCH (NSS) POSITION IN THE CENTER OF THE CONTROL Switch pin Eccentric plug
ADJUSTMENTS SHAFT FREE PLAY AREA ,OCATE THE
(continued) SWITCH PIN IN THE SLOT OF THE SWITCH
CAM BY TURNING THE ECCENTRIC PLUG
WHILE CHECKING THE PIN POSITION
DEPTH IN THE PLUG7HEN THE PIN 90° 90°

ENGAGES THE CAM SLOT THE PIN WILL BE

AT ITS MAXIMUM DEPTH IN THE PLUG Control mounting Eccentric plug
adjustment range
(AND TIGHTEN THE PLUG LOCK NUT TO surface
P104 151E
HOLD THE ECCENTRIC PLUG IN POSITION

4URN THE CONTROL SHAFT AN EQUAL

AMOUNT IN EITHER DIRECTION FROM
NEUTRAL4HE SWITCH PIN SHOULD MOVE OUT OF THE ECCENTRIC PLUG AN EQUAL DISTANCE
WHEN THE CONTROL SHAFT IS TURNED4URN THE ECCENTRIC PLUG TO CENTER THE SWITCH PIN
WITH THE CAM SLOT /NLY A SMALL AMOUNT OF ADJUSTMENT IN EITHER DIRECTION IS NEEDED TO
CENTER THE PIN

7HILE HOLDING THE ECCENTRIC PLUG IN PLACE TIGHTEN THE ECCENTRIC PLUG LOCK NUT TO
.sM ; LBFsFT= 2EINSTALL AND ADJUST THE SWITCH AS OUTLINED IN THE PREVIOUS SECTION

4HE ECCENTRIC PLUG NORMALLY REQUIRES BETWEEN AND TURNS TO INSTALL INTO THE
CONTROL HOUSING

C#AUTION
$O NOT TURN THE ECCENTRIC PLUG INTO OR OUT OF THE HOUSING BEYOND SPECIlCATIONS

/NCE THE SWITCH IS CORRECTLY ADJUSTED HOLD THE SWITCH IN PLACE AND TIGHTEN THE LOCK
NUT TO .sM ; LBFsFT= TORQUE

NSS deadband adjustment (conditions ii & iii)

4HE .33 DEADBAND MUST BE WIDE ENOUGH SO THE .33 WILL NOT OPEN WITHIN THE CONTROL
SHAFT FREE PLAY AREA AND IT MUST BE NARROW ENOUGH SO THE .33 WILL OPEN BEFORE THE UNIT
BUILDS BAR PSI DIFFERENTIAL SYSTEM PRESSURE IN EITHER DIRECTION

)NSTALL TWO BAR ; PSI= PRESSURE GAUGES IN THE SYSTEM PRESSURE GAUGE PORTS
- AND -

5SING TWO INCH WRENCHES HOLD THE NEUTRAL START SWITCH FROM TURNING AND
LOOSEN THE LOCK NUT

$ISCONNECT THE EXTERNAL CONTROL LINKAGE AND MAKE CERTAIN THE CONTROL SHAFT IS IN ITS
NEUTRAL POSITION

!TTACH A CONTINUITY CHECKER TO THE TERMINALS OF THE SWITCH7ITH THE CONTROL SHAFT IN
ITS NEUTRAL POSITION TURN THE SWITCH CLOCKWISE #7 UNTIL THE SWITCH OPENS THEN TURN
THE SWITCH COUNTERCLOCKWISE ##7 UNTIL IT CLOSES4URN THE SWITCH COUNTERCLOCKWISE
##7 AN ADDITIONAL TURN ² AFTER THE SWITCH CLOSES

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928 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

MDC NEUTRAL (OLD THE SWITCH IN PLACE AND TIGHTEN Neutral start switch
START SWITCH (NSS) THE LOCK NUT TO .sM LBFsFT
ADJUSTMENTS TORQUE
(continued)
7ITH THE CONTINUITY CHECKER ATTACHED
TO THE SWITCH ROTATE THE CONTROL Control shaft

HANDLE OR THE CONTROL SHAFT IN EACH

DIRECTION TO ASSURE THE SWITCH OPENS
WHEN THE CONTROL IS NOT IN THE NEUTRAL Switch lock nut

POSITION Neutral start switch

Switch cam
)F THE SWITCH CLOSES IN NEUTRAL AND
SATISFACTORILY OPENS IN EACH DIRECTION Switch pin 1-1/8 in

PROCEED TO CHECK THE SWITCH WITH ##t)

THE PRIME MOVER RUNNING4HE SWITCH P104 148E

MUST OPEN BEFORE THE UNIT BUILDS

BAR ; PSI= DIFFERENTIAL SYSTEM
PRESSURE IN EITHER DIRECTION

)F THE SWITCH OPENS AFTER THE UNIT BUILDS SYSTEM PRESSURE IN EITHER DIRECTION LOOSEN
THE SWITCH LOCK NUT AND TURN THE SWITCH CLOCKWISE #7 TURN ² 4IGHTEN THE
SWITCH LOCK NUT AND RECHECK THE SWITCH OPERATION 2EPEAT THIS PROCEDURE IF NECESSARY

)F THE SWITCH DOES NOT OPEN WITH AN EQUAL MOVEMENT OF THE CONTROL HANDLE IN EACH
DIRECTION TURN OFF PRIME MOVER REMOVE THE PRESSURE GAUGES AND CONTINUE WITH THE
NEXT SECTION

)F NEUTRAL START SWITCH OPERATION IS SATISFACTORY TURN OFF THE PRIME MOVER REMOVE THE
PRESSURE GAUGES AND RECONNECT THE EXTERNAL CONTROL LINKAGE

520L0818 s 2EV !" s !PRIL 2008 43

008 914 20 BOMAG 929
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

CHECKING SWITCH 2ECHECK SWITCH CONTINUITY TO DETERMINE WHETHER ADDITIONAL ADJUSTMENT OF THE ECCENTRIC
CONTINUITY PLUG IS NECESSARY W

W 7ARNING )NSTALL A BAR ; PSI= GAUGE IN EACH OF THE TWO SERVO CYLINDER GAUGE PORTS -
4HE FOLLOWING PROCEDURE AND - !TTACH A CONTINUITY CHECKER TO THE TERMINALS OF THE NEUTRAL START SWITCH
MAY REQUIRE THE VEHICLE
MACHINE TO BE DISABLED
WHEELS RAISED OFF THE Checking switch continuity
GROUND WORK FUNCTION
SerVO PRESSURE GAUGE PORT -
DISCONNECTED ETC WHILE
PERFORMING THE PROCEDURE G BAR ; PSI=
IN ORDER TO PREVENT INJURY
ServO PRESSURE GAUGE PORT - B 8
TO THE TECHNICIAN AND G BAR ; PSI= t .sM ; LBFsFT=
BYSTANDERS4AKE NECESSARY B 8
SAFETY PRECAUTIONS BEFORE t .sM ; LBFsFT=
MOVING THE VEHICLE
MACHINE

0 %

%NERGIZE THE STARTER CIRCUIT AND START THE PRIME MOVER

7HILE OPERATING AT NORMAL SPEED AND WITH THE PUMP IN ITS NEUTRAL ZERO mOW
POSITION NOTE THE PRESSURE READING ON THE GAUGES .OTE THIS READING AS THE BASE
PRESSURE

3LOWLY MOVE THE CONTROL HANDLE IN ONE DIRECTION WHILE OBSERVING THE PRESSURE
GAUGES AND THE CONTINUITY CHECKER4HE SWITCH MUST OPEN BEFORE THE PRESSURE ON
EITHER GAUGE INCREASES MORE THAN BAR ; PSI= FROM THE BASE PRESSURE OBTAINED AT
NEUTRAL

3LOWLY MOVE THE CONTROL HANDLE IN THE OPPOSITE DIRECTION !GAIN 4HE SWITCH MUST
OPEN BEFORE THE GAUGE PRESSURE INCREASES MORE THAN BAR ; PSI= FROM BASE
PRESSURE

6ERIFY CONTINUITY AGAIN WHEN THE CONTROL IS RETURNED TO NEUTRAL

)F THE SWITCH DOES NOT OPEN AT BASE PRESSURE PLUS TO BAR ; TO PSI= IN EITHER
DIRECTION STOP THE PRIME MOVER AND READJUST THE ECCENTRIC PLUG AS DESCRIBED IN THE
PREVIOUS SECTION )F THE PRESSURE DIFFERENCE IS EQUAL IN EACH DIRECTION BUT GREATER
THAN BAR ; PSI= LOOSEN THE SWITCH LOCK NUT AND TURN THE SWITCH CLOCKWISE
TURN ² TO INCREASE THE SENSITIVITY 2ETIGHTEN THE LOCK NUT AND RECHECK PRESSURE
DIFFERENCES AND CONTINUITY

!FTER VERIFYING PROPER CONTROL AND SWITCH OPERATION STOP THE PRIME MOVER 2EMOVE
THE CONTINUITY CHECKER AND PRESSURE GAUGES 2EINSTALL THE SERVO PRESSURE PORT PLUGS
AND RECONNECT THE ELECTRICAL LEADS FROM THE MACHINE STARTER CIRCUIT TO THE .33 )NSTALL
AND ADJUST THE EXTERNAL CONTROL LINKAGE IF NECESSARY

44 520L0818 s 2EV !" s !PRIL 2008

930 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

HYDRAULIC 4HE NEUTRAL ADJUSTMENT IS THE ONLY ADJUSTMENT THAT CAN BE MADE ON HYDRAULIC AND
DISPLACEMENT ELECTRIC DISPLACEMENT CONTROLS !LL OTHER FUNCTIONS ARE PRESET AT THE FACTORY
CONTROL (HDC) AND
ELECTRIC DISPLACEMENT -AKE THIS ADJUSTMENT ON A TEST STAND OR ON THE VEHICLEMACHINE WITH THE PRIME MOVER
CONTROL (EDC) OPERATING W
ADJUSTMENT

HDC and EDC neutral adjustment

W 7ARNING
SerVO PRESSURE GAUGE PORT -
4HE FOLLOWING PROCEDURE
MAY REQUIRE THE VEHICLE G BAR ; PSI=
ServO PRESSURE GAUGE PORT - B
MACHINE TO BE DISABLED
WHEELS RAISED OFF THE G BAR ; PSI= t .sM ; LBFsFT=
GROUND WORK FUNCTION B M72
DISCONNECTED ETC WHILE t .sM ; LBFsFT= I OR MM
PERFORMING THE PROCEDURE
IN ORDER TO PREVENT INJURY
TO THE TECHNICIAN AND
BYSTANDERS4AKE NECESSARY
SAFETY PRECAUTIONS BEFORE
MOVING THE VEHICLE
MACHINE M90
h OR MM
t .sM ; LBFsFT= OR
.sM ; LBFsFT=
0 %

)NSTALL A BAR ; PSI= GAUGE IN EACH OF THE TWO DISPLACEMENT CONTROL CYLINDER
GAUGE PORTS - AND - $ISCONNECT THE EXTERNAL CONTROL INPUT HYDRAULIC OR
ELECTRONIC FROM THE CONTROL 3TART THE PRIME MOVER AND OPERATE AT NORMAL SPEED

,OOSEN THE LOCK NUT - WITH A MM OR MM HEX WRENCH

5SING A MM OR MM INTERNAL HEX WRENCH ROTATE THE ADJUSTING SCREW -

CLOCKWISE UNTIL THE PRESSURE INCREASES IN ONE OF THE PRESSURE GAUGES .OTE THE
ANGULAR POSITION OF THE WRENCH 2OTATE THE NEUTRAL ADJUSTING SCREW COUNTERCLOCKWISE
UNTIL THE PRESSURE INCREASES BY AN EQUAL AMOUNT ON THE OTHER GAUGE !GAIN NOTE THE
ANGULAR POSITION OF THE WRENCH

2OTATE THE ADJUSTING SCREW CLOCKWISE HALF THE DISTANCE BETWEEN THE LOCATIONS NOTED
ABOVE4HE GAUGES SHOULD READ THE SAME PRESSURE CASE PRESSURE INDICATING THAT THE
CONTROL IS IN ITS NEUTRAL POSITION

(OLD THE NEUTRAL ADJUSTING SCREW STATIONARY4IGHTEN THE NEUTRAL ADJUSTING SCREW
LOCK NUT TO .sM ; LBFsIN= FOR THE MM SCREW OR .sM ; LBFsIN= FOR THE MM
SCREW $O NOT OVERTORQUE THE NUT

/NCE THE NEUTRAL POSITION IS SET STOP THE PRIME MOVER REMOVE THE GAUGES AND INSTALL
THE GAUGE PORT PLUGS 2ECONNECT THE EXTERNAL CONTROL INPUT

520L0818 s 2EV !" s !PRIL 2008 45

008 914 20 BOMAG 931
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

SPEED SENSOR 7HEN INSTALLING OR ADJUSTING THE SPEED SENSOR ON A PUMP IT MUST BE SET AT A SPECIlC
ADJUSTMENT DISTANCE FROM THE SPEED RING ON THE UNITS CYLINDER4O LOCATE THE POSITION OF THE SPEED
SENSOR ON THE UNIT OR DESCRIPTION SEE THE CORRESPONDING SECTION

,OOSEN THE SENSOR LOCK NUT WITH AN Cross section view of speed sensor in
INCH HEX WRENCH variable pump

4URN THE SENSOR CLOCKWISE #7 BY

HAND UNTIL IT CONTACTS THE SPEED RING
Gap

4URN THE SENSOR COUNTERCLOCKWISE

##7 TURN ² TO ESTABLISH THE
Speed sensor
NOMINAL GAP OF MM ; INCH= Magnetic speed ring
Cylinder block
4HEN TURN THE SENSOR CLOCKWISE #7 P104 152E

UNTIL THE WRENCH mATS ON SENSOR BODY

ARE POSITIONED AT A ² ANGLE TO THE Positioning speed sensor relative to
PUMP SHAFT CENTER LINE pump shaft
Shaft centerline
1/2 inch wrench flats
-OST OPEN END WRENCHES HAVE A ²
HANDLE OFFSET 22° 22°

4HE lNAL SENSOR POSITION SHOULD BE Speed sensor with Speed sensor with
BETWEEN ² AND TURN ² packard connector turck connector

COUNTERCLOCKWISE ##7 FROM THE Shaft centerline

1/2 inch wrench flats
POINT WHERE THE SENSOR CONTACTS THE
SPEED RING
22° 22°
(OLD SENSOR IN POSITION WITH A
Speed sensor with Speed sensor with
INCH HEX WRENCH WHILE TIGHTENING packard connector turck connector
THE LOCK NUT TO .sM ; LBFsFT=
P104 155E

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932 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

STANDARD PROCEDURES Removing the pump

"EFORE WORKING ON THE PUMP CLEAN THE OUTSIDE OF THE PUMP )F THE PUMP HAS AN AUXILIARY
PUMP ATTACHED REMOVE BOTH PUMPS AS A SINGLE UNIT4AG AND CAP ALL HYDRAULIC LINES AS
THEY ARE DISCONNECTED AND PLUG ALL OPEN PORTS TO ENSURE THAT CONTAMINATION DOES NOT
ENTER THE SYSTEM

CCaution
#ONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID YOUR WARRANTY4AKE
PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND REINSTALLING SYSTEM LINES

Disassembly
7ITH THE PRIME MOVER OFF THOROUGHLY CLEAN THE OUTSIDE OF THE PUMP

4AG CAP AND DISCONNECT EACH HYDRAULIC LINE CONNECTED TO THE PUMP !S HYDRAULIC
LINES ARE DISCONNECTED PLUG EACH OPEN PORT TO ENSURE THAT DIRT AND CONTAMINATION
DO NOT ENTER THE SYSTEM

2EMOVE THE PUMP AND ITS AUXILIARY PUMP IF APPLICABLE AS A SINGLE UNIT

Inspection
%NSURE THE WORK SURFACE AND SURROUNDING AREA ARE CLEAN AND FREE OF CONTAMINANTS

)NSPECT THE SYSTEM FOR CONTAMINATION

,OOK AT THE HYDRAULIC mUID FOR SIGNS OF SYSTEM CONTAMINATION mUID DISCOLORATION
FOAM SLUDGE OR SMALL METAL PARTICLES

Reassembly
"EFORE REPLACING THE PUMP ON THE MACHINE REPLACE ALL lLTERS AND DRAIN AND lLL THE
HYDRAULIC SYSTEM WITH THE CORRECT HYDRAULIC mUID

&LUSH THE LINES BEFORE REPLACING THE HYDRAULIC mUID

520L0818 s 2EV !" s !PRIL 2008 47

008 914 20 BOMAG 933
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

SHAFT SEAL AND SHAFT 9OU CAN REPLACE THE SHAFT AND SEAL WITHOUT MAJOR DISASSEMBLY OF THE UNIT #LEAN PUMP
REPLACEMENT AND SURROUNDING AREA THOROUGHLY $ISCONNECT AND REMOVE THE PUMP FROM THE UNIT AND
CLEAN IT THOROUGHLY BEFORE STARTING REPAIRS -ARK ALL CONNECTIONS FOR LATER REASSEMBLY

Shaft removal
0OSITION THE PUMP WITH THE SHAFT FACING UP

)F THE UNIT IS POSITIONED HORIZONTALLY OR MOVED OR JARRED WHILE THE SHAFT IS OUT THE CYLINDER
BLOCK COULD MOVE OUT OF PLACE MAKING SHAFT INSTALLATION DIFlCULT

2EMOVE THE THREE OR FOUR SCREWS , HOLDING THE RETAINER PLATE , AND SEAL
CARRIER , TO THE HOUSING USING A MM HEX WRENCH UNIT A MM INTERNAL
HEX WRENCH THROUGH UNITS OR A MM INTERNAL HEX WRENCH THROUGH
UNITS 2EMOVE THE RETAINER PLATE

#ERTAIN EARLIER PRODUCTION UNITS USE A Shaft assembly

ONE PIECE RETAINER PLATE AND SEAL CARRIER
L70

!FTER REMOVING THE SCREWS THE

L60
SPRING FORCE ON THE SHAFT MAY MOVE
THE SEAL CARRIER OUT OF ITS BORE BY
L30
APPROXIMATELY MM ; INCH= )F
THE SEAL CARRIER DOES NOT MOVE FROM L40
ITS BORE PRY IT FROM ITS BORE ANDOR
LIGHTLY TAP THE END OF THE SHAFT WITH A L50
SOFT MALLET L20

2EMOVE THE / RING , FROM THE

SEAL CARRIER AND DISCARD L10

0LACE SEAL CARRIER AND SEAL IN AN ARBOR

L100
PRESS AND PRESS OUT THE SEAL ,

2EMOVE SHAFT , AND ROLLER

BEARING ASSEMBLY , FROM
PUMP9OU CAN TRANSFER THE BEARING
ASSEMBLY TO THE NEW SHAFT

5SING SNAP RING PLIERS REMOVE THE

RETAINING RING , THAT SECURES THE
ROLLER BEARING ASSEMBLY 2EMOVE THE
ROLLER BEARING ASSEMBLY

P106 181E

48 520L0818 s 2EV !" s !PRIL 2008

934 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

SHAFT SEAL AND SHAFT Inspection

REPLACEMENT )NSPECT THE SEAL CARRIER THE NEW SEAL AND THE / RING FOR ANY DAMAGE OR NICKS
(continued)
)NSPECT THE SHAFT AND BEARING FOR RUST WEAR OR CONTAMINATION 3PIN THE BEARING IN
YOUR HAND FEELING FOR ROUGHNESS 2EPLACE IF NECESSARY

Reassembly
5SING THE ARBOR PRESS PRESS THE NEW SEAL , INTO SEAL CARRIER , "E CAREFUL NOT TO
DAMAGE THE SEAL

)F THE SHAFT IS NOT BEING REPLACED PROCEED TO STEP

0LACE ROLLER BEARING ASSEMBLY ON NEW SHAFT AND SECURE WITH THE RETAINING RING

)NSTALL AN INSTALLATION SLEEVE OR WRAP SPLINE OR KEYED END OF SHAFT WITH PLASTIC lLM TO
PREVENT DAMAGE TO THE SEALING LIP ON THE SEAL DURING INSTALLATION

,UBRICATE AND INSTALL A NEW / RING , ON THE SEAL CARRIER ,UBRICATE THE SEAL WITH
CLEAN PETROLEUM JELLY

!SSEMBLE THE SEAL CARRIER AND SEAL OVER THE SHAFT AND INTO THE HOUSING BORE )NSTALL
THE RETAINER PLATE IF USED

)NSTALL THE SCREWS AND TORQUE TO THE Shaft retainer screw torque
APPROPRIATE VALUE IN THE TABLE TO THE Frame size Torque
RIGHT n .sM ; LBFsFT=
n .sM ; LBFsFT=
4ORQUE THE SCREWS IN A SEQUENCED n .sM ; LBFsFT=
PATTERN THEN RECHECK

520L0818 s 2EV !" s !PRIL 2008 49

008 914 20 BOMAG 935
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

MULTI-FUNCTION VALVE Multi-function valve removal / installation

CARTRIDGES

/LDER MULTIFUNCTION
VALVES PRE CONTAIN
DIFFERENT COMPONENTS
See multifunction valves P2B1
- Pre 1988 PAGE FOR
DISASSEMBLY INSTRUCTIONS

P13
P06

P2A1

P106 180E

Removal Multi-function valve wrench size

2EMOVE MULTI FUNCTION VALVES 0! Frame size Wrench size
AND 0" USING HEX WRENCH LISTED IN n INCH
TABLE n INCH

2EMOVE AND DISCARD / RINGS 0 AND 0

2ELIEVE SPRING PRESSURE BY REMOVING BYPASS ACTUATOR 0 USING A WRENCH4O
RETAIN PRESSURE SETTING DO NOT SEPARATE ADJUSTING SCREW 0 AND LOCKNUT 0 FROM
BYPASS ACTUATOR 0

2EMOVE AND DISCARD / RING 0

-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY9OU MAY PURCHASE / RINGS
SEPARATELY

4HE POPPET SEAT SECTION IS PRESSED OVER A LIP 0LACE THE CARTRIDGE IN A VISE AND PRY THE
POPPET SEAT 0 OFF WITH AN APPROPRIATE TOOL -AINTAIN SUFlCIENT CONTROL TO PREVENT
THE INTERNAL COMPONENTS FROM mYING LOOSE $O NOT DAMAGE PARTS DURING DISASSEMBLY

2EMOVE INTERNAL PARTS 0 0 0 0 0 0 0 AND 0

50 520L0818 s 2EV !" s !PRIL 2008

936 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

MULTI-FUNCTION VALVE Multi-function valve

CARTRIDGES
(continued) P04
P03
P01
P02
P05

P06

P07
P08
P17
P16
P15
P14
P09
P11
P13
P12

E101 531E

Inspection
#LEAN AND INSPECT ALL DISASSEMBLED PARTS

Reassembly
,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 0 0 0 AND
0

0LACE THE CARTRIDGE IN A VISE AND PRESS ON THE POPPET SEAT 0

,UBRICATE AND INSTALL NEW / RINGS 0 0 0

)NSTALL BYPASS ACTUATOR 0 WITH PRESSURE LIMITER VALVE 0 4ORQUE TO .sM
; LBFsFT=

C#AUTION
)F PRESSURE LIMITER 0 WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER
TO MODEL CODE SPECIlCATIONS

C#AUTION )NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE C

$O NOT OVERTORQUE THE
MULTI FUNCTION VALVE
CARTRIDGES Multi-function valve torque
Frame size Torque
n .sM ; LBFsFT=
n .sM ; LBFsFT=

520L0818 s 2EV !" s !PRIL 2008 51

008 914 20 BOMAG 937
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

MULTI-FUNCTION VALVE Removal Multi-function valve wrench size

CARTRIDGES - PRE 1988 2EMOVE MULTI FUNCTION VALVES USING Frame size Wrench size
HEX WRENCH LISTED IN TABLE n INCH
n INCH

2EMOVE AND DISCARD / RINGS 0 AND 0

)T IS NOT NECESSARY TO REMOVE THE BYPASS FUNCTION 0 EXCEPT FOR CLEANING7RENCH
SIZE IS

-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY / RINGS MAY BE PURCHASED
SEPARATELY

4O RETAIN PRESSURE SETTING DO NOT DISASSEMBLE BYPASS FUNCTION 0

2EMOVE RETAINING RING 0 WITH A SNAP RING PLIERS

2EMOVE POPPET SEAT 0

2EMOVE INTERNAL PARTS 0 0 0 0 AND 0

Inspection
#LEAN AND INSPECT ALL DISASSEMBLED PARTS

Multi-function valve - pre 1988

P14

P19
P12

P06

P21
P15
P14
P09
P11
P13 P22

E101 532E

52 520L0818 s 2EV !" s !PRIL 2008

938 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

MULTI-FUNCTION VALVE Reassembly

CARTRIDGES - PRE 1988 ,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 AND 0
(continued)
)NSTALL POPPET SEAT 0

)NSTALL RETAINING RING 0

)F PREVIOUSLY REMOVED LUBRICATE AND INSTALL / RING 0

)F PREVIOUSLY REMOVED REASSEMBLE AND INSTALL BYPASS ACTUATOR 0 4ORQUE TO
.sM ; LBFsFT=

,UBRICATE AND INSTALL NEW / RINGS 0 0

C#AUTION
)F PRESSURE LIMITER WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER TO
MODEL CODE SPECIlCATIONS

C#AUTION )NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE BELOW C
$O NOT OVERTORQUE THE
MULTI FUNCTION VALVE
CARTRIDGES Multi-function valve torque
Frame size Torque
n .sM ; LBFsFT=
n .sM ; LBFsFT=

PRESSURE OVERRIDE Removal Pressure override valve components

VALVE (OPTION FOR 180 2EMOVE THE FOUR SCREWS ATTACHING
FRAME SIZE) THE PRESSURE OVERRIDE VALVE TO THE
Screws
PUMP END CAP WITH A MM INTERNAL
HEX WRENCH 2EMOVE AND DISCARD THE Pressure override
/ RINGS valve

Inspection
O-rings
#LEAN AND INSPECT VALVE FOR DAMAGE
TO PARTS

Reassembly
)NSTALL NEW / RINGS )NSTALL THE VALVE
ONTO THE PUMP END CAP AND TORQUE
THE SCREWS TO .sM ; LBFsFT=

E101 079E

520L0818 s 2EV !" s !PRIL 2008 53

008 914 20 BOMAG 939
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

CHARGE PRESSURE 4HE CHARGE PRESSURE RELIEF VALVE IS SHIM ADJUSTABLE EARLY MODELS OR SCREW ADJUSTABLE
RELIEF VALVE LATE MODELS 3CREW ADJUSTABLE CHARGE RELIEF VALVE IS SHOWN

Removal
2EMOVE THE SHIM ADJUSTABLE CHARGE RELIEF VALVE PLUG WITH A INCH HEX WRENCH

"EFORE REMOVING THE SCREW ADJUSTABLE RELIEF VALVE PLUG MARK THE PLUG + LOCK NUT
+ AND HOUSING TO APPROXIMATELY MAINTAIN THE ORIGINAL ADJUSTMENT WHEN ASSEM
BLING 2EMOVE THE SCREW ADJUSTABLE CHARGE RELIEF VALVE PLUG BY LOOSENING THE LOCK
NUT WITH A HEX WRENCH CORRESPONDING TO THE TABLE

5NSCREW THE PLUG USING A LARGE Lock nut wrench size

SCREWDRIVER OR INCH HEX WRENCH Frame size Wrench size
2EMOVE AND DISCARD THE / RING + n INCH
n INCH
2EMOVE THE SPRING + AND RELIEF
VALVE POPPET +
Charge pressure relief valve
Inspection
)NSPECT THE POPPET + AND MATING
K90
SEAT IN THE ENDCAP FOR DAMAGE OR h ,OCK NUT
FOREIGN MATERIAL t ,OCK NUT TORQUE

7HEN INSPECTING SHIM ADJUSTABLE +

VALVES DO NOT ALTER THE SHIMS OR h IN
INTERCHANGE PARTS d+ K

Reassembly K70
)NSTALL THE POPPET + AND SPRING
K80
+ &OR SHIM ADJUSTABLE VALVES
INSTALL THE SHIMS AND PLUG TORQUE
TO .sM ; LBFsFT= &OR SCREW
ADJUSTABLE VALVES INSTALL THE PLUG 3EE APPROPRIATE TABLE
WITH ITS LOCK NUT ALIGNING THE MARKS
MADE AT DISASSEMBLY AND TORQUE THE
LOCK NUT TO .sM ; LBFsFT=

#HECK THE CHARGE PRESSURE AND

ADJUST IF NECESSARY 2EFER TO Charge
pressure adjustments PAGE

0 %

54 520L0818 s 2EV !" s !PRIL 2008

940 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

AUXILIARY PAD Removal

2EMOVE THE FOUR END CAP SCREWS * 2EMOVE AND DISCARD SPECIAL WASHERS *

C#AUTION Aux. pad screw wrench size

/N EARLIER PRODUCTION FRAME SIZE Frame size Wrench sizes
PUMPS WITH TWIN PORTS SECURE THE END n EARLY MM INTERNAL HEX
CAP TO THE PUMP HOUSING WITH A CLAMP TO LATE MM INTERNAL HEX
AVOID GASKET DAMAGE MM HEX
n MM HEX
2EMOVE THE AUXILIARY PAD * AND n MM INTERNAL HEX
DISCARD THE / RINGS * AND * n MM INTERNAL HEX

Inspection
)NSPECT THE AUXILIARY PAD FOR DAMAGE AND REPLACE IF NECESSARY

4AKE CARE TO ASSURE THE SURFACES ARE CLEAN AND FREE OF ANY FOREIGN MATERIAL OR PAINT
PRIOR TO INSTALLING THE AUXILIARY PAD

C#AUTION
$O NOT ALLOW THE FORCE OF THE CYLINDER BLOCK SPRING AND SWASHPLATE LEVELER SPRINGS TO
SEPARATE THE END CAP FROM THE PUMP HOUSING 'ASKET DAMAGE AND EXTERNAL LEAKAGE MAY
RESULT

Auxiliary pad components (typical)

J50
J80
Endcap screw J70
Screw torque

J60
See appropriate table for wrench size and torque
E101 084E

Inspection
)NSPECT THE AUXILIARY PAD COMPONENTS FOR WEAR OR DAMAGE AND REPLACE IF ANY IS
FOUND

4AKE CARE TO ENSURE THE SURFACES ARE CLEAN AND FREE OF ANY FOREIGN MATERIAL OR PAINT
PRIOR TO INSTALLING THE AUXILIARY PAD

Reassembly
,UBRICATE AND INSTALL / RING * ON END CAP PILOT

)NSTALL THE AUXILIARY MOUNTING PAD End cap screw torque

* ON REAR OF ENDCAP Frame size Torque
.sM ; LBFsFT=
)NSTALL FOUR LARGE SCREWS * .sM ; LBFsFT=
4ORQUE ENDCAP SCREWS IN A AND NEW WASHERS * THROUGH .sM ; LBFsFT=
CRISS CROSS PATTERN THE MOUNTING PAD AND END CAP n .sM ; LBFsFT=
INTO THE HOUSING4ORQUE PER THE n .sM ; LBFsFT=
ACCOMPANYING TABLE
520L0818 s 2EV !" s !PRIL 2008 55
008 914 20 BOMAG 941
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

CHARGE PUMP 4HE FOLLOWING PROCEDURE SHOWS HOW TO REMOVE AND INSTALL A CHARGE PUMP

Removal
&OR PUMPS WITH AN AUXILIARY MOUNTING PAD REFER TO THE Auxiliary Pad INSTRUCTIONS
PAGE

C#AUTION
/N EARLIER PRODUCTION FRAME SIZE PUMPS WITH TWIN PORTS SECURE THE ENDCAP TO THE
PUMP HOUSING WITH A CLAMP TO AVOID GASKET DAMAGE

2EMOVE THE SIX SCREWS ( HOLDING THE CHARGE PUMP COVER RETAINER (

2EMOVE THE RETAINER ( AND THE Retainer screw wrench size
CHARGE PUMP COVER * 2EMOVE Frame size Wrench size
AND DISCARD / RING * .OTE THE n MM
ORIENTATION OF THE GEROTOR ASSEMBLY n MM
(

Current charge pump conﬁguration

H40

H05

H60
H50
H31
J50
J15

J30

H70
E101 082E
H80

2EFER TO APPROPRIATE Sauer-Danfoss Series 90 service parts manual FOR EARLIER CHARGE PUMP
CONlGURATIONS

2EMOVE THE CHARGE PUMP COUPLING ( AND CHARGE PUMP DRIVE KEY (

2EMOVE THE CHARGE PUMP GEROTOR ASSEMBLY (

56 520L0818 s 2EV !" s !PRIL 2008

942 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

CHARGE PUMP 2EMOVE THE ALIGNMENT PIN (

(continued)
2EMOVE THE INNER PORT PLATE (

Inspection
)NSPECT ALL PARTS FOR ABNORMAL WEAR OR DAMAGE AND REPLACE IF NECESSARY

)F INSTALLING A DIFFERENT DISPLACEMENT CHARGE PUMP THE GEROTOR ASSEMBLY GEROTOR OUTER
ECCENTRIC RING AND INNER PORT PLATE EARLY AND LATE PRODUCTION PUMPS OR OUTER SPACER
PLATES INTERMEDIATE PRODUCTION PUMPS MUST BE REPLACED TOGETHER )F DIFFERENT
THICKNESS PORT PLATES ARE USED IN AN EARLY PRODUCTION CHARGE PUMP ASSEMBLY THE THICKER
PLATE IS THE INNER PORT PLATE INSTALLED NEXT TO THE PUMP END CAP

$IFFERENT PRODUCTION CHARGE PUMP ASSEMBLIES INCLUDE A DIFFERENT QUANTITY TYPE OF PORT
PLATES AND SPACER PLATES

Reassembly
"E SURE TO INSTALL THE CHARGE PUMP IN THE Orienting alignment pin
PROPER ORIENTATION )F UNSURE OF CHARGE
Discharge Gerotor Discharge
PUMP ROTATION REFER TO THE MODEL CODE assembly
Alignment pin

4HE ORIENTATION OF THE GEROTOR ASSEMBLY

Inlet Inlet
OUTER ECCENTRIC RING AND THE LOCATION
Alignment pin
OF THE ALIGNMENT PIN IN THE END CAP
Gerotor assembly
DETERMINE THE CHARGE PUMP ROTATION
Left hand rotation Right hand rotation
(outside looking into pump) (outside looking into pump)
$O NOT MIX CHARGE PUMP PARTS FROM P104 160E
DIFFERENT PRODUCTION PERIODS !LWAYS
INSTALL AS A COMPLETE ASSEMBLY

)NSTALL THE INNER PORT PLATE ( AND THE GEROTOR ASSEMBLY OUTER RING

)NSTALL THE ALIGNMENT PIN ( TO PROPERLY ORIENT THE PORT PLATES AND OUTER ECCENTRIC
RING FOR CORRESPONDING PUMP ROTATION

0RIOR TO INSTALLATION LUBRICATE THE )$ /$ AND SIDE FACES OF THE GEROTOR ASSEMBLY

)NSTALL THE GEROTOR ASSEMBLY (

)NSTALL THE OUTER PORT PLATE EARLY PRODUCTION AND INTERMEDIATE PRODUCTION PUMPS
ONLY

)NSTALL THE SPACER PLATE IF PRESENT INTERMEDIATE PRODUCTION PUMPS

)NSTALL THE CHARGE PUMP DRIVE KEY ( INTO THE CHARGE PUMP COUPLING ( AND
RETAIN WITH PETROLEUM JELLY

520L0818 s 2EV !" s !PRIL 2008 57

008 914 20 BOMAG 943
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

CHARGE PUMP )NTERMEDIATE PRODUCTION CMÃ AND CMÃ PUMPS USE THE SAME CHARGE PUMP
(continued) COUPLING4WO KEYWAYS ARE PROVIDED IN THE COUPLING FOR THE CHARGE PUMPS USED IN THESE
UNITS4HE REAR KEYWAY WITH IDENTIlER GROOVE IS USED IN CMÃ PUMPS4HE FRONT KEYWAY
CLOSEST TO THE INTERNALLY SPLINED END OF THE SHAFT IS USED IN CMÃ PUMPS

)NSTALL THE CHARGE PUMP COUPLING4HE INTERNALLY SPLINED END OF THE COUPLING MUST
ENGAGE THE MAIN PUMP SHAFT

4HE OUTSIDE DIAMETER OF THE INTERNALLY SPLINED END OF SOME EARLY PRODUCTION CHARGE
PUMP COUPLINGS WERE CHAMFERED %ARLY PRODUCTION END CAPS MAY NOT BE MACHINED TO
ACCEPT A NON CHAMFERED COUPLING !LWAYS USE A CHAMFERED CHARGE PUMP COUPLING IN
PUMPS WITH THE EARLY ENDCAP

&OR PUMPS WITH AN AUXILIARY MOUNTING PAD INSTALL THE AUXILIARY DRIVE COUPLING

&OR PUMPS WITH NO AUXILIARY PAD INSTALL A NEW / RING * ONTO CHARGE PUMP COVER
)F AN AUXILIARY PAD IS INSTALLED AN / RING IS NOT USED ON THE COVER

#AREFULLY REMOVE THE ALIGNMENT PIN FROM THE CHARGE PUMP PARTS )NSTALL THE PIN IN ITS
HOLE IN THE CHARGE PUMP COVER * SEE PREVIOUS PAGE FOR CORRECT ORIENTATION AND
RETAIN WITH PETROLEUM JELLY )NSTALL THE COVER WITH ALIGNMENT PIN INTO THE END CAP
AND ALIGNED CHARGE PUMP PARTS 4AKE CARE NOT TO DAMAGE THE COVER / RING IF USED

C#AUTION
)N ORDER TO AVOID LOSS OF CHARGE PRESSURE IN PUMPS WITH AN AUXILIARY MOUNTING PAD
ALWAYS INSTALL THE CHARGE PUMP COVER WITH THE PAD DRAIN HOLE LOCATED ON THE SAME SIDE
OF THE END CAP AS THE CHARGE INLET PORT 2EFER TO THE SECTION “Auxiliary Pad Installation” FOR
DETAILS

)NSTALL THE CHARGE PUMP COVER Retainer screw torque

RETAINER ( AND THE SIX INTERNAL Frame size Torque
HEX SCREWS ( 4ORQUE THE SCREWS n .sM ; LBFsFT=
PER THE TABLE AT THE RIGHT n .sM ; LBFsFT=

&OR PUMPS WITH AUXILIARY MOUNTING PADS INSTALL THE / RING AND AUXILIARY MOUNTING
PAD ADAPTOR ONTO THE END CAP 2EFER TO THE CORRESPONDING SECTION FOR INSTRUCTIONS ON
AUXILIARY PAD INSTALLATION

ADDING AN AUXILIARY )F INSTALLING AN AUXILIARY PAD KIT ON A PUMP THAT WAS PREVIOUSLY WITHOUT ONE CAREFULLY
PAD TO A PUMP REMOVE THE ALIGNMENT PIN FROM THE CHARGE PUMP PARTS
PREVIOUSLY WITHOUT
ONE )NSTALL THE PIN IN ITS HOLE IN THE NEW CHARGE PUMP COVER WITH HOLE FOR THE AUXILIARY
COUPLING AND RETAIN WITH PETROLEUM JELLY

)NSTALL THE NEW CHARGE PUMP COVER WITH ALIGNMENT PIN INTO THE END CAP AND THE
ALIGNED CHARGE PUMP PARTS

,UBRICATE AND INSTALL / RING )NSTALL AUXILIARY PAD 2EFER TO PREVIOUS SECTIONS Auxiliary
pad PAGE AND Charge pump PAGE FOR INSTRUCTIONS

58 520L0818 s 2EV !" s !PRIL 2008

944 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

INTEGRAL CHARGE Removal Lock nut wrench size and torque

PRESSURE FILTER 2EMOVE THE lLTER CANISTER . FROM Frame size Wrench size Torque
REPLACEMENT THE lLTER HEAD . AS DESCRIBED ON n INCH .sM ; LBFsFT=
THE CANISTER n INCH .sM ; LBFsFT=
n INCH .sM ; LBFsFT=
(OLD THE lLTER HEAD IN PLACE AND
LOOSEN THE LOCK NUT . USING THE WRENCH SIZE CORRESPONDING TO PUMP FRAME SIZE

2OTATE THE lLTER HEAD COUNTERCLOCKWISE TO REMOVE IT FROM THE HOUSING 2EMOVE AND
DISCARD THE / RING .

2EMOVE THE HYDRAULIC TUBE . FROM ITS BORE IN THE ENDCAP

Inspection
)NSPECT THE lLTER HEAD AND LOCK NUT SEALING SURFACES )F YOU lND ANY NICKS OR SCRATCHES
REPLACE THE DAMAGED COMPONENTS

Reassembly
)NSTALL THE HYDRAULIC TUBE . INTO ITS BORE IN THE ENDCAP )NSTALL THE lLTER HEAD .
INTO THE PORT USING A NEW / RING . 4HE HYDRAULIC TUBE SHOULD GO IN WITH LOW FORCE

!FTER ROTATING THE lLTER HEAD CLOCKWISE SO THAT THE THREADS ENGAGE WITH THE THREADS
C#AUTION IN THE ENDCAP CONTINUE TO ROTATE IT CLOCKWISE BETWEEN AND REVOLUTIONS 0OSITION
&AILURE TO INSTALL THE lLTER HEAD AS DESIRED C
MANIFOLD OR lLTER HEAD
TO A SUFlCIENT DEPTH IN 7HILE HOLDING THE lLTER HEAD IN THE DESIRED POSITION TIGHTEN THE SWIVEL LOCK NUT
THE END CAP WILL RESULT IN . AND TORQUE AS SHOWN IN TABLE
INSUFlCIENT ENGAGEMENT
OF THE TUBE IN THE END )NSTALL A NEW lLTER CANISTER . PER THE INSTRUCTIONS ON THE lLTER CANISTER
CAP BORE4HIS MAY ALLOW
UNlLTERED OIL TO BYPASS THE
lLTER AND ENTER THE CHARGE Integral charge pressure ﬁlter
SYSTEM

N25 N20
N15 Fi"!#"
#""! #
N36A

N36
11/16 in
$ $t]

N40

N10
N35A
N35
11/16 in
$ $t] P106 182E

520L0818 s 2EV !" s !PRIL 2008 59

008 914 20 BOMAG 945
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

PUMP CONTROL COVER Removal

PLATE 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF COVER PLATE

5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX COVER PLATE MOUNTING SCREWS
- 2EMOVE THE COVER PLATE - AND GASKET - FROM HOUSING $ISCARD THE
GASKET

C#AUTION
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

Reassembly
)NSTALL A NEW GASKET ON THE HOUSING )NSTALL THE COVER PLATE AND INSTALL THE SCREWS
4ORQUE THE SCREWS TO .sM ; LBFsFT=

)NSTALL A SEALING WASHER UNDER THE HEAD OF ANY MOUNTING SCREWS THAT ARE INSTALLED INTO
THROUGH HOLES IN THE HOUSING

Pump controls cover plate

M90 X
h MM
.sM ; LBFsFT=

-
3EAL WASHER
LOCATION CC

-
d

0 %

60 520L0818 s 2EV !" s !PRIL 2008

946 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an HDC/EDC module showing

CONTROL ORIFICES DESCRIBED IN THE INSTRUCTIONS FOR THE oriﬁce locations
SPECIlC DISPLACEMENT CONTROL A
B
TA P
/RIlCE PLUGS MAY BE LOCATED IN TB
THE CONTROL ASSEMBLY AT THE PUMP
HOUSING FACE 2EMOVE THE ORIlCE
PLUGS ONE AT A TIME TO AVOID MIXING
THEM UP WITH A MM INTERNAL HEX
WRENCH .OTE THE LOCATION OF EACH Orifice plugs

PLUG DO NOT INTERCHANGE PLUGS Orifice check valve

#LEAN REINSTALL AND TORQUE THE ORIlCE E101 085E

PLUGS TO .sM ; LBFsFT=

!SSEMBLE THE CONTROL ONTO THE PUMP 2EFER TO THE INSTRUCTIONS FOR THE SPECIlC CONTROL

DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an MDC module showing

CONTROL ORIFICE DESCRIBED IN THE INSTRUCTIONS FOR THE oriﬁce locations
CHECK VALVE SPECIlC DISPLACEMENT CONTROL
TA A B TB

4HE ORIlCE CHECK VALVE IS LOCATED IN P

THE CONTROL ASSEMBLY AT THE SURFACE

OF THE PUMP HOUSING FACE 2EMOVE
THE SPRING RETAINER AND SPRING FROM
Orifice plugs
THE ORIlCE CHECK VALVE CAVITY AND
THEN REMOVE THE ORIlCE CHECK VALVE
Orifice check valve
#LEAN AND INSTALL THE ORIlCE CHECK E101 086E

VALVE IN THE CAVITY AND THEN INSTALL

THE SPRING AND SPRING RETAINER TO HOLD THE ORIlCE CHECK VALVE IN POSITION

!SSEMBLE THE CONTROL ONTO THE PUMP 2EFER TO THE INSTRUCTIONS FOR THE SPECIlC CONTROL

DISPLACEMENT $O NOT REMOVE THE ADAPTER PLATE UNLESS Displacement control adapter plate (early
CONTROL ADAPTER LEAKAGE IS EVIDENT4HE MOUNTING SCREWS production 130 cm³ pumps only)
PLATE (EARLY WITH SEALING COMPOUND ARE DIFlCULT TO Adapter plate
screws
PRODUCTION 130 REMOVE
PUMPS ONLY) 6 mm
4HE SCREWS FASTENING THE CONTROL ADAPTER

PLATE TO THE HOUSING HAVE SEALING

COMPOUND ON THE THREADS9OU MAY O-rings Adapter plate
REMOVE THEM WITH A MM INTERNAL HEX
WRENCH IF NECESSARY 2EMOVE AND DISCARD
THE / RINGS AND SEALS Seal

7HEN INSTALLING THE ADAPTER PLATE

REPLACE SCREWS WITH SEALING COMPOUND
AND ENSURE THE NEW / RINGS AND SEAL ARE
E101 087E
IN THE PROPER POSITION4ORQUE THE SCREWS
TO .sM ; LBFsFT=
520L0818 s 2EV !" s !PRIL 2008 61
008 914 20 BOMAG 947
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

MANUAL DISPLACEMENT Removal

CONTROL (MDC) 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL

5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX CONTROL MOUNTING SCREWS -
2EMOVE THE CONTROL - WITH ORIlCE CHECK VALVE 4 AND SPRING 4 AND CONTROL
GASKET - FROM THE HOUSING $ISCARD THE GASKET

)F NECESSARY REMOVE THE CONTROL HANDLE - BY REMOVING THE LOCKING NUT - AND
WASHER -

C#AUTION
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

Reassembly
)NSTALL A NEW GASKET - )NSPECT CONTROL TO ASSURE THAT THE CONTROL ORIlCE CHECK
VALVE AND SPRING ARE IN THEIR PROPER POSITION IN THE CONTROL

)NSTALL THE CONTROL %NGAGE THE PIN ON THE CONTROL LINKAGE INTO THE MATING HOLE IN THE
LINK ATTACHED TO THE SWASHPLATE

7ITH THE CONTROL IN POSITION MOVE CONTROL LEVER BOTH DIRECTIONS TO CHECK PROPER
ENGAGEMENT OF CONTROL LINKAGE PIN )F PROPERLY ASSEMBLED LEVER WILL RETURN TO
CENTER )F LEVER DOES NOT RETURN TO CENTER REMOVE THE CONTROL AND REPEAT THE ABOVE
PROCEDURE

MDC removal/installation
M72
3 - h 8 mm
h IN M70 .sM ; LBFsFT=
.sM ; LBFsFT=

- X
I MM
.sM ; LBFsFT=

-
3EAL WASHER d
LOCATION CC
4

4 4

0 %

62 520L0818 s 2EV !" s !PRIL 2008

948 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

MANUAL DISPLACEMENT )F REMOVED INSTALL THE CONTROL HANDLE - AND LOCKING NUT - WITH WASHER -
CONTROL (MDC) (OLD THE POSITION OF THE HANDLE AND TORQUE THE LOCKING NUT TO .sM ; LBFsFT= USING
(continued) AN MM HEX WRENCH

!LIGN THE CONTROL GASKET AND INSTALL THE SCREWS4ORQUE THE SCREWS TO .sM
; LBFsFT=

W 7ARNING )NSTALL A SEALING WASHER UNDER THE HEAD OF MOUNTING SCREWS THAT ARE INSTALLED INTO
4HE NEUTRAL START SWITCH THROUGH HOLES IN THE HOUSING
NEUTRAL MUST BE READJUSTED
AFTER REASSEMBLING THE
-$# MODULE )F THE CONTROL IS EQUIPPED WITH A NEUTRAL START SWITCH REFER TO MDC Neutral start switch
adjustment INSTRUCTIONS PAGE

SOLENOID OVERRIDE Removal

VALVE FOR MDC 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF VALVE

2EMOVE THE SOLENOID FROM THE VALVE BY REMOVING THE NUT WITH A INCH HEX
WRENCH 2EMOVE THE SOLENOID VALVE - FROM THE MANIFOLD - WITH A INCH
HEX WRENCH

5SING A MM INTERNAL HEX WRENCH REMOVE THE TWO SCREWS - AND REMOVE
SOLENOID MANIFOLD - FROM HOUSING 2EMOVE AND DISCARD THE GASKET -

Reassembly
4ORQUE VALVE - TO .sM ; LBFsFT=4ORQUE SOLENOID NUT TO .sM ; LBFsFT=
$O NOT OVERTORQUE THE SOLENOID NUT

)NSTALL A NEW GASKET ON THE CONTROL HOUSING )NSTALL THE MANIFOLD ONTO THE CONTROL
HOUSING ALIGN THE GASKET AND INSTALL THE SCREWS4ORQUE THE SCREWS TO .sM
; LBFsFT=

Solenoid override valve removal/installation

M90 (x6)
5 mm M77
] M76A
M76C
M76B
M76

M78 (x2)
5 mm
M75
]
P106 186E

520L0818 s 2EV !" s !PRIL 2008 63

008 914 20 BOMAG 949
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

SOLENOID OVERRIDE Removal

VALVE FOR MDC WITH 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF VALVE
PRESSURE RELEASED
BRAKE 5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SOLENOID VALVE MOUNTING SCREWS
- 2EMOVE THE SOLENOID VALVE - WITH / RINGS FROM THE ADAPTER PLATE $ISCARD
THE / RINGS

5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR ADAPTER PLATE MOUNTING SCREWS
- 2EMOVE THE ADAPTER PLATE AND / RINGS - - AND - FROM THE CONTROL
HOUSING $ISCARD THE / RINGS

Reassembly
5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS - - - ON THE
ADAPTER PLATE 0LACE THE ADAPTER PLATE INTO POSITION AND INSTALL THE SCREWS -
4ORQUE THE SCREWS TO .sM ; LBFsFT=

5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS ONTO THE SOLENOID VALVE
ASSEMBLY - AND INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE )NSTALL THE
SCREWS - AND TORQUE TO .sM ; LBFsFT=

Solenoid override valve removal/installation

M98 (x4)
4 mm
M9
t]

M95
M96
M97 M92 (x4)
4 mm
t]
P106 192E

64 520L0818 s 2EV !" s !PRIL 2008

950 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

HYDRAULIC AND Removal

ELECTRIC DISPLACEMENT 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL
CONTROLS
5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX CONTROL MOUNTING SCREWS -
2EMOVE THE CONTROL - WITH ORIlCE CHECK VALVE 4 AND SPRING 4 AND CONTROL
GASKET - FROM HOUSING $ISCARD THE GASKET

C#AUTION
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

Reassembly
)NSTALL A NEW GASKET - 6ERIFY THE CONTROL ORIlCE CHECK VALVE AND SPRING 4 ARE IN
THEIR PROPER POSITION IN THE CONTROL

0OSITION THE CONTROL ON THE HOUSING )NSERT THE CONTROL LINKAGE PIN INTO THE
SWASHPLATE LINK

Hydraulic/Electric displacement control

M90 X
I MM
.sM ; LBFsFT=

-
d

4
4

0 %

520L0818 s 2EV !" s !PRIL 2008 65

008 914 20 BOMAG 951
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

7ITH THE CONTROL IN POSITION MOVE CONTROL ASSEMBLY LEFT AND RIGHT TO CHECK
ENGAGEMENT OF PIN IN THE LINK 0ROPER ENGAGEMENT IS INDICATED BY AN INCREASING
RESISTANCE AS THE CONTROL IS MOVED AWAY FROM CENTER POSITION .ON ENGAGEMENT OF
PIN IS INDICATED BY LACK OF SPRING FORCE )N CASE OF NON ENGAGEMENT REMOVE CONTROL
AND REPEAT THE ABOVE PROCEDURE

!LIGN THE CONTROL GASKET AND INSTALL THE SCREWS4ORQUE THE SCREWS TO .sM
; LBFsFT=

)NSTALL A SEALING WASHER UNDER THE HEAD OF ANY MOUNTING SCREWS THAT ARE INSTALLED INTO
THROUGH HOLES IN THE HOUSING

PRESSURE CONTROL Removal

PILOT (PCP) FOR 4HOROUGHLY CLEAN EXTERNAL SURFACES OF CONTROL
ELECTRIC DISPLACEMENT
5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SCREWS - AND REMOVE THE
0#0 -

Inspection
#HECK SURFACES FOR NICKS OR DAMAGE #LEAN INTERNAL SCREENS

Reassembly
)NSTALL NEW / RINGS - AND - IN 0#0 (OUSING 0LACE 0#0 AGAINST %$# HOUSING
AND INSTALL THE SCREWS - 4ORQUE TO .sM ; LBFsFT=

$O NOT REMOVE BLACK PLASTIC COVER FROM THE ALUMINUM PLATE4HIS IS NOT A SERVICEABLE ITEM
AND WILL VOID THE PRODUCT WARRANTY

PCP removal/installation M90 (x6)

5 mm
''$]

Seal washer
location
(42, 180, 250 cc)
M97

M96 (x3)

M98 (x4)
M9
4 mm
' 't] P106 194E

66 520L0818 s 2EV !" s !PRIL 2008

952 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

3-POSITION (FNR) Removal

ELECTRIC CONTROL 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL

5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SOLENOID VALVE MOUNTING SCREWS
7 2EMOVE THE SOLENOID VALVE 7 WITH / RINGS 7! AND ORIlCE FROM
THE ADAPTER PLATE

5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX ADAPTER PLATE MOUNTING SCREWS
C#AUTION - 2EMOVE THE ADAPTER PLATE AND GASKET - FROM THE HOUSING $ISCARD THE
0ROTECT EXPOSED SURFACES GASKET C
AND CAVITIES FROM DAMAGE
AND FOREIGN MATERIAL Inspection
)NSPECT THE ORIlCE INSTALLED BETWEEN THE VALVE AND ADAPTER PLATE4HIS ORIlCE must BE
INSTALLED IN THE CASE DRAIN PASSAGE FOR PROPER PRESSURE LIMITER OPERATION

Reassembly
)NSTALL A SEALING WASHER )NSTALL A NEW GASKET - ON THE HOUSING 0LACE THE ADAPTER PLATE INTO POSITION AND
UNDER THE HEAD OF ANY INSTALL THE SCREWS - C4ORQUE THE SCREWS TO .sM ; LBFsFT=
MOUNTING SCREWS THAT
ARE INSTALLED INTO THROUGH )NSTALL NEW / RINGS 7! AND THE ORIlCE ONTO THE SOLENOID VALVE ASSEMBLY AND
HOLES IN THE HOUSING INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE )NSTALL SCREWS 7 4ORQUE TO
.sM ; LBFsFT=

FNR removal/installation
7 X
I MM
.sM ; LBFsFT=

7!
- X d
I MM
.sM ; LBFsFT= 4
4
4 M900
-

3EAL WASHER
LOCATION CC
4

- 4
4
d

0 %

520L0818 s 2EV !" s !PRIL 2008 67

008 914 20 BOMAG 953
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
-INOR REPAIR

DISPLACEMENT )F THE PUMP IS EQUIPPED WITH CONTROL Filter screen installation

CONTROL FILTER lLTER SCREENS IN THE PUMP HOUSING LATE B90
SCREENS PRODUCTION PRESS THEM INTO POSITION
WITH THE ROUNDED EDGE OF THE lLTER P106 690E

SCREENS FACING THE CONTROL UNTIL THEY ARE

mUSH TO MM ; INCH= BELOW THE
SURFACE OF THE HOUSING

SPEED SENSOR Removal

,OOSEN THE LOCK NUT USING A IN HEX WRENCH

5NSCREW THE SPEED SENSOR " FROM THE PUMP HOUSING 2EMOVE AND DISCARD THE
/ RING "!

Reassembly
)NSTALL A NEW / RING BEFORE REINSTALLING THE SENSOR

2EINSTALL THE SPEED SENSOR WITH LOCK NUT AND / RING INTO THE HOUSING !DJUST THE
GAP BETWEEN THE SENSOR AND THE MAGNETIC SPEED RING AS INSTRUCTED IN Speed sensor
adjustment PAGE AND TORQUE THE SENSOR LOCK NUT TO .sM ; LBFsFT=

)F A SPEED SENSOR IS NOT INSTALLED USE A IN INTERNAL HEX WRENCH TO TORQUE THE
HOUSING PLUG " TO .sM ; LBFsFT=

Typical location of speed sensor

B83 O-ring plug

]
B83A

B83 B83A

]

E101 095E

68 520L0818 s 2EV !" s !PRIL 2008

954 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ORQUE CHART

FASTENER SIZE AND Item Fastener Frame size Wrench size Torque
TORQUE CHART B83 3PEED SENSOR LOCK NUT IN HEX .sM ; LBFsFT=
E60 3IDE COVER SCREW MM HEX .sM ; LBFsFT=
"LIND HOLES MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
E60 3IDE COVER SCREW MM HEX .sM ; LBFsFT=
4HRU HOLES MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
& 3ERVO CYLINDER SCREW MM HEX .sM ; LBFsFT=
F211 MM HEX .sM ; LBFsFT=
' %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
G97 MM INTERNAL HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
H80 #HARGE PUMP RETAINING SCREW MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
J80 %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
EARLY MM INTERNAL HEX .sM ; LBFsFT=
LATE MM INTERNAL HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
K10 #HARGE PRESSURE VALVE PLUG IN HEX .!
K90 #HARGE PRESSURE LOCK NUT IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
L70 3HAFT RETAINING SCREW MM HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
M72 -$# HANDLE NUT 8 mm .sM ; LBFsFT=
M78 $E STROKE VALVE MANIFOLD SCREW MM INTERNAL HEX .sM ; LBFsFT=
M85 %CCENTRIC PLUG LOCK NUT IN HEX .sM ; LBFsFT=
M88 .EUTRAL START SWITCH LOCK NUT IN HEX .sM ; LBFsFT=
M90 #ONTROL MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M92 3OLENOID VALVE MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M98 0#0 MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
N10 &ILTER REDUCER ASSEMBLY IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
N37 &ILTER PLUG ASSEMBLY IN INTERNAL HEX .sM ; LBFsFT=
0" -ULTI FUNCTION VALVE IN HEX .sM ; LBFsFT=
P2A1 IN HEX .sM ; LBFsFT=

520L0818 s 2EV !" s !PRIL 2008 69

008 914 20 BOMAG 955
20.1 Travel and vibration pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ORQUE CHART

PLUG SIZE AND TORQUE )F ANY PLUGS OR lTTINGS ARE REMOVED FROM THE PUMP DURING SERVICING INSTALL AND TORQUE AS
CHART INDICATED IN THE ACCOMPANYING TABLEC

!LWAYS INSTALL NEW / RINGS BEFORE REINSTALLING THE PLUGS OR lTTINGS

C#AUTION
4ORQUE PLUGS OR lTTINGS Item O-ring plug Wrench size Torque
INSTALLED INTO ALUMINUM B70, B72 INTERNAL HEX WRENCH .sM ; LBFsFT=
HOUSINGS TO THE LOWER B71 INTERNAL HEX WRENCH .sM ; LBFsFT=
VALUES SPECIlED FOR B80 INTERNAL HEX WRENCH .sM ; LBFsFT=
INTERNAL HEX PLUGS OF THE B82, B83 INTERNAL HEX WRENCH .sM ; LBFsFT=
SAME SIZE G18 INTERNAL HEX WRENCH .sM ; LBFsFT=
G45-G50 INCH HEX WRENCH .sM ; LBFsFT=
G52-G54 INTERNAL HEX WRENCH .sM ; LBFsFT=
H90 (not shown) INTERNAL HEX WRENCH .sM ; LBFsFT=
N35, N36 (not shown) INCH HEX WRENCH .sM ; LBFsFT=
N37 INTERNAL HEX WRENCH .sM ; LBFsFT=

956 BOMAG 008 914 20

Travel and vibration pump 20.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
.OTES

520L0818 s 2EV !" s !PRIL 2008 71

008 914 20 BOMAG 957
20.1 Travel and vibration pump

OUR PRODUCTS Sauer-Danfoss Mobile Power and Control Systems

– Market Leaders Worldwide
(YDROSTATIC TRANSMISSIONS
3AUER $ANFOSS IS A COMPREHENSIVE SUPPLIER PROVIDING COMPLETE
(YDRAULIC POWER STEERING
SYSTEMS TO THE GLOBAL MOBILE MARKET
%LECTRIC POWER STEERING
3AUER $ANFOSS SERVES MARKETS SUCH AS AGRICULTURE CONSTRUCTION ROAD
%LECTROHYDRAULIC POWER STEERING
BUILDING MATERIAL HANDLING MUNICIPAL FORESTRY TURF CARE AND MANY
#LOSED AND OPEN CIRCUIT AXIAL PISTON OTHERS
PUMPS AND MOTORS
'EAR PUMPS AND MOTORS 7E OFFER OUR CUSTOMERS OPTIMUM SOLUTIONS FOR THEIR NEEDS AND
DEVELOP NEW PRODUCTS AND SYSTEMS IN CLOSE COOPERATION AND
"ENT AXIS MOTORS PARTNERSHIP WITH THEM
/RBITAL MOTORS
3AUER $ANFOSS SPECIALIZES IN INTEGRATING A FULL RANGE OF SYSTEM
4RANSIT MIXER DRIVES COMPONENTS TO PROVIDE VEHICLE DESIGNERS WITH THE MOST ADVANCED
0LANETARY COMPACT GEARS TOTAL SYSTEM DESIGN

0ROPORTIONAL VALVES 3AUER $ANFOSS PROVIDES COMPREHENSIVE WORLDWIDE SERVICE FOR ITS
$IRECTIONAL SPOOL VALVES PRODUCTS THROUGH AN EXTENSIVE NETWORK OF 'LOBAL 3ERVICE 0ARTNERS
STRATEGICALLY LOCATED IN ALL PARTS OF THE WORLD
#ARTRIDGE VALVES
(YDRAULIC INTEGRATED CIRCUITS
,OCAL ADDRESS
(YDROSTATIC TRANSAXLES
)NTEGRATED SYSTEMS
&AN DRIVE SYSTEMS
%LECTROHYDRAULICS
-ICROCONTROLLERS AND SOFTWARE
%LECTRIC MOTORS AND INVERTERS
*OYSTICKS AND CONTROL HANDLES 3AUER $ANFOSS 53 #OMPANY 3AUER $ANFOSS !P3
$ISPLAYS %AST TH 3TREET $+ .ORDBORG $ENMARK
!MES )! 53! 0HONE
3ENSORS 0HONE &AX
&AX
3AUER $ANFOSS 'MB( #O /(' 3AUER $ANFOSS $AIKIN ,4$
0OSTFACH $ .EUMüNSTER 3ANNOMIYA 'RAND "LDG &
+ROKAMP $ .EUMüNSTER 'ERMANY )SOGAMI DORI #HUO KU
0HONE +OBE (YOGO *APAN
&AX 0HONE
&AX

WWWSAUER DANFOSSCOM
520L0818 s 2EV !" s !PRIL 2008

958 BOMAG 008 914 20

Travel and vibration pump 20.1

Series 90 Pumps

Repair Instructions

008 914 20 BOMAG 959

20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
2EVISIONS

HISTORY OF REVISIONS Table of Revisions

Date Page Changed Rev.

!PRIL 79 4ORQUE FOR ' ' ' ' " " " " CHANGED !"
TO .M ; LBFsFT=
$EC &IRST PRINTING !!

¹ 3AUER $ANFOSS !LL RIGHTS RESERVED

2 11019577 s 2EV !" s !PRIL

960 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
Contents

INTRODUCTION /VERVIEW

'ENERAL INSTRUCTIONS
3AFETY PRECAUTIONS
5NINTENDED MACHINE MOVEMENT
&LAMMABLE CLEANING SOLVENTS
&LUID UNDER PRESSURE
0ERSONAL SAFETY
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE 7

DISASSEMBLY 3HAFT

-ULTI FUNCTION VALVE CARTRIDGES 9
-ULTI FUNCTION VALVE CARTRIDGES PRE
#HARGE PRESSURE RELIEF VALVE
0RESSURE OVERRIDE VALVE OPTION FOR FRAME SIZE
!UXILIARY PAD
#HARGE PUMP
)NTEGRAL CHARGE PRESSURE lLTER REPLACEMENT
0UMP CONTROL COVER PLATE
-ANUAL DISPLACEMENT CONTROL -$# 7
3OLENOID OVERRIDE VALVE FOR -$#
3OLENOID OVERRIDE VALVE FOR -$# WITH PRESSURE RELEASED BRAKE 9
(YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS 0
0RESSURE CONTROL PILOT 0#0 FOR ELECTRIC DISPLACEMENT CONTROL %$#
0OSITION &.2 ELECTRIC CONTROL
$ISPLACEMENT CONTROL ORIlCES %$#($# CONTROL
$ISPLACEMENT CONTROL ORIlCE CHECK VALVE -$# CONTROL
$ISPLACEMENT CONTROL ADAPTER PLATE EARLY PRODUCTION PUMPS ONLY
$ISPLACEMENT CONTROL lLTER SCREENS
3PEED SENSOR
3ERVO RELIEF VALVES
%NDCAP9
6ALVEPLATE0
3IDECOVER0
3IDECOVER DISASSEMBLY
#YLINDER BLOCK
#YLINDER BLOCK
3ERVO CYLINDERS
3WASHPLATE
0ISTON ASSEMBLY
3WASHPLATE

INSPECTION /VERVIEW 7

3HAFT ASSEMBLY 7
0ISTONS AND SLIPPERS7
#YLINDER BLOCK
%NDCAP JOURNAL BEARING
6ALVEPLATE
-ULTI FUNCTION VALVE CARTRIDGES9
#HARGE PRESSURE RELIEF VALVE 0
#HARGE PUMP0
11019577 s 2EV !" s !PRIL 3
008 914 20 BOMAG 961
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
Contents

INSPECTION (YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS

(CONTINUED) )NTEGRAL CHARGE PRESSURE lLTER
3WASHPLATE
3ERVO PISTON
#YLINDER BLOCK

ASSEMBLY #YLINDER BLOCK

3ERVO PISTON 2INGS
3ERVO ARM
3WASHPLATE GUIDE
2OLL PIN AND mAT WASHER
0ISTON ASSEMBLY 7
&IXED CLEARANCE HOLD DOWN BEARING
"EARING CAGE 0
(OUSING
3ERVO CYLINDER SCREWS
$ISPLACEMENT LIMITER
"EARING CAGE LOCATOR LINK
6ERIFY PROPER ASSEMBLY
3WASHPLATE LEVELER
)NSTALLING LEVELER AND SIDE COVER
3ETTING LEVELER NEUTRAL POSITION
#YLINDER BLOCK INSTALLATION7
0OSITIONING THE SIDE COVER 7
%ND CAP INSTALLATION
0REPARING FOR END CAP INSTALLATION
%ND CAP PARTS9
%ND CAP INSTALLATION9
3PEED SENSOR0
-ULTI FUNCTION VALVE CARTRIDGES PRE
0RESSURE OVERRIDE VALVE OPTION FOR FRAME SIZE
#HARGE PRESSURE RELIEF VALVE
#HARGE PUMP
!UXILIARY PAD
$ISPLACEMENT CONTROL lLTER SCREENS
)NTEGRAL CHARGE PRESSURE lLTER REPLACEMENT
0UMP CONTROL COVER PLATE7
$ISPLACEMENT CONTROL ADAPTER PLATE EARLY PRODUCTION PUMPS ONLY 7
(YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS
-ANUAL DISPLACEMENT CONTROL -$# 9
3OLENOID OVERRIDE VALVE FOR -$#70
3OLENOID OVERRIDE VALVE FOR -$# WITH PRESSURE RELEASED BRAKE 7
0RESSURE CONTROL PILOT 0#0 FOR ELECTRIC DISPLACEMENT CONTROL %$# 7
0OSITION &.2 ELECTRIC CONTROL 7
-ULTI FUNCTION VALVE CARTRIDGES7
)NSTALLING SHAFT AND BEARING7
&INAL ASSEMBLY AND TESTING 77
&ASTENER SIZE AND TORQUE CHART 7
0LUG SIZE AND TORQUE CHART 79
&ASTENERS AND PLUGS79

4 11019577 s 2EV !" s !PRIL

962 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
)NTRODUCTION

OVERVIEW 4HIS MANUAL DETAILS MAJOR REPAIR PROCEDURES FOR 3ERIES PUMPS4HESE INCLUDE THE
COMPLETE DISASSEMBLY INSPECTION AND REASSEMBLY OF THE UNIT7HERE REWORK OF WORN
OR DAMAGED COMPONENTS IS POSSIBLE SPECIlCATIONS APPEAR TO ENSURE THESE PARTS MEET
FACTORY TOLERANCES /NLY 3AUER $ANFOSS 'LOBAL 3ERVICE 0ARTNERS '30S ARE AUTHORIZED TO
PERFORM MAJOR REPAIRS 3AUER $ANFOSS TRAINS 'LOBAL 3ERVICE 0ARTNERS AND CERTIlES THEIR
FACILITIES ON A REGULAR BASIS

W 7ARNING
5SE OF COMPONENTS THAT DO NOT COMPLY WITH REWORK SPECIlCATIONS MAY RESULT IN LOSS OF
PERFORMANCE WHICH MAY CONSTITUTE A SAFETY HAZARD $O NOT REUSE COMPONENTS THAT DONT
COMPLY TO GIVEN SPECIlCATIONS REPLACE WITH GENUINE 3AUER $ANFOSS SERVICE PARTS

-INOR REPAIR PROCEDURES ADJUSTMENTS AND TROUBLESHOOTING INFORMATION APPEAR IN THE

Series 90 Pumps Service Manual 520L0818 -INOR REPAIRS INCLUDE SERVICE OPERATIONS YOU
CAN PERFORM WITHOUT REMOVING THE UNITS ENDCAP 2EMOVAL OF THE ENDCAP VOIDS YOUR
WARRANTY

&OLLOW THESE GENERAL PROCEDURES WHEN REPAIRING 3ERIES PUMPS

GENERAL INSTRUCTIONS
w Remove the unit
0RIOR TO PERFORMING MAJOR REPAIRS REMOVE THE UNIT FROM THE VEHICLEMACHINE #HOCK
THE WHEELS ON THE VEHICLE OR LOCK THE MECHANISM TO INHIBIT MOVEMENT "E AWARE THAT
HYDRAULIC mUID MAY BE UNDER HIGH PRESSURE ANDOR HOT )NSPECT THE OUTSIDE OF THE
PUMP AND lTTINGS FOR DAMAGE #AP HOSES AND PLUG PORTS AFTER REMOVAL TO PREVENT
CONTAMINATION

e Keep it clean
#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY PUMP LIFE ON EITHER NEW OR
REPAIRED UNITS #LEAN THE OUTSIDE OF THE PUMP THOROUGHLY BEFORE DISASSEMBLY4AKE CARE
TO AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS IN A CLEAN SOLVENT WASH AND
AIR DRYING IS USUALLY ADEQUATE

l Lubricate moving parts

$URING ASSEMBLY COAT ALL MOVING PARTS WITH CLEAN HYDRAULIC mUID4HIS ASSURES THAT THESE
PARTS ARE LUBRICATED DURING START UP

d Replace all O-rings and gaskets

3AUER $ANFOSS RECOMMENDS THAT YOU REPLACE ALL / RINGS SEALS AND GASKETS ,IGHTLY
LUBRICATE ALL / RINGS WITH CLEAN PETROLEUM JELLY PRIOR TO ASSEMBLY

t Secure the unit

&OR MAJOR REPAIR PLACE THE UNIT IN A STABLE POSITION WITH THE SHAFT POINTING DOWNWARD )T
IS NECESSARY TO SECURE THE PUMP WHILE REMOVING AND TORQUING THE ENDCAP BOLTS

11019577 s 2EV !" s !PRIL 5

008 914 20 BOMAG 963
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
)NTRODUCTION

Unintended machine movement

Flammable cleaning solvents

W Warning
3OME CLEANING SOLVENTS ARE mAMMABLE4O AVOID POSSIBLE lRE DO NOT USE CLEANING
SOLVENTS IN AN AREA WHERE A SOURCE OF IGNITION MAY BE PRESENT

Fluid under pressure

Personal safety
W Warning
0ROTECT YOURSELF FROM INJURY 5SE PROPER SAFETY EQUIPMENT INCLUDING SAFETY GLASSES AT ALL
TIMES

6 11019577 s 2EV !" s !PRIL

964 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
)NTRODUCTION

SYMBOLS USED IN  7!2.).' MAY RESULT IN INJURY  4IP HELPFUL SUGGESTION

SAUER-DANFOSS
LITERATURE  #!54)/. MAY RESULT IN DAMAGE TO  ,UBRICATE WITH HYDRAULIC mUID
PRODUCT OR PROPERTY
 !PPLY GREASEPETROLEUM JELLY
 2EUSABLE PART
 !PPLY LOCKING COMPOUND
 .ON REUSABLE PART USE A NEW PART
 )NSPECT FOR WEAR OR DAMAGE
 .ON REMOVABLE ITEM
 #LEAN AREA OR PART
 /PTION n EITHER PART MAY EXIST
 "E CAREFUL NOT TO SCRATCH OR DAMAGE
 3UPERSEDED n PARTS ARE NOT
INTERCHANGEABLE  .OTE CORRECT ORIENTATION

 -EASUREMENT REQUIRED  -ARK ORIENTATION FOR REINSTALLATION

 &LATNESS SPECIlCATION  4ORQUE SPECIlCATION

 0ARALLELISM SPECIlCATION  0RESS IN n PRESS lT

 %XTERNAL HEX HEAD  0ULL OUT WITH TOOL n PRESS lT

 )NTERNAL HEX HEAD  #OVER SPLINES WITH INSTALLATION

SLEEVE
 4ORX HEAD
 0RESSURE MEASUREMENTGAUGE
 / RING BOSS PORT LOCATION OR SPECIlCATION

11019577 s 2EV !" s !PRIL 7

008 914 20 BOMAG 965
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SHAFT Shaft and bearing Removing the shaft and bearing assembly
0OSITION PUMP WITH THE SHAFT
POINTING UP L70

.UMBER OF SCREWS AND WRENCH SIZE VARIES L60

BY MODEL
L30
2EMOVE THE THREE OR FOUR SCREWS
L40
, HOLDING THE RETAINER PLATE ,
AND SEAL CARRIER , TO THE HOUSING L50
USING A MM HEX WRENCH
L20
UNIT A MM INTERNAL HEX WRENCH
THROUGH UNITS OR A MM
INTERNAL HEX WRENCH THROUGH L10
UNITS 2EMOVE THE RETAINER PLATE

0RY THE SEAL CARRIER , FROM ITS L100

BORE9OU MAY TAP LIGHTLY ON THE END
OF THE SHAFT WITH A SOFT MALLET TO
FACILITATE REMOVAL

2EMOVE THE / RING , FROM THE

SEAL CARRIER AND DISCARD

0LACE SEAL CARRIER IN AN ARBOR PRESS

AND PRESS OUT THE SEAL , $ISCARD
SEAL
P106 181E

,IFT THE SHAFT AND BEARING ASSEMBLY

OUT OF THE PUMP

2EMOVE THE SNAP RING ,

2EMOVE THE BEARING WASHER AND

ROLLER ASSEMBLY ,

0RESS THE INNER BEARING RACE OFF THE

SHAFT ,

8 11019577 s 2EV !" s !PRIL

966 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

MULTI-FUNCTION VALVE Multi-function valve removal

CARTRIDGES

/LDER MULTIFUNCTION
VALVES PRE CONTAIN
DIFFERENT COMPONENTS P2B1
See multifunction valves
- Pre 1988 PAGE 0 FOR
DISASSEMBLY INSTRUCTIONS
P13

P06

P2A1

E101 537E

Removal Multi-function valve wrench size

2EMOVE MULTI FUNCTION VALVES 0! AND Frame size Wrench size
0" USING HEX WRENCH LISTED IN TABLE n INCH
n INCH

11019577 s 2EV !" s !PRIL 9

008 914 20 BOMAG 967
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

MULTI-FUNCTION VALVE Disassembly

CARTRIDGE (continued) 2EMOVE AND DISCARD / RINGS 0 AND 0

2ELIEVE SPRING PRESSURE BY REMOVING BYPASS ACTUATOR 0 USING A WRENCH4O
RETAIN PRESSURE SETTING DO NOT SEPARATE ADJUSTING SCREW 0 AND LOCKNUT 0 FROM
BYPASS ACTUATOR 0

2EMOVE AND DISCARD / RING 0

-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY9OU MAY PURCHASE / RINGS
SEPARATELY

2EMOVE INTERNAL PARTS 0 0 0 0 0 0 0 AND 0

Multi-function valve

P04
P03
P01
P02

P05

P06

P07
P08
P17
P16
P15
P14
P09
P11
P13

P12

E101 531E

10 11019577 s 2EV !" s !PRIL

968 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

MULTI-FUNCTION VALVE Removal Multi-function valve wrench size

CARTRIDGES - PRE 1988 2EMOVE MULTI FUNCTION VALVES USING HEX Frame size Wrench size
WRENCH LISTED IN TABLE n INCH
n INCH

Disassembly
2EMOVE AND DISCARD / RINGS 0 AND 0

)T IS NOT NECESSARY TO REMOVE THE BYPASS ACTUATOR 0 EXCEPT FOR CLEANING7RENCH
SIZE IS

-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY / RINGS MAY BE PURCHASED
SEPARATELY

4O RETAIN PRESSURE SETTING DO NOT DISASSEMBLE BYPASS ACTUATOR 0

2EMOVE RETAINING RING 0 WITH A SNAP RING PLIERS

2EMOVE POPPET SEAT 0

2EMOVE INTERNAL PARTS 0 0 0 0 AND 0

Multi-function valve - pre 1988

P14

P19

P12

P06

P21
P15
P14
P11 P22
P09
P1
P13

E101 532E

11019577 s 2EV !" s !PRIL 11

008 914 20 BOMAG 969
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

CHARGE PRESSURE 4HE CHARGE PRESSURE RELIEF VALVE IS Charge pressure relief valve
RELIEF VALVE SHIM ADJUSTABLE EARLY MODELS OR
SCREW ADJUSTABLE LATE MODELS 3CREW +
h ,OCK NUT
ADJUSTABLE CHARGE RELIEF VALVE IS SHOWN

Removal +
2EMOVE THE SHIM ADJUSTABLE CHARGE h IN
RELIEF VALVE PLUG WITH A INCH HEX d+ +
WRENCH 2ETAIN SHIMS
+
"EFORE REMOVING THE SCREW
ADJUSTABLE RELIEF VALVE PLUG MARK +
THE PLUG + LOCK NUT + AND
HOUSING TO APPROXIMATELY MAINTAIN
THE ORIGINAL ADJUSTMENT WHEN ASSEM
3EE TABLE FOr
BLING 2EMOVE THE SCREW ADJUSTABLE WRENCH SIZe
CHARGE RELIEF VALVE PLUG BY LOOSENING
THE LOCK NUT WITH A HEX WRENCH
CORRESPONDING TO THE TABLE

5NSCREW THE PLUG USING A LARGE

SCREWDRIVER OR INCH HEX WRENCH
2EMOVE AND DISCARD THE / RING +

2EMOVE THE SPRING + AND RELIEF

VALVE POPPET +

Lock nut wrench size

Frame size Wrench size
n INCH % %

n INCH

PRESSURE OVERRIDE Removal Pressure override valve components

VALVE (OPTION FOR 180 2EMOVE FOUR SCREWS ATTACHING
Screws
FRAME SIZE) THE PRESSURE OVERRIDE VALVE TO THE
END CAP WITH A MM INTERNAL HEX Pressure override
WRENCH valve

2EMOVE AND DISCARD THE / RINGS

O-rings

E101 079E

12 11019577 s 2EV !" s !PRIL

970 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

AUXILIARY PAD Removal

2EMOVE FOUR END CAP SCREWS * 2EMOVE AND DISCARD SEAL WASHERS *

2EMOVE THE AUXILIARY PAD * AND DISCARD THE / RING *

Auxiliary pad components (typical)

J50
J80
Endcap screw J70

J60
See table for wrench size and torque
E101 084E

Auxiliary pad screw wrench size

Frame size Wrench sizes
n EARLY MM INTERNAL HEX
LATE MM INTERNAL HEX
MM HEX
n MM HEX
n MM INTERNAL HEX
n MM INTERNAL HEX

11019577 s 2EV !" s !PRIL 13

008 914 20 BOMAG 971
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

CHARGE PUMP Removal

&OR PUMPS WITH AN AUXILIARY MOUNTING PAD REFER TO THE Auxiliary Pad instructions
PAGE

2EMOVE AND DISCARD SIX SCREWS ( FROM THE CHARGE PUMP COVER RETAINER (

2EMOVE RETAINER ( AND THE Retainer screw wrench size

CHARGE PUMP COVER * 2EMOVE Frame size Wrench size
AND DISCARD / RING * .OTE THE n MM
ORIENTATION OF THE GEROTOR ASSEMBLY n MM
(

Current charge pump conﬁguration

H40

H05

H60
H50
H31

J15

J50
J30

H70
E101 539E
H80

2EFER TO APPROPRIATE Sauer-Danfoss Series 90 service parts manual FOR EARLIER CHARGE PUMP
CONlGURATIONS

2EMOVE CHARGE PUMP COUPLING ( AND CHARGE PUMP DRIVE KEY (

2EMOVE THE CHARGE PUMP GEROTOR ASSEMBLY (

2EMOVE THE ALIGNMENT PIN (

2EMOVE THE VALVE PLATE (

14 11019577 s 2EV !" s !PRIL

972 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

INTEGRAL CHARGE Removal Lock nut wrench size and torque

PRESSURE FILTER 2EMOVE lLTER CANISTER . FROM THE Frame size Wrench size Torque
REPLACEMENT lLTER HEAD . AS DESCRIBED ON THE n INCH .sM ; LBFsFT=
CANISTER n INCH .sM ; LBFsFT=
n INCH .sM ; LBFsFT=

(OLD lLTER HEAD IN PLACE AND LOOSEN THE LOCK NUT . USING THE WRENCH SIZE IN THE
TABLE

2OTATE lLTER HEAD COUNTERCLOCKWISE TO REMOVE IT FROM THE HOUSING 2EMOVE AND
DISCARD THE / RING .

2EMOVE HYDRAULIC TUBE . FROM ITS BORE IN THE ENDCAP

Integral charge pressure ﬁlter

N25 N20
N15 Filter manifold lock nut

N36A

N36
11/16 in

N40

N10
N35A
N35
11/16 in
P106 182E

11019577 s 2EV !" s !PRIL 15

008 914 20 BOMAG 973
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

PUMP CONTROL COVER Removal

PLATE 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING COVER PLATE

5SING A MM INTERNAL HEX WRENCH REMOVE SIX COVER PLATE MOUNTING SCREWS -
2EMOVE THE COVER PLATE - AND GASKET - FROM HOUSING $ISCARD THE GASKET

CCaution
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

Pump controls cover plate

M90 X
MM
t .sM ; LBFsFT=

-
3EAL WASHER
LOCATION CC

-
d

0 %

16 11019577 s 2EV !" s !PRIL

974 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

MANUAL DISPLACEMENT Removal

CONTROL (MDC) 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING CONTROL

5SING A MM INTERNAL HEX WRENCH REMOVE SIX CONTROL MOUNTING SCREWS -
2EMOVE THE CONTROL - WITH ORIlCE CHECK VALVE 4 AND SPRING 4 AND CONTROL
GASKET - FROM THE HOUSING $ISCARD THE GASKET

)F NECESSARY REMOVE THE CONTROL HANDLE - BY REMOVING THE LOCKING NUT - AND
WASHER -

CCaution
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

MDC removal/installation
-
3 - h MM
h IN M70

- X
I MM

-
3EAL WASHER d
LOCATION CC
4

4 4

0 %

11019577 s 2EV !" s !PRIL 17

008 914 20 BOMAG 975
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SOLENOID OVERRIDE Removal

VALVE FOR MDC 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING VALVE

2EMOVE THE SOLENOID FROM THE VALVE BY REMOVING THE COIL NUT WITH A INCH HEX
WRENCH 2EMOVE THE SOLENOID VALVE - FROM THE MANIFOLD - WITH A INCH
HEX WRENCH 2EMOVE THE / RINGS -! " AND BACKUP RING -# DISCARD

5SING A MM INTERNAL HEX WRENCH REMOVE TWO SCREWS - AND REMOVE SOLENOID
MANIFOLD - FROM HOUSING 2EMOVE AND DISCARD THE GASKET -

Solenoid override valve removal/installation

Seal washer
location
(42, 180, 250 cc)

M77
M76A
M76C
M76B
M76

M78 (x2)
5 mm
M75
P106 186E

18 11019577 s 2EV !" s !PRIL

976 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SOLENOID OVERRIDE Removal

VALVE FOR MDC WITH 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING VALVE
PRESSURE RELEASED
BRAKE 5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SOLENOID VALVE MOUNTING SCREWS
- 2EMOVE THE SOLENOID VALVE - WITH / RINGS FROM THE ADAPTER PLATE $ISCARD
THE / RINGS

5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR ADAPTER PLATE MOUNTING SCREWS
- 2EMOVE THE ADAPTER PLATE AND / RINGS - - AND - FROM THE CONTROL
HOUSING $ISCARD THE / RINGS

Solenoid override valve removal/installation

M98 (x4)
4 mm
M9

M95
M96
M97 M92 (x4)
4 mm

P106 192E

11019577 s 2EV !" s !PRIL 19

008 914 20 BOMAG 977
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

HYDRAULIC AND Removal

ELECTRIC DISPLACEMENT 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING CONTROL
CONTROLS
5SING A MM INTERNAL HEX WRENCH REMOVE SIX CONTROL MOUNTING SCREWS -
$ISCARD SEAL WASHER IF PRESENT 2EMOVE CONTROL - WITH ORIlCE CHECK VALVE 4
AND SPRING 4 AND CONTROL GASKET - FROM HOUSING $ISCARD THE GASKET

CCaution
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

Hydraulic/Electric displacement control

- X
I MM

-
d

4
4

0 %

20 11019577 s 2EV !" s !PRIL

978 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

PRESSURE CONTROL Removal

PILOT (PCP) FOR 4HOROUGHLY CLEAN EXTERNAL SURFACES OF CONTROL
ELECTRIC DISPLACEMENT
CONTROL (EDC) 5SING A MM INTERNAL HEX WRENCH REMOVE FOUR SCREWS - AND REMOVE THE 0#0
- 2EMOVE AND DISCARD THE / RINGS - -

$O NOT DISASSEMBLE THE

0#0 - )T IS AVAILABLE PCP removal/installation
ONLY AS A COMPLETE UNIT

M97

M96 (x3)

M98 (x4)
M9
4 mm
P106 194E

11019577 s 2EV !" s !PRIL 21

008 914 20 BOMAG 979
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

3-POSITION (FNR) Removal

ELECTRIC CONTROL 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL

5SING A MM INTERNAL HEX WRENCH REMOVE FOUR SOLENOID VALVE MOUNTING SCREWS
7 2EMOVE THE SOLENOID VALVE 7 WITH / RINGS 7! AND ORIlCE FROM
THE ADAPTER PLATE

5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX ADAPTER PLATE MOUNTING SCREWS
CCaution - 2EMOVE THE ADAPTER PLATE AND GASKET - FROM THE HOUSING $ISCARD THE
0ROTECT EXPOSED SURFACES GASKET C
AND CAVITIES FROM DAMAGE
AND FOREIGN MATERIAL )F NECESSARY REMOVE AND CLEAN THE THREE ORIlCES 4 4 4 USING A MM
INTERNAL HEX WRENCH AND A MM INTERNAL HEX WRENCH

$O NOT DISASSEMBLE THE FNR removal/installation

&.2 CONTROL )T IS AVAILABLE 7 X
I MM
AS A COMPLETE UNIT ONLY

7!
- X d
I MM
4
4
4
-

3EAL WASHER
LOCATION CC
4

- 4
4
d

0 %

22 11019577 s 2EV !" s !PRIL

980 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an HDC/EDC module showing

CONTROL ORIFICES DESCRIBED IN THE INSTRUCTIONS FOR THE oriﬁce locations
(EDC/HDC CONTROL) SPECIlC DISPLACEMENT CONTROL A
B
TA P
9OU MAY lND ORIlCE PLUGS IN THE TB
CONTROL ASSEMBLY AT THE PUMP
HOUSING FACE4O AVOID MIXING THEM
UP REMOVE CLEAN AND REPLACE
ORIlCE PLUGS INDIVIDUALLY 5SE A MM
INTERNAL HEX WRENCH TO REMOVE THE Orifice plugs
PLUGS .OTE THE LOCATION OF EACH PLUG Orifice check valve
DO NOT INTERCHANGE PLUGS #LEAN E101 085E

REINSTALL AND TORQUE THE ORIlCE PLUGS

TO .sM ; LBFsFT=

DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an MDC module showing

CONTROL ORIFICE DESCRIBED IN THE INSTRUCTIONS FOR THE oriﬁce locations
CHECK VALVE (MDC SPECIlC DISPLACEMENT CONTROL
CONTROL) TA A B TB

4HE ORIlCE CHECK VALVE IS IN THE P

CONTROL ASSEMBLY AT THE SURFACE OF

THE PUMP HOUSING FACE 2EMOVE THE
SPRING RETAINER AND SPRING FROM THE
Orifice plugs
ORIlCE CHECK VALVE CAVITY AND THEN
REMOVE THE ORIlCE CHECK VALVE
Orifice check valve
#LEAN AND INSTALL THE ORIlCE CHECK E101 086E

VALVE IN THE CAVITY AND THEN INSTALL

THE SPRING AND SPRING RETAINER
TO HOLD THE ORIlCE CHECK VALVE IN
POSITION

DISPLACEMENT $O NOT REMOVE THE ADAPTER PLATE UNLESS Displacement control adapter plate (early
CONTROL ADAPTER LEAKAGE IS EVIDENT4HE MOUNTING SCREWS production 130 cm³ pumps only)
PLATE (EARLY WITH SEALING COMPOUND ARE DIFlCULT TO Adapter plate
PRODUCTION 130 REMOVE screws
PUMPS ONLY)
4HE SCREWS FASTENING THE CONTROL ADAPTER 6 mm
PLATE TO THE HOUSING HAVE SEALING
t]
COMPOUND ON THE THREADS9OU MAY O-rings
REMOVE THEM WITH A MM INTERNAL HEX Adapter plate
WRENCH IF NECESSARY 2EMOVE AND DISCARD
THE / RINGS AND SEALS Seal

E101 087E

11019577 s 2EV !" s !PRIL 23

008 914 20 BOMAG 981
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

DISPLACEMENT )F YOU REMOVE THE SCREENS REPLACE WITH Filter screen installation
CONTROL FILTER NEW SCREENS 0RESS THEM INTO POSITION B90
SCREENS WITH THE ROUNDED EDGE OF THE SCREEN
FACING THE CONTROL UNTIL THEY ARE mUSH TO P106 690E

MM ; INCH= BELOW THE SURFACE OF

THE HOUSING

SPEED SENSOR Removal

,OOSEN THE LOCK NUT USING AN IN HEX WRENCH

5NSCREW SPEED SENSOR " FROM THE PUMP HOUSING 2EMOVE AND DISCARD THE / RING
"!

Typical location of speed sensor

B83 O-ring plug

ft]
B83A

B83 B83A

E101 095E

24 11019577 s 2EV !" s !PRIL

982 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SERVO RELIEF VALVES #ERTAIN FRAME SIZE PUMPS WITH TWIN PORT END CAPS MAY HAVE THE SERVO RELIEF VALVES AND
ROTATION PLUGS IN A REMOVABLE ROTATION BLOCK

5SING A MM INTERNAL HEX WRENCH REMOVE THE ROTATION BLOCK SCREWS

2EMOVE THE BLOCK

2EMOVE THE GASKET

3OME PUMPS HAVE A PRESSURE LIMITER FUNCTION

2EMOVE THE SERVO RELIEF VALVES FROM THE END CAP OR ROTATION BLOCK 5SE A
SCREWDRIVER

Servo relief valve removal

Veiw 'C'

View 'C'
View 'C'

P80
P802
P70

P702

With Pressure Limiters Without Pressure Limiters

P106 729E

Servo relief passage plugs

3OME PUMPS HAVE PRESSURE LIMITER VALVES ANDOR RELIEF VALVES

.OTE THE POSITION OF THE ROTATION PIPE PLUGS

5SING A INCH INTERNAL HEX WRENCH REMOVE THE SERVO RELIEF PASSAGE PLUGS FROM THE
END CAP OR ROTATION BLOCK

5SING A INCH INTERNAL HEX WRENCH REMOVE THE PIPE PLUGS FROM THE END CAP OR
ROTATION BLOCK

#LEAN PASSAGES WITH A SUITABLE SOLVENT

3EE THE ILLUSTRATIONS ON THE FOLLOWING PAGES FOR PROPER PLUG AND VALVE LOCATIONS ON
VARIOUS PUMPS

11019577 s 2EV !" s !PRIL 25

008 914 20 BOMAG 983
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SERVO RELIEF VALVES Installing servo relief valves

(continued) )NSTALL SERVO RELIEF VALVES OR RELIEF VALVE PASSAGE PLUGS INTO THE END CAP OR ROTATION
BLOCK

)NSTALL SERVO RELIEF VALVES IN THE END CAP OR ROTATION BLOCK OF PUMPS WITH PRESSURE
LIMITER FUNCTIONS OR RELIEF VALVES

)NSTALL THE ROTATION PIPE PLUGS INTO THE END CAP OR ROTATION BLOCK W

W 7ARNING
-AKE SURE THE PRESSURE LIMITER LOGIC PLUGS ARE IN THE CORRECT PORTS FOR PUMP ROTATION
5NCONTROLLABLE MACHINE MOVEMENT RESULTS FROM IMPROPER PLUG INSTALLATION6ERIFY CORRECT
PRESSURE LIMITER FUNCTION4EST THE PUMP BEFORE INSTALLING IN MACHINE !LSO TEST IT BEFORE
RELEASING THE MACHINE FROM REPAIR

4ORQUE THE SERVO RELIEF VALVES OR RELIEF VALVE PASSAGE PLUGS TO .sM ; LBFsFT=

4ORQUE THE ROTATION PIPE PLUGS TO .sM ; LBFsFT=

)NSTALL ROTATION BLOCK GASKET AND SCREWS IF USED

4ORQUE THE ROTATION BLOCK SCREWS TO .sM ; LBFsFT=

Speciﬁcations
Pressure limiter Pump rotation Holes with Holes with servo Holes with Open holes
Port A Port B pipe plugs relief valves O-ring plugs
9ES 9ES 2IGHT #7 .ONE
9ES 9ES ,EFT ##7 .ONE
.O .O %ITHER .ONE
9ES .O 2IGHT #7 .ONE
9ES .O ,EFT ##7 .ONE
9ES 9ES 2IGHT #7 WITH .ONE
AUTOMOTIVE CONTROL
9ES 9ES ,EFT ##7 WITH .ONE
AUTOMOTIVE CONTROL

030 twin ported end cap (early units) 030 Twin ported end cap

3 4
7 6
5 6
5
3 4
7
1 1

2
2

0 0

26 11019577 s 2EV !" s !PRIL

984 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SERVO RELIEF VALVES 042 twin ported end cap (early units) 042 twin ported end cap
(continued)
6 3 6
2 2
3
5

5 1 4 1
7 4 7

0
0

055 side ported end cap 055 twin ported end cap

6 6
2 2
4 5 4
1 1
7 7

5 3 3

0 0

075 side and twin ported end cap 075 twin ported end cap rotation block

6 1 2

4 2
1

5 4 3
5
7 3

0
6 7

11019577 s 2EV !" s !PRIL 27

008 914 20 BOMAG 985
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SERVO RELIEF VALVES 100 side ported end cap 100 twin ported end cap
(continued)

6 6 2
2

4 7 1 5 7

3
3
1
5 4

0
0

130 twin ported end cap 180 twin ported end cap rotation block

4 3
1 2
5

5 4
3

6 1 2 6
7

0
250 twin port end cap

5 4
3 6
7
2 1

28 11019577 s 2EV !" s !PRIL

986 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

ENDCAP 0LACE THE PUMP ON THE WORK SURFACE WITH ENDCAP ' FACING UP

.UMBER OF SCREWS AND WRENCH SIZE VARIES BY MODEL

5SING A OR MM INTERNAL HEX WRENCH OR A MM HEX WRENCH REMOVE THE OR

SCREWS '' FASTENING THE END CAP TO THE PUMP HOUSING

4HE SCREW ' RETAINS A SPACER ' A (J80) Screw removal

LIFTING BRACKET ' AND A WASHER ' Pump size Wrench size
CC MM INTERNAL HEX
2EMOVE SCREWS * IF PRESENT CC MM HEX
2EFER TO THE TABLE Screw removal FOR CC AND CC MM HEX
WRENCH SIZES CC MM INTERNAL HEX
CC AND CC MM INTERNAL HEX
2EMOVE END CAP ' FROM HOUSING

4HE ALIGNMENT PINS AND VALVE PLATE WILL USUALLY REMAIN WITH THE HOUSING

2EMOVE AND DISCARD END CAP GASKET '

2EMOVE THE HARDENED SHIMS % FROM THE END CAP POCKETS

Removing the end cap and gasket

G97
G95
G94
J80
G93
G90

G04

E24

E101 101

11019577 s 2EV !" s !PRIL 29

008 914 20 BOMAG 987
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

VALVEPLATE Valveplate and springs Removing internal parts

2EMOVE VALVE PLATE # NOTING
DIRECTION OF ARROWS ON VALVE PLATE

2EMOVE THE LONG SPRINGS % FROM

THE SWASHPLATE LEVELER D95

3OME UNITS HAVE DUAL SWASHPLATE LEVELER B50 (2X)

SPRINGS AN INNER SPRING NESTED INSIDE
EACH OF THE STANDARD SPRINGS
B10
2EMOVE THE SHORT SWASHPLATE HOLD
DOWN SPRING $ IF PRESENT E82
E101 102
Arrows C80
2EMOVE THE TWO ALIGNMENT PINS
"

SIDECOVER -ARK THE ORIENTATION OF THE SIDE Removing the side cover
COVER % TO THE HOUSING

3TRAIGHTEN THE LOCKING TABS USED ON

EARLIER PRODUCTION UNITS

2EMOVE THE SIDE COVER SCREWS

% 2EFER TO TABLE BELOW FOR WRENCH
SIZES

2EMOVE SIDE COVER ASSEMBLY FROM

PUMP HOUSING

Side cover screw removal

B10
Pump size Wrench size
CC MM HEX
CC THROUGH CC MM HEX
CC THROUGH CC MM HEX

E101 103
E60

30 11019577 s 2EV !" s !PRIL

988 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SIDECOVER Side cover components Leveler disassembly

DISASSEMBLY 2EMOVE SPACER WASHERS IF USED ON
E30
THE LEVELER SPRING SEATS %
E30

3OME UNITS WITH DUAL SWASHPLATE LEVELER

SPRINGS HAVE SPACER WASHERS ON THE
LEVELER SPRING SEATS
E22
2EMOVE SPRING SEATS % FROM
SWASHPLATE LEVELER %

3OME LEVELERS DO NOT HAVE REMOVABLE

Spacer
SPRING SEATS Washer

2EMOVE THE SEALING NUTS % AND

GUIDE POSTS % HOLDING THE LEVELER
% TO THE SIDE COVER % 2EFER TO
TABLE BELOW FOR WRENCH SIZES E90

Sealing nut removal

Pump size Wrench sizes
CC AND CC MM OPEN END
MM HEX

CC THROUGH CC INCH OPEN END
MM HEX
CC THROUGH CC MM OPEN END
MM HEX

E101 104
.OTE THE ORIENTATIONS OF THE LEVELER
% AND SIDE COVER % E40

2EMOVE LEVELER % FROM SIDE COVER

% Cylinder block removal

2EMOVE THE INSERT ASSEMBLY %

2EMOVE AND DISCARD SIDE COVER / C12

RING %

CYLINDER BLOCK 2EMOVE THE CYLINDER BLOCK # FROM

THE HOUSING

4HE SWASHPLATE AND PISTON ASSEMBLY

REMAINS IN THE HOUSING C4AKE CARE TO
PREVENT PISTONS FROM BEING SCRATCHED
WHILE THE CYLINDER BLOCK IS OUT OF THE
HOUSING 4HE PISTONS ARE NOT SELECTIVELY
lTTED HOWEVER UNITS WITH HIGH HOURLY
USAGE MAY DEVELOP WEAR PATTERNS
.UMBER THE PISTONS AND BORES FOR RE E101 131
ASSEMBLY IF THEY ARE TO BE REUSED

11019577 s 2EV !" s !PRIL 31

008 914 20 BOMAG 989
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

CYLINDER BLOCK -OST REPAIRS DO NOT REQUIRE BLOCK SPRING Cylinder block disassembly
REMOVAL 0ERFORM THIS PROCEDURE ONLY
IF YOU SUSPECT PROBLEMS WITH THE BLOCK
SPRING C16
W 7ARNING
2ISK OF PERSONAL INJURY
C15
#OMPRESSING THE BLOCK 5SING A PRESS APPLY PRESSURE ON
SPRING REQUIRES TO THE BLOCK SPRING WASHER # TO
. ; TO LBF = 5SE A COMPRESS THE BLOCK SPRING #
PRESS SUFlCIENT TO MAINTAIN #OMPRESS THE SPRING ENOUGH TO C14
THIS FORCE WITH REASONABLE SAFELY REMOVE THE SPIRAL RETAINING
EFFORT %NSURE THE SPRING IS RING # 7HILE MAINTAINING
SECURE BEFORE ATTEMPTING PRESSURE UNWIND THE SPIRAL RETAINING
TO REMOVE THE SPIRAL RING #AREFULLY RELEASE THE PRESSURE C13
RETAINING RING 2ELEASE THE AND REMOVE THE OUTER BLOCK SPRING
PRESSURE SLOWLY AFTER THE WASHER BLOCK SPRING AND INNER
RETAINING RING IS REMOVED BLOCK SPRING WASHER # FROM THE
CYLINDER BLOCK W

C12

E101-113

32 11019577 s 2EV !" s !PRIL

990 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SERVO CYLINDERS -ARK THE SERVO CYLINDERS && AND HOUSING " 4HIS HELPS TO IDENTIFY EACH
SERVO CYLINDER && WITH ITS RESPECTIVE SIDE OF THE HOUSING "

.UMBER OF SCREWS AND WRENCH SIZE VARIES BY MODEL

5SING A MM OR MM HEX WRENCH REMOVE THE OR SCREWS &&

RETAINING EACH SERVO CYLINDER && TO THE HOUSING "

A &OR EARLY PRODUCTION UNITS CAREFULLY PRY EACH CYLINDER && FROM THE
HOUSING " BY USING A SCREWDRIVER IN THE NOTCHES IN THE CYLINDER
4HE SERVO PISTON WILL
REMAIN IN THE HOUSING B &OR LATER PRODUCTION UNITS INSTALL AN MM OR MM SCREW IN THE THREADED
&OR LATER PRODUCTION UNITS HOLE IN THE CENTER OF EACH CYLINDER && AND PULL THE CYLINDERS FROM THE
WITH DISPLACEMENT LIMITERS HOUSING "
REMOVE THE NUT
&& AND LIMITER
SCREW && FROM Servo cylinder removal
EACH SERVO CYLINDER
F112 F113
&& AND INSTALL AN
MM OR MM SCREW IN
ITS PLACE AS A PULLER SCREW F40

F50

F40
F50

B10

F40
F50

F212
F213 E101 105E

11019577 s 2EV !" s !PRIL 33

008 914 20 BOMAG 991
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SWASHPLATE 2EMOVE THE SWASHPLATE BEARING CAGE LINK PIN $ FROM THE HOUSING THROUGH THE
CONTROL OPENING

CMÃ DISPLACEMENT 2EMOVE THE BEARING CAGE LOCATOR LINK $ FROM THE SWASHPLATE THROUGH THE CONTROL
PUMPS USE A SCREW AS THE OPENING
LINK PIN 2EMOVE IT WITH A
MM INTERNAL HEX WRENCH IF CC AND CC PUMPS HAVE SCREW TYPE LINK PINS /NE IS AT THE CONTROL OPENING4HE
NECESSARY OTHER IS AT THE SIDE COVER OPENING

2EMOVE THE SWASHPLATE $ AND PISTON ASSEMBLY # THROUGH THE HOUSING SIDE
COVER OPENING
5NITS WITH AN AUTOMOTIVE
CONTROL HAVE A THREADED $ISENGAGE THE SERVO ARM $ FROM THE SLIDER BLOCK & IN THE SERVO PISTON AS YOU
HOLE IN ONE END OF THE REMOVE THE ASSEMBLY
SERVO PISTON4HIS IS FOR THE
CENTERING ASSIST SPRING 2EMOVE THE SERVO PISTON AND SLIDER BLOCK & FROM HOUSING
ASSEMBLY &OR THESE UNITS
NOTE THE ORIENTATION OF 2EMOVE THE CRADLE BEARING CAGE AND RACES WITH LOCATING PINS
THE SERVO PISTON IN THE
HOUSING 4HE BEARING RACE LOCATING PINS ARE A LOOSE lT

Disassembling the swashplate

Locating Pin

Servo piston

F20

D10
D95 D85 Bearing race

D80 Bearing cage

C20

D10
D50
D80
D85

C20
D50 E101 106E

34 11019577 s 2EV !" s !PRIL

992 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

PISTON ASSEMBLY 5SING A MM OR MM HEX WRENCH REMOVE THE SCREWS C70 AND SPACERS #
HOLDING THE TWO SLIPPER GUIDE HOLD DOWN BEARINGS # TO THE SWASHPLATE $

$ISCARD SCREWS # 2EPLACE WITH NEW SCREWS WHEN PUMP IS ASSEMBLED

2EMOVE THE HOLD DOWN BEARINGS # AND SPACERS #

2EMOVE THE SLIPPER GUIDE # AND PISTONS # FROM THE SWASHPLATE $

2EMOVE THE PISTON ASSEMBLIES # FROM THE SLIPPER GUIDE #

Removing the piston/slipper assembly

C20

C30

C50
D50

C40

C20

C30

C50
D50

C40

E101 107E

11019577 s 2EV !" s !PRIL 35

008 914 20 BOMAG 993
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SWASHPLATE 2EMOVE GUIDE $ AND FEEDBACK LINK - BY REMOVING SPECIAL LOCKING SCREW $
$ISCARD LOCKING SCREW 3EE TABLE Swashplate components BELOW FOR WRENCH SIZES

2EMOVE SERVO ARM $ FROM SWASHPLATE $ BY REMOVING LOCKING SCREW $
$ISCARD LOCKING SCREW 3EE TABLE Swashplate components BELOW FOR WRENCH SIZES

#LEAN THE THREADED HOLES FOR THE HOLD DOWN SCREWS IN SWASHPLATE $ OF ALL OLD
LOCKING COMPOUND 5SE A - 8 OR - 8 THREAD TAP FOR THIS PROCEDURE

#LEAN THE THREADED HOLES FOR THE LOCKING SCREWS $ $ IN SWASHPLATE $ OF ALL
OLD LOCKING COMPOUND 5SE A THREAD TAP GIVEN IN THE TABLE BELOW FOR THIS PROCEDURE

Swashplate components
Pump size D55 wrench size D55 thread size D65 wrench size D65 thread size
CC AND CC MM HEX - MM INTERNAL HEX -
CC AND CC MM HEX - MM INTERNAL HEX -
CC AND CC MM HEX - MM INTERNAL HEX -
CC AND CC MM HEX - MM INTERNAL HEX -

Removing the swashplate guide and servo arm

M14
M14
D10
D10

D50 D50

E101 191E

36 11019577 s 2EV !" s !PRIL

994 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
Inspection

OVERVIEW #LEAN ALL PARTS IN A SUITABLE SOLVENT 2EPLACE / RINGS GASKETS SHAFT SEAL )NSPECT ALL PARTS
FOR DAMAGE NICKS OR UNUSUAL WEAR PATTERNS 2EPLACE ALL PARTS WITH UNUSUAL OR EXCESSIVE
WEAR OR DISCOLORATION WHICH INDICATES EXCESSIVE HEAT

SHAFT ASSEMBLY Inspection

)NSPECT THE SEAL CARRIER FOR ANY DAMAGE OR NICKS )NSPECT THE SHAFT AND BEARING FOR RUST
WEAR OR CONTAMINATION 3PIN THE BEARING IN YOUR HAND FEELING FOR ROUGHNESS 2EPLACE IF
NECESSARY

Shaft assembly

Shaft

Bearing

Seal Carrier

E101 541E

PISTONS AND SLIPPERS )NSPECT THE PISTONS FOR DAMAGE AND Inspect pistons
DISCOLORATION $ISCOLORED PISTONS MAY
INDICATE EXCESSIVE HEAT DO NOT REUSE
Slipper
)NSPECT THE RUNNING SURFACE OF THE
SLIPPERS 2EPLACE ANY PISTON ASSEMBLIES
WITH SCORED OR ROUNDED SLIPPER EDGES
-EASURE THE SLIPPER FOOT THICKNESS
2EPLACE ANY PISTON ASSEMBLIES WITH P104 109E
WORN SLIPPERS #HECK THE SLIPPER AXIAL
END PLAY 2EPLACE ANY PISTON ASSEMBLIES
WITH EXCESSIVE END PLAY 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT
REWORK GUIDELINES

11019577 s 2EV !" s !PRIL 37

008 914 20 BOMAG 995
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
Inspection

CYLINDER BLOCK %XAMINE THE RUNNING FACE OF THE CYLINDER Inspect cylinder block
BLOCK 4HE SURFACE SHOULD BE SMOOTH AND
FREE OF NICKS AND BURRS 2EMOVE ANY BURRS
%NSURE THAT NO SCRATCHES OR GROOVES EXIST
Cylinder
THESE MAY DRASTICALLY REDUCE OUTPUT block
mOW AND LIFE OF PUMP 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT A
REWORK GUIDELINES

flat to 0.0026 mm check for burrs

[0.000100 in]
P106 692E

ENDCAP JOURNAL )NSPECT THE ENDCAP VALVE PLATE AND End cap and journal bearing
BEARING SEALING SURFACES FOR NICKS AND SCRATCHES
#HECK SURFACE mATNESS 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT
REWORK GUIDELINES )F ANY OF THE BASE
W 7ARNING METAL IS VISIBLE THROUGH THE PLASTIC
$O NOT DAMAGE THE VALVE BEARING MATERIAL REPLACE THE END CAP
PLATE SURFACE OF THE END JOURNAL BEARING ' 5SE A SUITABLE
CAP WHEN REMOVING THE PULLER TO REMOVE THE BEARING W0RESS THE
BEARING JOURNAL BEARING INTO THE END CAP '
USING A PRESS PIN -AKE SURE BEARING IS
mUSH TO MM ; INCHES= BELOW
THE VALVE PLATE SURFACE OF THE END CAP
'

2EPLACE ENDCAP )F JOURNAL BEARING SPINS

IN THE ENDCAP
E101 108

VALVEPLATE )NSPECT VALVE PLATE FOR WEAR AND SCRATCHES 3CRATCHES DEEP ENOUGH FOR YOU TO FEEL WITH
YOUR lNGERNAIL OR A PENCIL TIP ARE NOT ACCEPTABLE $O NOT ATTEMPT TO REWORK 3ERIES
VALVE PLATES REPLACE IF DAMAGED

38 11019577 s 2EV !" s !PRIL

996 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
Inspection

MULTI-FUNCTION VALVE Inspection

CARTRIDGES #LEAN AND INSPECT ALL PARTS #ARTRIDGE IS AVAILABLE AS COMPLETE UNIT ONLY
/ RINGS ARE AVAILABLE SEPARATELY

Multi-function valve
P04
P03
P01
P02

P05

P06

P07
P08
P17
P16
P15
P14
P09
P11
P13

P12

E101 531E

Multi-function valve - pre 1988

P14

P19

P12

P06

P21
P15
P14
P11 P22
P09
P1
P13

E101 532E

11019577 s 2EV !" s !PRIL 39

008 914 20 BOMAG 997
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
Inspection

CHARGE PRESSURE Inspection

RELIEF VALVE )NSPECT THE POPPET + AND MATING SEAT IN THE ENDCAP FOR DAMAGE OR FOREIGN MATERIAL
7HEN INSPECTING SHIM ADJUSTABLE VALVES DO NOT ALTER THE SHIMS OR INTERCHANGE PARTS

Charge pressure relief valve

,OCK NUt

"ODY

/ RING

3PRING

Seat

% %

CHARGE PUMP Inspection

)NSPECT ALL PARTS FOR WEAR OR DAMAGE AND REPLACE IF NECESSARY #HECK GEROTOR ASSEMBLY
AND VALVE PLATE FOR PITTING FROM CAVITATION

Charge pump
H40

H05

H60
H50
H31
J50
J15

J30

H70
E101 542E
H80

40 11019577 s 2EV !" s !PRIL

998 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
Inspection

INTEGRAL CHARGE Inspection

PRESSURE FILTER )NSPECT THE lLTER HEAD AND LOCK NUT SEALING SURFACES )F YOU lND ANY NICKS OR SCRATCHES
REPLACE DAMAGED COMPONENTS

Integral charge pressure ﬁlter manifold

N25 N20
N15

N36A

N36

N10
N35A
N35
11/16 in
E101 543E

HYDRAULIC AND Inspection

ELECTRIC DISPLACEMENT )NSPECT MACHINED SURFACES ON CONTROL AND PUMP FOR NICKS AND SCRATCHES 2EPLACE CONTROL
CONTROLS IF YOU lND DAMAGE TO MACHINED SURFACES

Hydraulic/Electric displacement controls

% %

11019577 s 2EV !" s !PRIL 41

008 914 20 BOMAG 999
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
Inspection

SWASHPLATE )NSPECT RUNNING SURFACE FOR WEAR OR SCRATCHES )NSPECT HOLD DOWN SCREW HOLES FOR
DAMAGE )F SCREW HOLES ARE DAMAGED REPLACE SWASHPLATE )NSPECT FOR WEAR IN LEVELER PAD
AREAS EXCESSIVE WEAR MAY AFFECT PUMP NEUTRAL )F YOU lND DAMAGE REPLACE SWASHPLATE
)NSPECT SWASHPLATE GUIDE $ FOR WEAR 2EPLACE IF NECESSARY 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT REWORK GUIDELINES

Swashplate and guide inspection

D50

Hold down
screw holes

Running surface

Leveler pad areas E101 548E

42 11019577 s 2EV !" s !PRIL

1000 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
Inspection

SERVO PISTON )NSPECT THE SERVO PISTON FOR WEAR 2EMOVE AND DISCARD SEAL RINGS & AND EXPANDER
/ RINGS & 2EPLACE SERVO PISTON IF NECESSARY 2EPLACE / RINGS AND SEAL RINGS BEFORE
REASSEMBLY

Servo piston inspection

Servo piston

E101 112E

CYLINDER BLOCK 6ISUALLY INSPECT THE CYLINDER BLOCK Cylinder block inspection
SPRING AND WASHERS FOR INDICATIONS OF
WEAR OR DAMAGE 2EPLACE IF WEAR CRACKS C16
OR OTHER DAMAGE IS PRESENT

C15

C14

C13

C12

E101-113

11019577 s 2EV !" s !PRIL 43

008 914 20 BOMAG 1001
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
Inspection

CYLINDER BLOCK #OAT ALL PARTS WITH CLEAN HYDRAULIC Cylinder block assembly
mUID PRIOR TO REASSEMBLY
W 7ARNING C16
2ISK OF PERSONAL INJURY )NSTALL THE INNER BLOCK SPRING WASHER
#OMPRESSING THE BLOCK # BLOCK SPRING # AND OUTER
SPRING REQUIRES TO WASHER # INTO THE CYLINDER C15
. ; TO LBF = 5SE A BLOCK 5SING A PRESS COMPRESS THE
PRESS SUFlCIENT TO MAINTAIN BLOCK SPRING ENOUGH TO EXPOSE THE
THIS FORCE WITH REASONABLE RETAINING RING GROOVE7IND THE SPIRAL
C14
EFFORT %NSURE THE SPRING IS RETAINING RING # INTO THE GROOVE
SECURE BEFORE ATTEMPTING IN THE CYLINDER BLOCK W
TO REMOVE THE SPIRAL
RETAINING RING 2ELEASE THE 2ELEASE PRESSURE ON SPRING6ISUALLY C13
PRESSURE SLOWLY AFTER THE CHECK THAT SPIRAL RETAINING RING IS
RETAINING RING IS REMOVED PROPERLY POSITIONED IN ITS GROOVE

C12

E101-113

SERVO PISTON RINGS )NSTALL NEW EXPANDER / RINGS & INTO THE SEAL GROOVES IN THE SERVO PISTON )NSTALL
THE SEAL RINGS & IN THE GROOVES OVER THE EXPANDER / RINGS & C

C Caution !LLOW THE ASSEMBLY TO SET FOR AT LEAST MINUTES4HIS ALLOWS THE SEAL RINGS & TO
$O NOT STRETCH THE RETURN TO THEIR ORIGINAL UNSTRETCHED SIZE
SEAL RINGS ANY MORE
THAN NECESSARY DURING Servo piston assembly
INSTALLATION

Servo piston

P106 730E

44 11019577 s 2EV !" s !PRIL

1002 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

SERVO ARM )NSTALL THE SERVO ARM $

!LIGN PRESS lT DESIGN SERVO ARMS WITH THE SWASHPLATES SLOT AND THREADED HOLES WHILE
INSTALLING 0RESS COMPLETELY INTO THE SWASHPLATE SLOT

)NSTALL NEW LOCKING SCREW $ WITH PRE APPLIED LOCKING COMPOUND INTO SWASHPLATE

4ORQUE LOCKING SCREW $ 3EE TABLE BELOW FOR WRENCH SIZES AND TORQUES

Servo arm speciﬁcations

Pump size Wrench size (for D55) 4ORQUE .sM ;LBFsFT=
CC THROUGH CC MM HEX ;=
CC MM HEX ;=
CC MM HEX ;=
CC CC MM HEX ;=

Servo arm installation

D10 D10

D50 D50

E101 110

11019577 s 2EV !" s !PRIL 45

008 914 20 BOMAG 1003
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

SWASHPLATE GUIDE !SSEMBLE THE SWASHPLATE GUIDE $ AND FEEDBACK LINK - TO THE SWASHPLATE
)NSTALL NEW LOCKING SCREW $ WITH PRE APPLIED LOCKING COMPOUND USING AN INTERNAL
HEX WRENCH

4ORQUE THE SCREW TO SPECIlCATIONS IN THE TABLE BELOW

7HEN INSTALLING THE GUIDE ONTO THE CC SWASHPLATE HOLD THE STRAIGHT SIDES OF THE
GUIDE PERPENDICULAR TO THE SLIPPER SURFACE OF THE SWASHPLATE $ WHILE TIGHTENING
SCREW
Special locking screw speciﬁcations
Pump size D65 wrench sizes 4ORQUE .sM ;LBFsFT=
CC AND CC MM INTERNAL HEX ;=
CC THROUGH CC MM INTERNAL HEX ;=
CC MM INTERNAL HEX ;=
CC AND CC MM INTERNAL HEX ;=

Attaching swashplate guide

D65

M14

D60

D50
D50

E101 111

Roll pin and ﬂat washer

)NSTALL THE HEADED ROLL PIN $ AND mAT WASHER $ IF REMOVED &OR PROPER DISTANCE
( BETWEEN THE WASHER $ AND THE SIDE OF THE SWASHPLATE FOLLOW THE TABLES Roll pin
speciﬁcations (A) AND (B) BELOW

Roll pin speciﬁcations (A) Pin and washer positions

Pump frame size Distance, H: + 0.1, -0.25 mm
; INCHES=
CC MM ; INCHES= Swashplate
NO WASHER D75

Roll pin speciﬁcations (B)

D70
Pump frame size Distance, H: ± 0.25 mm
;¼ INCHES=
Distance H
CC MM ; INCHES= P104 188E
CC THROUGH CC MM ; INCHES=
CC MM ; INCHES=
CC AND CC ;=
;=
0IN AT SIDE COVER POSITION
0IN AT CONTROL POSITION

46 11019577 s 2EV !" s !PRIL

1004 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

PISTON ASSEMBLY Piston assembly

!SSEMBLE THE PISTON ASSEMBLIES # INTO THE SLIPPER GUIDE #

C Caution ,UBRICATE THE SLIPPER AND SWASHPLATE RUNNING SURFACES

-OST PARTS HAVE CRITICAL
HIGH TOLERANCE SURFACES #ENTER THE PISTONS # AND GUIDE # ON THE SWASHPLATE
4AKE CARE NOT TO DAMAGE
THESE SURFACES DURING
ASSEMBLY 0ROTECT EXPOSED Piston assembly
SURFACES OPENINGS AND
PORTS FROM DAMAGE AND
FOREIGN MATERIAL

D10

C20

D50

C20

D50

E101 114

11019577 s 2EV !" s !PRIL 47

008 914 20 BOMAG 1005
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

PISTON ASSEMBLY Fixed-clearance hold-down bearing

(continued)
3OME EARLY PRODUCTION PUMPS USE A SPRING LOADED HOLD DOWN MECHANISM 3ERVICE PARTS
FOR THE SPRING LOADED HOLD DOWN MECHANISM ARE NO LONGER AVAILABLE4HE lXED CLEARANCE
HOLD DOWN BEARING MUST BE INSTALLED IF HOLD DOWN PARTS REQUIRE REPLACEMENT ON THESE
EARLY PUMPS 2EFER TO THE APPROPRIATE Service Parts Manual FOR MORE INFORMATION

!SSEMBLE ONE HALF OF THE lXED CLEARANCE SLIPPER GUIDE HOLD DOWN BEARINGS #

0OSITION SPACERS # OVER THE THREADED HOLES IN THE SWASHPLATE $

C Caution )NSTALL ONE SLIPPER GUIDE HOLD DOWN BEARING # AND SPACERS # C
0OSITION THE SPLIT BETWEEN
THE # SLIPPER GUIDE )NSTALL NEW SCREWS C70 THROUGH THE SLIPPER GUIDE HOLD DOWN BEARING # AND
BEARING PLATES IN LINE WITH SPACERS # C
THE $ SWASHPLATE ARM
,OCATE THE BEARING SURFACE C Caution
OF THE # BEARING PLATES !LWAYS USE NEW SCREWS WITH PROPER LOCKING COMPOUND
NEXT TO THE # SLIPPER
GUIDE 3TART THE SCREWS C70 INTO THE SWASHPLATE $ DO NOT TORQUE

0OSITION SLIPPER GUIDE WITH PISTONS UNDER lRST HOLD DOWN BEARING

!SSEMBLE SECOND SLIPPER GUIDE HOLD DOWN BEARING WITH SCREWS AND SPACERS ONTO THE
SWASHPLATE 3TART THE SCREWS DO NOT TORQUE

,UBRICATE SLIPPER GUIDE AND HOLD DOWN BEARINGS

Hold-down bearing installation

D50

D10

C30

C20

C40

C50

E101 115

48 11019577 s 2EV !" s !PRIL

1006 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

PISTON ASSEMBLY Alternate hold-down bearing installation

(continued) D50

D10

C30

C20

C40

D50

C50

P106 542E

4ORQUE THE SLIPPER GUIDE HOLD DOWN Torque settings

SCREWS C70 TO THE SPECIlCATIONS IN Pump size 4ORQUE .sM ;LBFsFT=
Torque settings CC THROUGH CC ;=
CC THROUGH CC ;=

%NSURE THE SLIPPER GUIDE # AND PISTON SLIPPERS # SLIDE FREELY ON THE SWASHPLATE
AFTER ALL BOLTS ARE TORQUED

11019577 s 2EV !" s !PRIL 49

008 914 20 BOMAG 1007
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

BEARING CAGE .EW PARTS HAVE LOCKING PIN " INTEGRAL TO BEARING RACE &OR OLDER PUMPS LOCKING PINS
ARE SEPARATE FROM RACES4HE LOCATING PINS ASSURE PROPER ASSEMBLY
2ETAIN THE RACES IN POSITION WITH PETROLEUM JELLY

)NSTALL THE BEARING RACES INTO THE HOUSING POSITIONING THE RACES ON THE LOCATING PINS
"

!SSEMBLE AND LUBRICATE THE BEARING CAGE

)NSTALL THE BEARING CAGE ON THE BEARING RACES

Bearing assembly

Bearing race

New parts have locking pin (B20) integral

to bearing race. For older pumps, locking
pins are separate from races. B20
B20

P106 513E

50 11019577 s 2EV !" s !PRIL

1008 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

HOUSING 2EFER TO THE ILLUSTRATION Housing installations, NEXT PAGE FOR THE NEXT STEPS

0OSITION THE SERVO PISTON & IN THE HOUSING

&OR UNITS WITH AN ,UBRICATE AND INSTALL THE BRONZE SLIDER BLOCK & ONTO THE SERVO PISTON
AUTOMOTIVE CONTROL
THE SERVO PISTON HAS A #AREFULLY LOWER THE SWASHPLATE ASSEMBLY INTO THE HOUSING THROUGH THE END CAP
THREADED HOLE ON ITS OPENING 0ROTECT THE PISTONS FROM BEING SCRATCHED
MACHINED END 0UT THIS END
ON THE SIDE OF THE HOUSING (OLD THE SWASHPLATE ASSEMBLY APPROXIMATELY MM ;³ INCH= ABOVE THE CRADLE
WHERE THE CENTERING ASSIST BEARINGS
SPRING SLEEVE IS LOCATED
0OSITION THE FEEDBACK LINK $ IN THE CONTROL OPENING

,OWER THE SWASHPLATE ASSEMBLY ONTO THE CRADLE BEARINGS

C Caution 0OSITION THE SERVO PISTON ON THE SLIDER BLOCK & 4HE PARTS SHOULD SLIDE FREELY
"E SURE TO ASSEMBLE THE
CORRECT SERVO CYLINDER ON ,UBRICATE INSIDE THE SERVO CYLINDERS (OLD THE SERVO PISTON IN PLACE AND INSTALL THE
EACH SIDE OF THE HOUSING SERVO CYLINDERS C

&OR UNITS WITH AN AUTOMOTIVE CONTROL THERE IS A SPECIAL SERVO CYLINDER ON THE CENTERING
ASSIST SPRING SIDE OF THE HOUSING

)F PREVIOUSLY REMOVED INSTALL NEW SCREENS " 5SE PROPER INSTALLATION TOOL

11019577 s 2EV !" s !PRIL 51

008 914 20 BOMAG 1009
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

HOUSING (continued) Servo cylinder screws

)NSTALL THE SERVO CYLINDERS & COMPLETELY INTO THE HOUSING BORES

C Caution .UMBER OF SCREWS AND WRENCH SIZES VARY BY MODEL

)F THE SERVO CYLINDERS ARE
NOT SEATED COMPLETELY INTO )NSTALL THE OR SCREWS && Servo cylinder screw torques
THE BORES TIGHTENING OF IN EACH SERVO CYLINDER C Pump size F111/F211
THE SCREWS CAN DAMAGE THE .sM ;LBFsFT=
/ RINGS 4ORQUE TO SPECIlCATIONS IN Servo CC ;=
cylinder screw torques CC ;=
CC ;=
&OR UNITS WITH AN AUTOMOTIVE CONTROL CC ;=
INSTALL THE SERVO CYLINDER SCREWS ON TO THE CC ;=
HOUSINGS CENTERING ASSIST SPRING SIDE CC ;=
CC AND CC ;=
)F PREVIOUSLY REMOVED REPLACE
SCREENS " WITH NEW SCREENS

Housing installations

F20

F10

F111

Swashplate assembly F112

D14

F111 F113

F213 B60
O

F212
F211

F211 E101 118E

52 11019577 s 2EV !" s !PRIL

1010 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

HOUSING (continued) Displacement limiter.

)NSTALL DISPLACMENT LIMITERS & & INTO SERVO CYLINDERS TO LOCATION MARKED
DURRING DISASSEMBLY7RENCH SIZES ARE SHOWN IN TABLE BELOW

)NSTALL NEW SEAL LOCK NUTS & & ONTO DISPLACEMENT LIMITERS4ORQUE SEAL
LOCK NUTS WHILE HOLDING DISPLACEMENT LIMITER7RENCH SIZES AND TORQUE VALUES ARE
SHOWN IN TABLE BELOW 2EFER TO THE Series 90 Pumps Service Manual 520L0818 FOR
DISPLACEMENT LIMITER ADJUSTMENT INFORMATION

Displacment limiter and seal lock nut wrench sizes and torques
Pump size F113 F213 F112/F212 F112/F212
wrench size wrench 4ORQUE .sM ;LBFsFT=
CC CC MM MM ;=
CC MM MM ;=
CC AND CC MM MM ;=

Housing installations

F20

Servo piston

F111

Swashplate assembly F112

D14

F113
F111

F213
B60
O

F211
F212

F211
E101 118E

11019577 s 2EV !" s !PRIL 53

008 914 20 BOMAG 1011
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

BEARING CAGE LOCATOR !LIGN THE SWASHPLATES BEARING CAGE SLOT WITH THE HEADED SPRING PIN !LIGN WITH THE
LINK HOUSINGS PIN HOLE 3EE ILLUSTRATION Locator link position FOR CORRECT ORIENTATION

(OOK THE CAGE LOCATOR LINK $ OVER THE SPRING PIN BETWEEN THE WASHER AND THE
SWASHPLATE

2OTATE THE LINK $ INTO THE BEARING CAGE SLOT

FRAME SIZE PUMPS DO NOT HAVE A WASHER ON THE SPRING PIN

!LIGN THE LOCATOR LINK $ HOLE WITH THE HOUSING HOLE

)NSTALL THE LINK PIN $ THROUGH THE LOCATOR LINK $ AND INTO THE HOUSING

AND PUMPS USE A mAT HEAD SCREW AS THE LINK PIN 3TEPS AND REFER TO THESE
C Caution PUMPS
!LWAYS USE A NEW SCREW
WITH PROPER LOCKING )NSTALL A NEW SCREW WITH LOCKING COMPOUND THROUGH THE LOCATOR LINK $ AND INTO
COMPOUND THE HOUSING C

C Caution 4IGHTEN THE SCREW INTO THE HOUSING $O THIS UNTIL THE HEAD OF THE SCREW IS AT A HEIGHT OF
$O ./4 TORQUE THIS SCREW TO MM ; TO INCHES= FROM THE PUMP HOUSINGS MACHINED SURFACE C
AGAINST THE $ LOCATOR
LINK4HE LINK MUST ROTATE Locator link position
FREELY Finished Assembly

Housing pin hole

D80
D85

Bearing cage slot

Headed spring
pin washer

E101 120E

54 11019577 s 2EV !" s !PRIL

1012 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

VERIFY PROPER 0USH THE SWASHPLATE ASSEMBLY TOWARD THE CONTROL SIDE OF THE HOUSING UNTIL THE
ASSEMBLY SWASHPLATE GUIDE CONTACTS THE BEARING RACE

#HECK FOR CLEARANCE BETWEEN THE SERVO ARM AND THE SLIDER BLOCK

%NSURE SWASHPLATE ASSEMBLY MOVES FREELY ON BEARINGS

2OTATE SWASHPLATE ON BEARINGS TO CHECK FOR CONTROL LINK MOVEMENT AND PROPER
LOCATOR LINK POSITION

SWASHPLATE LEVELER 0LACE INSERTS % ONTO SIDE COVER Attach leveler to side cover
%
E30

0OSITION THE SWASHPLATE LEVELER %

ON THE SIDE COVER INSERTS %

.OTE THE ORIENTATION OF THE LEVELER

% AND THE SIDE COVER %

)NSTALL THE GUIDE POSTS %

E22
AND SEALING NUTS % 3EE Guide
post/sealing nut installation TABLE
FOR WRENCH SIZES AND TORQUE
SPECIlCATIONS E90

)NSTALL THE LEVELER SPRING SEATS % IF

NECESSARY

3OME PUMPS DO NOT HAVE REMOVABLE

SWASHPLATE LEVELER SPRING SEATS %

E40
E101 121

Guide post/sealing nut installation

Pump size Wrench sizes 4ORQUE .sM ;LBFsFT=
CC AND CC MM OPEN END ;=
MM HEX
CC THROUGH CC
INCH OPEN END ;=
MM HEX
CC THROUGH CC MM OPEN END ;=
MM HEX

11019577 s 2EV !" s !PRIL 55

008 914 20 BOMAG 1013
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

INSTALLING LEVELER ,UBRICATE AND INSTALL A NEW SIDE COVER / RING %
AND SIDE COVER
)NSTALL THE SIDE COVER ASSEMBLY C

C Caution )NSTALL SIDE COVER SCREWS % WITHOUT LOCKING COMPOUND AT OCLOCK AND
3LIDE SWASHPLATE LEVELER OCLOCK LOCATIONS4IGHTEN ONLY TO HALF TORQUE
% TOWARD THE CASE DRAIN
PORT4HIS ALLOWS THE LEVELER 4HIS HOLDS THE % COVER WHILE CHECKING THE ZERO ANGLE POSITION OF THE SWASHPLATE
% TO CLEAR THE SIDE OF
THE SWASHPLATE DURING SIDE Setting leveler - neutral position
COVER INSTALLATION )F REUSING ORIGINAL PARTS ROTATE THE SIDE COVER % TO ALIGN THE MARKS ON THE COVER
AND HOUSING ADDED DURING DISASSEMBLY )F USING NEW SWASHPLATE LEVELER PARTS
ALIGNMENT MARKS MAY NOT BE ACCURATE

!PPLY A FORCE OF TO . ; TO LBF = TO THE SWASHPLATE LEVELER % 4HIS ENSURES

BOTH ARMS ARE IN CONTACT WITH THE SWASHPLATE #LAMP A mAT PLAT ONTO THE PUMP
HOUSING AS SHOWN IN Leveling swashplate DRAWING BELOW

%NSURE THE SWASHPLATE IS ON ITS BEARINGS

-EASURE WITH A DEPTH MICROMETER TO lND THE DISTANCE FROM THE END CAP FACE OF THE
HOUSING TO THE OUTER EDGE OF THE SWASHPLATE SURFACE
W 7ARNING
4HESE MEASUREMENTS MUST 4AKE A SECOND MEASUREMENT AT A POINT ² FROM THE lRST POINT OF MEASUREMENT AT
NOT VARY BY MORE THAN THE OPPOSITE EDGE OF SWASHPLATE SURFACE W
MM ; INCHES=

Side cover and O-ring installations

Slide towards this end
Blind housing screw when installing
torques and Through
8 AND 9 ARE MEASUREMENTS housing screw torques
Case drain
FROM THE TOP OF THE port
SWASHPLATE TO THE END OF
THE HOUSING $IFFERENCE
BETWEEN 8 AND 9 MUST BE E20
LESS THAN
MM ; IN=

Leveling swashplate E10

22-44 N [5-10 lb]

Y X
B10

E101 122E
P106 516E

56 11019577 s 2EV !" s !PRIL

1014 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

INSTALLING LEVELER Positioning the side cover

AND SIDE COVER 2OTATE THE SIDE COVER % WHICH WILL ALSO ROTATE THE LEVELER AND SWASHPLATE UNTIL
(continued) THE MEASURED DEPTH ON EACH SIDE OF THE SWASHPLATE IS WITHIN MM ; IN=

)NSTALL THE REMAINING SCREWS % WITH PRE APPLIED LOCKING COMPOUND
W 7ARNING
4HESE MEASUREMENTS MUST 4ORQUE THESE SCREWS TO THE SPECIlCATIONS IN Blind housing screw torques AND Through
NOT VARY BY MORE THAN housing screw torques.
MM ; INCHES=
2EPLACE THE SCREWS % USED INITIALLY TO HOLD THE SIDE COVER ON WHILE SETTING
NEUTRAL WITH NEW SCREWS THAT HAVE LOCKING COMPOUND

4ORQUE THESE SCREWS TO THE SPECIlCATIONS IN Blind housing screw torques.

Through housing screw torques Blind housing screw torques

Pump size 4ORQUE .sM ;LBFsFT= Pump size 4ORQUE .sM ;LBFsFT=
CC AND CC ;= CC AND CC ;=
CC THROUGH CC ;= CC THROUGH CC ;=
CC THROUGH CC ;= CC THROUGH CC ;=

CYLINDER BLOCK 0OSITION PISTONS USING A TWISTING Installing cylinder block

INSTALLATION MOTION SO THAT THEY ALL LEAN IN A
Turn cylinder block
CLOCKWISE DIRECTION counterclockwise when
placing on pistons.
3ET CYLINDER BLOCK # ONTO PISTONS O
SO EACH BLOCK BORE SITS ON TOP OF A
PISTON
C12
0REVENT THE PISTONSSLIPPERS FROM
TURNING BY CAREFULLY PLACING a
SCREWDRIVER BETWEEN THE SLIPPER
RETAINER AND SWASHPLATE $O NOT
SCRATCH SWASHPLATE OR SLIPPERS
Lean pistons clockwise.
4URN THE CYLINDER BLOCK
COUNTERCLOCKWISE

4HIS MAKES THE PISTONS STAND UP STRAIGHT O

AND lT INTO THE BLOCK BORES

,OWER THE BLOCK ONTO THE PISTONS

2ELUBRICATE PISTON BORES AND CYLINDER

BLOCK

E101 130E

11019577 s 2EV !" s !PRIL 57

008 914 20 BOMAG 1015
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

END CAP INSTALLATION Preparing for end cap installation Installing the valve plate
)NSTALL THE END CAP ALIGNMENT PINS
" INTO THE HOUSING

,UBRICATE THE RUNNING SURFACE OF THE B50

CYLINDER BLOCK
B50

)NSTALL THE VALVE PLATE # ON THE

ALIGNMENT PINS

.OTE THE DIRECTION OF THE ARROW CUT

OUTS IN THE VALVE PLATE

7HEN VIEWING FROM THE END CAP SIDE E101 123E

OF VALVE PLATE THE ARROWS MUST POINT IN

THE OPPOSITE DIRECTION OF PUMP ROTATION Installing the springs
&OR EXAMPLE A RIGHT HAND CLOCKWISE
ROTATION PUMP MUST HAVE THE ARROWS
POINTING IN THE COUNTERCLOCKWISE
DIRECTION E80
D95
)NSTALL THE LONG SPRINGS %
WITH INNER SPRINGS IF USED ON THE
SWASHPLATE LEVELER SPRING SEATS

)F USED INSTALL THE SHORT SPRING $

ON THE SERVO ARM BRACKET

3OME MODELS ARE BUILT WITH AN ALTERNATE

SERVO ARM WHICH DOES NOT REQUIRE SPRING
$
E101 124

0LACE NEW END CAP GASKET ' Installing the gasket

C Caution ON THE HOUSING IN THE ORIENTATION
$O NOT BEND OR DAMAGE SHOWN LOCATED BY THE ALIGNMENT
THE END CAP GASKET DURING PINS C
INSTALLATION
G30 C

E101 125E

58 11019577 s 2EV !" s !PRIL

1016 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

END CAP INSTALLATION End cap parts Installations into end cap
(continued) ,UBRICATE THE END CAP JOURNAL
BEARING ' 0RESS BEARING INTO
HOUSING IF NECESSARY

)NSTALL THE HARDENED SHIMS %

IN THE END CAP POCKETS FOR THE
SWASHPLATE LEVELER SPRINGS

2ETAIN THE SHIMS USING PETROLEUM JELLY End cap

4HE SHIM POCKETS ARE DIFFERENT DEPTH IN

ENDCAP

E24
E101 126E

End cap installation Fastening end cap to housing

,OWER THE END CAP ONTO HOUSING
WHILE POSITIONING THE SPRINGS IN THEIR
END CAP POCKETS
G95
)NSTALL THE LARGE END CAP SCREWS G94
* G93
7HEN PROPERLY INSTALLED
THE END CAP ENGAGES 4IGHTEN THE LARGE END CAP SCREWS
THE ALIGNMENT PINS4HE * EVENLY 3EE Large end cap screw
SPRINGS HOLD THE END CAP torques
TO MM ; TO INCH=
AWAY FROM THE HOUSING .UMBER OF SCREWS AND WRENCH SIZE VARIES
BY MODEL
E101 127E
)NSTALL THE OR SMALLER SCREWS
'' HOLDING THE END CAP TO Torque 6 mm internal hex
THE HOUSING #"'#$)t]
Torque 8 mm internal hex
#"'#$ )t]
4HERE IS A LIFTING BRACKET ' SPACER
' AND WASHER ' ON THE END CAP See Large endcap screw
SCREW ' torques for appropriate J80
torque values.

4ORQUE THE MM INTERNAL HEX SCREWS

' ' TO .sM ; LBFsFT= Large end cap screw torques
Pump size 4ORQUE .sM ;LBFsFT=
4ORQUE THE MM INTERNAL HEX SCREWS CC ;=
' ' TO .sM ; LBFsFT= CC ;=
CC ;=
CC ;=
CC ;=
CC ;=
CC AND CC ;=

11019577 s 2EV !" s !PRIL 59

008 914 20 BOMAG 1017
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

SPEED SENSOR Assembly

)NSTALL A NEW / RING "! ONTO THE SENSOR "

5SING AN WRENCH INSTALL THE SPEED SENSOR WITH LOCK NUT AND / RING INTO
THE HOUSING !DJUST THE GAP BETWEEN THE SENSOR AND THE MAGNETIC SPEED RING AS
INSTRUCTED IN Speed sensor adjustment in Series 90 Pumps Service Manual 520L0818
!FTER ADJUSTMENT TORQUE THE SENSOR LOCK NUT TO .sM ; LBFsFT=

)F A SPEED SENSOR IS NOT INSTALLED USE A IN INTERNAL HEX WRENCH TO TORQUE THE
HOUSING PLUG " TO .sM ; LBFsFT=

Speed sensor
B83 O-ring plug

ft]
B83A

B83 B83A

E101 095E

60 11019577 s 2EV !" s !PRIL

1018 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

MULTI-FUNCTION VALVE Multi-function valve - pre 1988

CARTRIDGES - PRE 1988
P14

P19

P12

P06

P21
P15
P14
P11 P22
P09
P1
P13

E101 532E

Assembly
,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 AND 0

)NSTALL POPPET SEAT 0

)NSTALL RETAINING RING 0

,UBRICATE AND INSTALL / RING 0

)F PREVIOUSLY REMOVED REASSEMBLE AND INSTALL BYPASS ACTUATOR 0 4ORQUE TO

.sM ; LBFsFT=

,UBRICATE AND INSTALL NEW / RINGS 0 0

CCaution
)F PRESSURE LIMITER WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER TO
MODEL CODE SPECIlCATIONS

)NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE BELOW C

Multi-function valve wrench size Multi-function valve torque

Frame size Wrench size Frame size Torque
n INCH n .sM ; LBFsFT=
n INCH n .sM ; LBFsFT=

11019577 s 2EV !" s !PRIL 61

008 914 20 BOMAG 1019
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

PRESSURE OVERRIDE Assembly Pressure override valve components

VALVE (OPTION FOR 180 )NSTALL NEW / RINGS
FRAME SIZE)
Screws
)NSTALL THE VALVE ONTO THE PUMP END
CAP AND TORQUE THE SCREWS TO .sM Pressure override
; LBFsFT= valve

O-rings

E101 079E

CHARGE PRESSURE Assembly Lock nut wrench size

RELIEF VALVE )NSTALL THE POPPET + AND SPRING Frame size Wrench size
+ n INCH
n INCH
&OR SHIM ADJUSTABLE VALVES INSTALL
THE SHIMS AND PLUG TORQUE TO
.sM ; LBFsFT= &OR SCREW ADJUSTABLE Charge pressure relief valve
VALVES INSTALL THE PLUG WITH ITS LOCK
NUT ALIGNING THE MARKS MADE AT
+
DISASSEMBLY AND TORQUE THE LOCK NUT h ,OCK NUT
TO .sM ; LBFsFT= t ,OCK NUT TORQUE

#HECK THE CHARGE PRESSURE AND +

ADJUST IF NECESSARY h IN

d+ +

3EE APPROPRIATE TABLE

62 11019577 s 2EV !" s !PRIL

1020 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

CHARGE PUMP Current charge pump conﬁguration

H40

H05

H60
H50
H31
J50
J15

J30

H70
E101 082E
H80

Retainer screw wrench size

Frame size Wrench size
n MM
n MM

Assembly
"E SURE TO INSTALL THE CHARGE PUMP IN THE PROPER ORIENTATION )F UNSURE OF CHARGE PUMP
ROTATION REFER TO THE MODEL CODE

4HE ORIENTATION OF THE GEROTOR ASSEMBLY OUTER ECCENTRIC RING AND THE LOCATION OF THE
ALIGNMENT PIN IN THE END CAP DETERMINE THE CHARGE PUMP ROTATION $O NOT MIX CHARGE
PUMP PARTS FROM DIFFERENT PRODUCTION PERIODS !LWAYS INSTALL AS A COMPLETE ASSEMBLY

)NSTALL THE VALVE PLATE ( AND THE GEROTOR ASSEMBLY OUTER RING

)NSTALL THE ALIGNMENT PIN ( TO PROPERLY ORIENT THE VALVE PLATE AND OUTER ECCENTRIC
RING FOR CORRESPONDING PUMP ROTATION

0RIOR TO INSTALLATION LUBRICATE THE )$ /$ AND SIDE FACES OF THE GEROTOR ASSEMBLY

)NSTALL THE GEROTOR ASSEMBLY (

)NSTALL THE OUTER PLATE EARLY PRODUCTION AND INTERMEDIATE PRODUCTION PUMPS ONLY
NOT SHOWN

11019577 s 2EV !" s !PRIL 63

008 914 20 BOMAG 1021
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

)NSTALL THE CHARGE PUMP COUPLING4HE INTERNALLY SPLINED END OF THE COUPLING MUST
ENGAGE THE MAIN PUMP SHAFT &OR PUMPS WITH AN AUXILIARY MOUNTING PAD INSTALL THE
AUXILIARY DRIVE COUPLING INSTEAD

4HE OUTSIDE DIAMETER OF THE INTERNALLY SPLINED END OF SOME EARLY PRODUCTION CHARGE
PUMP COUPLINGS WAS CHAMFERED %ARLY PRODUCTION END CAPS MAY NOT BE MACHINED TO
ACCEPT A NON CHAMFERED COUPLING !LWAYS USE A CHAMFERED CHARGE PUMP COUPLING IN
PUMPS WITH THE EARLY ENDCAP

&OR PUMPS WITH NO AUXILIARY PAD INSTALL A NEW / RING * ONTO CHARGE PUMP COVER
)F AN AUXILIARY PAD IS INSTALLED AN / RING IS NOT USED ON THE COVER

CCaution
)N ORDER TO AVOID LOSS OF CHARGE PRESSURE IN PUMPS WITH AN AUXILIARY MOUNTING PAD
ALWAYS INSTALL THE CHARGE PUMP COVER SO THE PAD DRAIN HOLE IS LOCATED ON THE SAME SIDE OF
THE END CAP AS THE CHARGE INLET PORT

)NSTALL THE CHARGE PUMP COVER Retainer screw torque

RETAINER ( AND THE SIX INTERNAL Frame size Torque
HEX SCREWS ( 4ORQUE THE SCREWS n .sM ; LBFsFT=
PER THE TABLE AT THE RIGHT n .sM ; LBFsFT=

&OR PUMPS WITH AUXILIARY MOUNTING PADS INSTALL THE / RING AND AUXILIARY MOUNTING
PAD ADAPTOR ONTO THE END CAP

64 11019577 s 2EV !" s !PRIL

1022 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

AUXILIARY PAD Auxiliary pad components (typical)

J50
J80
Endcap screw J70

J60
See table for wrench size and torque
E101 084E

Assembly
,UBRICATE AND INSTALL / RING * ON END CAP PILOT

)NSTALL THE AUXILIARY MOUNTING PAD * ON REAR OF ENDCAP

4ORQUE AUX PAD SCREWS IN A )NSTALL FOUR LARGE SCREWS * AND NEW WASHERS * THROUGH THE MOUNTING PAD AND
CRISS CROSS PATTERN END CAP INTO THE HOUSING4ORQUE PER THE ACCOMPANYING TABLE

Aux. pad screw wrench size Aux pad screw torque

Frame size Wrench sizes Frame size Torque
n EARLY MM INTERNAL HEX .sM ; LBFsFT=
LATE MM INTERNAL HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
n MM HEX n .sM ; LBFsFT=
n MM INTERNAL HEX n .sM ; LBFsFT=
n MM INTERNAL HEX

DISPLACEMENT )F THE PUMP IS EQUIPPED WITH CONTROL Filter screen installation

CONTROL FILTER lLTER SCREENS IN THE PUMP HOUSING LATE B90
SCREENS PRODUCTION PRESS THEM INTO POSITION
WITH THE ROUNDED EDGE OF THE lLTER P106 690E

SCREENS FACING THE CONTROL UNTIL THEY ARE

mUSH TO MM ; INCH= BELOW THE
SURFACE OF THE HOUSING

11019577 s 2EV !" s !PRIL 65

008 914 20 BOMAG 1023
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

INTEGRAL CHARGE Assembly

PRESSURE FILTER )NSTALL THE HYDRAULIC TUBE . INTO ITS BORE IN THE ENDCAP )NSTALL THE lLTER HEAD .
REPLACEMENT INTO THE PORT USING A NEW / RING . 4HE HYDRAULIC TUBE SHOULD GO IN WITH LOW FORCE

!FTER ROTATING THE lLTER HEAD CLOCKWISE SO THAT THE THREADS ENGAGE WITH THE THREADS
CCaution IN THE ENDCAP CONTINUE TO ROTATE IT CLOCKWISE BETWEEN AND REVOLUTIONS 0OSITION
&AILURE TO INSTALL THE lLTER HEAD AS DESIRED C
MANIFOLD OR lLTER HEAD
TO A SUFlCIENT DEPTH IN 7HILE HOLDING THE lLTER HEAD IN THE DESIRED POSITION TIGHTEN THE SWIVEL LOCK NUT
THE END CAP WILL RESULT IN . AND TORQUE AS SHOWN IN TABLE
INSUFlCIENT ENGAGEMENT
OF THE TUBE IN THE END )NSTALL A NEW lLTER CANISTER . PER THE INSTRUCTIONS ON THE lLTER CANISTER
CAP BORE4HIS MAY ALLOW
UNlLTERED OIL TO BYPASS THE
lLTER AND ENTER THE CHARGE Integral charge pressure ﬁlter
SYSTEM

N25 N20
N15 Filter manifold lock nut

N36A

N36
11/16 in

N40

N10
N35A
N35
11/16 in
P106 182E

Lock nut wrench size and torque

Frame size Wrench size Torque
n INCH .sM ; LBFsFT=
n INCH .sM ; LBFsFT=
n INCH .sM ; LBFsFT=

66 11019577 s 2EV !" s !PRIL

1024 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

PUMP CONTROL COVER Assembly

PLATE )NSTALL A NEW GASKET ON THE HOUSING )NSTALL THE COVER PLATE

)NSTALL SCREWS - USING A MM INTERNAL HEX WRENCH4ORQUE THE SCREWS TO .sM
; LBFsFT=

)NSTALL A SEALING WASHER UNDER THE HEAD OF ANY MOUNTING SCREWS THAT ARE INSTALLED INTO
THROUGH HOLES IN THE HOUSING

Pump controls cover plate M90 X

MM
t .sM ; LBFsFT=

-
3EAL WASHER
LOCATION CC

-
d

0 %

DISPLACEMENT )NSTALL NEW / RINGS USING PETROLEUM Displacement control adapter plate (early
CONTROL ADAPTER JELLY TO RETAIN THEM production 130 cm³ pumps only)
PLATE (EARLY Adapter plate
PRODUCTION 130 )NSTALL ADAPTER PLATE screws
PUMPS ONLY)
)NSTALL SCREWS USING A MM INTERNAL 6 mm
HEX WRENCH4ORQUE TO .sM
; LBFsFT= t]
O-rings
Adapter plate

Seal

E101 087E

11019577 s 2EV !" s !PRIL 67

008 914 20 BOMAG 1025
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

HYDRAULIC AND Assembly

ELECTRIC DISPLACEMENT )NSTALL A NEW GASKET - 6ERIFY THE CONTROL ORIlCE CHECK VALVE AND SPRING 4 ARE IN
CONTROLS THEIR PROPER POSITION IN THE CONTROL

0OSITION THE CONTROL - ON THE HOUSING )NSERT THE CONTROL LINKAGE PIN INTO THE
SWASHPLATE LINK

Hydraulic/Electric displacement control

- X
I MM

-
d

4
4

0 %

68 11019577 s 2EV !" s !PRIL

1026 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

MANUAL DISPLACEMENT Assembly

CONTROL (MDC) )NSTALL A NEW GASKET - )NSPECT CONTROL TO ASSURE THAT THE CONTROL ORIlCE CHECK
VALVE AND SPRING ARE IN THEIR PROPER POSITION IN THE CONTROL

)NSTALL THE CONTROL %NGAGE THE PIN ON THE CONTROL LINKAGE INTO THE MATING HOLE IN THE
LINK ATTACHED TO THE SWASHPLATE

)F REMOVED INSTALL THE CONTROL HANDLE - AND LOCKING NUT - WITH WASHER -
(OLD THE POSITION OF THE HANDLE AND TORQUE THE LOCKING NUT TO .sM ; LBFsFT=
USING AN MM HEX WRENCH

MDC installation -

3 - h MM
h IN M70

- X
I MM

-
3EAL WASHER d
LOCATION CC
4

4 4

0 %

!LIGN THE CONTROL GASKET AND INSTALL THE SCREWS4ORQUE THE SCREWS TO .sM
; LBFsFT=
W 7ARNING
2ISK OF IMPROPER MACHINE )NSTALL A SEALING WASHER UNDER THE HEAD OF MOUNTING SCREWS IN THE LOCATION SHOWN
START UP )F EQUIPPED WITH
.EUTRAL 3TART 3WITCH .33 )F THE CONTROL IS EQUIPPED WITH A NEUTRAL START SWITCH REFER TO MDC Neutral start switch
PERFORM .33 ADJUSTMENT adjustment INSTRUCTIONS IN THE Series 90 Pumps Service Manual 520L0818
PROCEDURE IN SERVICE

11019577 s 2EV !" s !PRIL 69

008 914 20 BOMAG 1027
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

SOLENOID OVERRIDE Solenoid override valve installationSeal washer

VALVE FOR MDC location
(42, 180, 250 cc)

M77
M76A
M76C
M76B
M76

M78 (x2)
5 mm
M75
P106 186E

Assembly
)NSTALL A NEW GASKET - ON THE CONTROL HOUSING )NSTALL THE MANIFOLD - ONTO
THE CONTROL HOUSING ALIGN THE GASKET AND INSTALL THE SCREWS - 4ORQUE THE SCREWS
TO .sM ; LBFsFT=

5SING A MM WRENCH TORQUE VALVE - TO .sM ; LBFsFT= )F SOLENOID WAS
REMOVED TORQUE SOLENOID NUT TO .sM ; LBFsFT= $O NOT OVERTORQUE THE SOLENOID
NUT

70 11019577 s 2EV !" s !PRIL

1028 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

SOLENOID OVERRIDE Assembly

VALVE FOR MDC WITH 5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS - - - ON THE
PRESSURE RELEASED ADAPTER PLATE 0LACE THE ADAPTER PLATE INTO POSITION AND USING A MM INTERNAL HEX
BRAKE INSTALL THE SCREWS - 4ORQUE THE SCREWS TO .sM ; LBFsFT=

5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS ONTO THE SOLENOID VALVE
ASSEMBLY - AND INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE 5SING A MM
INTERNAL HEX INSTALL THE SCREWS - AND TORQUE TO .sM ; LBFsFT=

Solenoid override valve installation

M98 (x4)
4 mm
M9

M95
M96
M97 M92 (x4)
4 mm

P106 192E

11019577 s 2EV !" s !PRIL 71

008 914 20 BOMAG 1029
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

PRESSURE CONTROL Assembly

PILOT (PCP) FOR 5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS - AND - IN 0#0
ELECTRIC DISPLACEMENT (OUSING
CONTROL (EDC)
0LACE 0#0 AGAINST %$# HOUSING AND USING A MM INTERNAL HEX INSTALL THE SCREWS
- 4ORQUE TO .sM ; LBFsFT=

$O NOT REMOVE BLACK PLASTIC COVER FROM THE ALUMINUM PLATE4HIS IS NOT A SERVICEABLE ITEM
AND REMOVAL VOIDS THE PRODUCT WARRANTY

PCP installation

M97

M96 (x3)

M98 (x4)
M9
4 mm
P106 194E

72 11019577 s 2EV !" s !PRIL

1030 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

3-POSITION (FNR) Assembly

ELECTRIC CONTROL )NSTALL A NEW GASKET - ON THE HOUSING 0LACE THE ADAPTER PLATE INTO POSITION AND
USING A MM INTERNAL HEX INSTALL THE SCREWS - )NSTALL A SEALING WASHER UNDER THE
HEAD OF MOUNTING SCREWS THAT ARE INSTALLED INTO THROUGH HOLES IN THE HOUSING4ORQUE
THE SCREWS TO .sM ; LBFsFT=

)NSTALL ORIlCES 4 AND 4 INTO ADAPTER PLATE USING A OR MM
INTERNAL HEX WRENCH )NSTALL ORIlCE 4 INTO ADAPTER PLATE USING A OR MM
INTERNAL HEX WRENCH4ORQUE - THREADS TO .sM ; LBSsLFT= - THREADS TO .sM
; LBSsLFT= AND - THREADS TO .sM ; LBSsLFT=

5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS 7! ONTO THE SOLENOID
VALVE ASSEMBLY AND INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE 5SING A MM
INTERNAL HEX INSTALL SCREWS 7 4ORQUE TO .sM ; LBFsFT=

FNR installation
7 X
I MM

7!
- X d
I MM
4
4
4
-

3EAL WASHER
LOCATION CC
4

- 4
4
d

0 %

11019577 s 2EV !" s !PRIL 73

008 914 20 BOMAG 1031
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

MULTI-FUNCTION VALVE Multi-function valve installation

CARTRIDGES

P2B1

P13
P06

P2A1

P106 180E

Multi-function valve

P04
P03
P01
P02

P05

P06

P07
P08
P17
P16
P15
P14
P09
P11
P13

P12

E101 531E

74 11019577 s 2EV !" s !PRIL

1032 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

Assembly
,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 0 0 0 AND
0

0LACE THE CARTRIDGE IN A VISE AND PRESS ON THE POPPET SEAT 0

,UBRICATE AND INSTALL NEW / RINGS 0 0 0

)NSTALL BYPASS ACTUATOR 0 WITH PRESSURE LIMITER VALVE 0 4ORQUE TO .sM
; LBFsFT=

CCaution
)F PRESSURE LIMITER 0 WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER
TO MODEL CODE SPECIlCATIONS
CCaution
$O NOT OVERTORQUE THE )NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE C
MULTI FUNCTION VALVE
CARTRIDGES Multi-function valve wrench size Multi-function valve torque
Frame size Wrench size Frame size Torque
n INCH n .sM ; LBFsFT=
n INCH n .sM ; LBFsFT=

11019577 s 2EV !" s !PRIL 75

008 914 20 BOMAG 1033
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

INSTALLING SHAFT AND Shaft and bearing installation

BEARING 0OSITION THE PUMP ON ITS END CAP

0RESS THE ROLLER BEARING , ONTO THE INPUT SHAFT , &OR UNITS WITH A PIECE
BEARING PRESS THE INNER RACE ONTO THE SHAFT THEN INSTALL THE OUTER RACECAGE ASSEMBLY
AND SPECIAL WASHER C

5SING SUITABLE RETAINING RING PLIERS INSTALL THE BEARING RETAINING RING ,

C Caution
$O NOT DAMAGE THE SEALING SURFACE IN THE HOUSING DURING SHAFTBEARING INSTALLATION

,UBRICATE AND INSTALL SHAFT AND BEARING ASSEMBLY THROUGH FRONT OF HOUSING ALIGNING
THE SHAFT SPLINE WITH THE CYLINDER BLOCK SPLINE )F PUMP IS EQUIPPED WITH AUXILIARY
PAD ALIGN CHARGE PUMP SHAFT WITH AUXILIARY PAD COUPLING

#ONTINUE TO LOWER THE SHAFT INTO THE UNIT WHILE ALIGNING THE END OF THE SHAFT WITH END
CAP JOURNAL BEARING

)F NECESSARY COAT THE ,UBRICATE AND PRESS SEAL , IN Installing the shaft and bearing assembly
OUTSIDE DIAMETER OF THE CARRIER ,
L70
SEAL LIGHTLY WITH A SEALANT (see table)
SUCH AS ,OCTITE4- (IGH ,UBRICATE AND INSTALL / RING , IN
0ERFORMANCE 3EALANT CARRIER , L60
PRIOR TO INSTALLA
TION4HIS AIDS IN PREVENTING ,UBRICATE AND PRESS SEAL CARRIER INTO L30
LEAKS CAUSED BY DAMAGE ITS BORE IN THE HOUSING
L40
TO THE SEAL BORE IN THE SEAL
CARRIER )NSTALL RETAINER PLATE , AND BOLTS L50
, 7RENCH SIZES AND TORQUE VALUES
L20
FOR RETAINER PLATE BOLTS ARE SHOWN IN
TABLE BELOW
L10

L70 wrench sizes and torques

Pump size Wrench size 4ORQUE .sM ;LBFsFT= L100
CC MM HEX .sM ; LBFsFT=
CC MM .sM ; LBFsFT=
INTERNAL HEX
CC MM .sM ; LBFsFT=
INTERNAL HEX

E101 534E

76 11019577 s 2EV !" s !PRIL

1034 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

FINAL ASSEMBLY AND Final assembly and testing procedures

TESTING 2OTATE THE PUMP SHAFT WITH A TORQUE WRENCH TO ASSURE CORRECT ASSEMBLY4HE TABLE Torque
to turn shaft at 0° (with seal assembly installed) shows TORQUES NECESSARY TO TURN THE
SHAFT AFTER BREAK AWAY

Torque to turn shaft at 0° (with seal assembly installed)

Pump size -INIMUM TORQUE .sM ;LBFsFT= -AXIMUM TORQUE .sM ;LBFsFT=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=

W 7ARNING
4EST THE PUMP BEFORE PUTTING IT INTO SERVICE6ERIFY CORRECT PRESSURE LIMITER AND CONTROL
FUNCTION )MPROPER FUNCTION OF THESE SYSTEMS CAN RESULT IN UNCONTROLLABLE MOVEMENT OF
THE VEHICLEMACHINE

11019577 s 2EV !" s !PRIL 77

008 914 20 BOMAG 1035
20.1 Travel and vibration pump
Series 90 Pumps
Repair Instructions
4ORQUE #HART

FASTENER SIZE AND Item Fastener Frame size Wrench size Torque
TORQUE CHART B83 3PEED SENSOR LOCK NUT IN HEX .sM ; LBFsFT=
E60 3IDE COVER SCREW MM HEX .sM ; LBFsFT=
"LIND HOLES MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
E60 3IDE COVER SCREW MM HEX .sM ; LBFsFT=
4HRU HOLES MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
F111/ 3ERVO CYLINDER SCREW MM HEX .sM ; LBFsFT=
F211 MM HEX .sM ; LBFsFT=
G90/ %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
G97 MM INTERNAL HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
H80 #HARGE PUMP RETAINING SCREW MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
J80 %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
EARLY MM INTERNAL HEX .sM ; LBFsFT=
LATE MM INTERNAL HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
K10 #HARGE PRESSURE VALVE PLUG IN HEX .!
K90 #HARGE PRESSURE LOCK NUT IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
L70 3HAFT RETAINING SCREW MM HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
M72 -$# HANDLE NUT MM .sM ; LBFsFT=
M78 $E STROKE VALVE MANIFOLD SCREW MM INTERNAL HEX .sM ; LBFsFT=
M85 %CCENTRIC PLUG LOCK NUT IN HEX .sM ; LBFsFT=
M88 .EUTRAL START SWITCH LOCK NUT IN HEX .sM ; LBFsFT=
M90 #ONTROL MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M92 3OLENOID VALVE MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M98 0#0 MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
N10 &ILTER REDUCER ASSEMBLY IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
N37 &ILTER PLUG ASSEMBLY IN INTERNAL HEX .sM ; LBFsFT=
P2B1/ -ULTI FUNCTION VALVE IN HEX .sM ; LBFsFT=
P2A1 IN HEX .sM ; LBFsFT=

78 11019577 s 2EV !" s !PRIL

1036 BOMAG 008 914 20

Travel and vibration pump 20.1
Series 90 Pumps
Repair Instructions
4ORQUE #HART

0ROPORTIONAL VALVES 3AUER $ANFOSS PROVIDES COMPREHENSIVE WORLDWIDE SERVICE FOR ITS
$IRECTIONAL SPOOL VALVES PRODUCTS THROUGH AN EXTENSIVE NETWORK OF 'LOBAL 3ERVICE 0ARTNERS
STRATEGICALLY LOCATED IN ALL PARTS OF THE WORLD
#ARTRIDGE VALVES
(YDRAULIC INTEGRATED CIRCUITS
,OCAL ADDRESS
(YDROSTATIC TRANSAXLES
)NTEGRATED SYSTEMS
&AN DRIVE SYSTEMS
%LECTROHYDRAULICS
-ICROCONTROLLERS AND SOFTWARE
%LECTRIC MOTORS AND INVERTERS
*OYSTICKS AND CONTROL HANDLES 3AUER $ANFOSS 53 #OMPANY 3AUER $ANFOSS !P3
$ISPLAYS %AST TH 3TREET $+ .ORDBORG $ENMARK
!MES )! 53! 0HONE
Sensors 0HONE &AX
&AX
3AUER $ANFOSS 'MB( #O /(' 3AUER $ANFOSS $AIKIN ,4$
0OSTFACH $ .EUMünster 3ANNOMIYA 'RAND "LDG &
+ROKAMP $ .EUMüNSTER 'ERMANY )SOGAMI DORI #HUO KU
0HONE +OBE (YOGO *APAN
&AX 0HONE
&AX

WWWSAUER DANFOSSCOM
11019577 s 2EV !" s !PRIL

1038 BOMAG 008 914 20

20.2 Vibration motor

008 914 20 BOMAG 1039

20.2 Vibration motor

This repair manual describes the fixed displacement motor A2FM/E; the repair procedures are identical
with the ones for the fixed displacement motor A2FE32, which differs only by a different housing design.

1040 BOMAG 008 914 20

Vibration motor 20.2
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 91 001-03-R/05.03
Konstantmotor A2FM/E ersetzt / replaces 04.00

Fixed Displacement Motor A2FM/E

Baureihe / Series 61

Reparaturanleitung / Repair Instructions

008 914 20 BOMAG 1041

20.2 Bosch Rexroth AG | Mobile Hydraulics
2 A2F | RDE 91 001-03-R/05.03
Vibration motor

Hinweis / Inhalt
Notice / Contents

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

INHALT Seite/ CONTENTS

Page

A2F A2F

Schnittbild 3-6 Sectional view

Allgemeine Reparaturhinweise 7 General repair instructions
Dichtsätze und Baugruppen 8-9 Seal kits and sub-assemblies
Triebwelle abdichten 10 Sealing of the drive shaft
Anschlußplatte abdichten 11-14 Sealing of the cover plate
Triebwerk ausbauen 15-16 Removal the rotary group
Überprüfungshinweise 17-18 Inspection guidelines
Triebwerk einbauen 19-21 Installing rotary group
Anziehdrehmomente 22-24 Tightening torques
Sicherheitsbestimmungen 25 Safety regulations

1042 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.23
Schnittbild
Sectional view

A2FM Pos.B

Pos.D

Pos.A

Meßpunkte: Measuring points:

Siehe Serviceinfo See service information

008 914 20 BOMAG 1043

20.2 Bosch Rexroth AG | Mobile Hydraulics
4 A2F | RDE 91 001-03-R/05.03
Vibration motor

Schnittbild
Sectional view

A2FM mit Spülventil /

A2FM with flushing valve

1044 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.25
Schnittbild
Sectional view

A2FE

008 914 20 BOMAG 1045

20.2 Bosch Rexroth AG | Mobile Hydraulics
6 A2F | RDE 91 001-03-R/05.03
Vibration motor

Schnittbild
Sectional view

A2FE

1046 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.27
Allgemeine Reparaturhinweise
General repair instructions

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

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

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

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

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

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

Check all seal and sliding surfaces for wear.

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

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen bzw. entlüften.

Before start-up fill up hydraulic aggregates with

hydraulic oil respectively deaerate.

008 914 20 BOMAG 1047

20.2 Bosch Rexroth AG | Mobile Hydraulics
8 A2F | RDE 91 001-03-R/05.03
Vibration motor

Dichtsätze und Baugruppen

Seal kits and sub-assemblies

Dichtsatz

Seal kit

Triebwerk, mechanischer Teil /

Rotary group, mechanical part

Triebwerk, mechanischer Teil;

muß abgestimmt werden Pos. "A".
(siehe Serviceinfo)

Rotary group, mechanical part;

has to be adjusted to item "A".
(see service info)

Lagersatz, komplett abgestimmt.

Pos. B (Stützscheibe und Sicherungsring
nicht tauschbar)
zusätzliche Abstimmung Pos. "A".
(siehe Serviceinfo)

Bearing set, matched

Item B (support disc and circlip are
not exchangeable)
Additional adjustment item "A".
(see service info)

1048 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.29
Dichtsätze und Baugruppen
Seal kits and sub-assemblies

Triebwerk, hydraulischer Teil /

Rotary group, hydraulic part

Triebwerk, hydraulischer Teil;

Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)

Rotary group, hydraulic part;

Adjustment of the hydraulic part Pos. "D".
(see service info)

Triebwerk komplett; - fertig vorabgestimmt -

Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)

Complete rotary group, - pre-adjusted -

Adjustment of the hydraulic part Pos. "D".
(see service info)

Spülventil

Flushing valve

Ventil

Valve

008 914 20 BOMAG 1049

20.2 Bosch Rexroth AG | Mobile Hydraulics
10 A2F | RDE 91 001-03-R/05.03
Vibration motor

Triebwelle abdichten
Sealing of the drive shaft

Bei nicht verzahnten Triebwellen: Paßfeder abneh-

men. Triebwelle abkleben,

For non-splined shafts: remove key.

Protect the drive shaft (e.g. tape).

Sicherungsring ausbauen, Verschlußring abdrücken

Remove circlip, prise off cover.

Sichtkontrolle
Wellendichtring (1), Verschlußring (2),
Triebwelle (3), Gehäuse (4), O-Ring (5).

Visual check
Shaft seal (1), cover (2), drive shaft (3),
housing (4), O-ring (5).

1050 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.2
11

Triebwelle abdichten
Sealing of the drive shaft

Wellendichtring demontieren.

Remove shaft seal.

Neuen Wellendichtring lagerichtig mit

passender Büchse einpressen.

Press in the new shaft seal,ensuring that

it is correctly orientated, using a suitable bush.

Neuen O-Ring einlegen, auf bündiges Anliegen

achten. O-Ring sowie Dicht- und Staublippe des
Wellendichtringes einfetten. (siehe Serviceinfo)

Fit new O-ring, ensure that it is correctly located.

Grease the O-ring as well as the seal and dust lips
of the shaft seal. (see service information)

Sicherungsring einbauen.
Sitzkontrolle des Sicherungsringes in der Nut.

Fit circlip.
Check to ensure that the circlip is correctly located
within the groove.

008 914 20 BOMAG 1051

20.2 Bosch Rexroth AG | Mobile Hydraulics
12 A2F | RDE 91 001-03-R/05.03
Vibration motor

Anschlußplatte abdichten
Sealing of the cover plate

Lage der Anschlußplatte zum Gehäuse kenn-

zeichnen (Pfeil), Befestigungsschrauben lösen.

Mark the position of the cover plate with regard

to the housing (arrow), loosen the fixing screws.

Anschlußplatte um Verdrillstift schwenken (1)

und abheben (2).

Swing the connection plate about the locating

pin (1) and lift off (2).

1052 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.2
13

Anschlußplatte abdichten
Sealing of the cover plate

Auf Montagestellung des Verdrillstiftes achten

(Pfeile).

Take the assembly position of the locating

pin (arrow) into account.

Pumpe, Drehrichtung rechts.

Saugseite / (Blick auf sphärische Fläche.)
Suction side Druckseite /
Pressure side Pump, clockwise rotation.
(viewed on spherical surface.)

Saugseite /
Druckseite / Pumpe, Drehrichtung links.
Suction side
Pressure side (Blick auf sphärische Fläche.)

Pump, anti-clockwise rotation.

(viewed on spherical surface.)

Motor, beide Drehrichtungen.

(Blick auf sphärische Fläche.)

Motor, bi-directional.
(Viewed on spherical surface.)

008 914 20 BOMAG 1053

20.2 Bosch Rexroth AG | Mobile Hydraulics
14 A2F | RDE 91 001-03-R/05.03
Vibration motor

Anschlußplatte abdichten
Sealing of the cover plate

Sichtkontrolle
O-Ring (1), Einstich (2), Platte (3).

Visual check
O-ring (1), Groove (2), Plate (3).

Neuen O-Ring einlegen, zuvor leicht einfetten.

Lightly grease and fit O-ring.

Anschlußplatte aufsetzen, auf Kennzeichnung und

Lage des Verdrillstiftes achten.

Place the cover plate onto the housing taking into

account the location mark and position of the
locating pin.

Befestigungsschrauben mit Drehmomenten-

schlüssel anziehen.

Tighten fixing screws using a torque wrench.

1054 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.2
15

Triebwerk ausbauen
Removal the rotary group

Lagersatz / Bearing set

Demontage der Anschlußplatte.

Steuerplatte abheben.
Zylinder am Mittelzapfen mit Schraube befestigen.

Removal of the connection plate.

Lift off the control plate.
Secure the cylinder to the centre pin using a screw.

Gewindestift,Zylinderschraube /
Threaded pin,socket head screw

NG / Size (mm)

10; 12; 16 M3 x 35
23; 28; 32 M5 x 45
45 M5 x 50
56; 63 M5 x 55
80; 90 M5 x 60
107; 125; 131 M6 x 70
160; 180 M6 x 85

008 914 20 BOMAG 1055

20.2 Bosch Rexroth AG | Mobile Hydraulics
16 A2F | RDE 91 001-03-R/05.03
Vibration motor

Triebwerk ausbauen
Removal the rotary group

Verschlußring, O-Ring und Paßscheibe ausbauen.

Remove the cover, O-ring and shim.

Triebwerk mit Vorrichtung ausbauen.

Withdraw the rotary group using an extractor.

Befestigungsschraube ausbauen.
Zylinder abheben.

Remove the fixing screw.

Lift off the cylinder.

Rückzugplatte demontieren, Schrauben sind

eingeklebt.
Komplettes Triebwerk bei ca. 120o C im Ölbad
erwärmen. Danach Befestigungsschrauben lösen!

Disassemble the retaining plate, screws are locked

with an adhesive.
Heat up the complete rotary group in an oil bath
to approx 120o C, then remove the fixing screws.

1056 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.2
17

Überprüfungshinweise
Inspection guidelines

Triebwelle
4 4 1. kein Passungsrost, nicht ausgeschlagen.
1 2
3 2. keine Einlaufspuren, riefenfrei.
3. Kalotten riefenfrei und keine Pittings.
4. Keine Laufspuren (Lagerdreher)
3
Drive shaft
1. No wear, or fretting
2. No traces of wear, free of scratches.
3. Cups free of wear and no pitting.
4. No traces of wear, (bearing rotation).

1
1. Axiales Kolbenspiel

1. Axial play of piston.

Alt / Old

Kolben
Riefenfrei, keine Pittings.

Piston
Neu / New
Free of scratches, no pitting.

1 2
Mittelzapfen
1. Riefenfrei, ohne Pittings.
2. Riefenfrei.

Center pin
1. Free of scratches, no pittings.
2. Free of scratches.

Rückzugplatte
Riefenfrei, keine Ausbrüche.

Retaining plate
Free of scratches, no wear.

008 914 20 BOMAG 1057

20.2 Bosch Rexroth AG | Mobile Hydraulics
18 A2F | RDE 91 001-03-R/05.03
Vibration motor

Überprüfungshinweise
Inspection guidelines

Zylinder/Steuerplatte
1. Bohrungen riefenfrei, nicht ausgelaufen.
2. Gleichmäßiges Tragbild, riß- und riefenfrei.

Cylinder / control plate

1. Bores unscratched, and no traces of wear.
2. Even load distribution, free of cracks and
grooves.

Gehäuse
Im Lagerbereich riefenfrei und keine
Einlaufspuren.

Housing
No traces of wear in the bearing area.

Nur kompletten Kolbensatz austauschen.

Only exchange the pistons as a complete set.

Zylinder und Steuerplatte nur gemeinsam

austauschen.

Only replace the cylinder and control plate as a pair.

1058 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.2
19

Triebwerk einbauen
Installing rotary group

Triebwelle mit Lager vormontiert verwenden.

Use a pre-assembled drive shaft with bearings.

S Abstimmung Pos. A / Adjustment item A

A = A* + S
S = Nennmaß - Sicherungsring /Safety ring
A A*

Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.

Fit retaining plate complete with pistons and

centre pin.
Uses screws with a Precote coating.

Druckfeder (1) und Abstimmscheibe (2) einbauen.

Fit the compression spring (1) and shim(2).

Zylinder in Neutralposition befestigen.

Fix the cylinder in the neutral position.

008 914 20 BOMAG 1059

20.2 Bosch Rexroth AG | Mobile Hydraulics
20 A2F | RDE 91 001-03-R/05.03
Vibration motor

Triebwerk einbauen
Installing rotary group

Triebwerk max. ausschwenken.

Swivel the rotary group to max.

Neuer Radialwellendichtring montiert?

Is the new shaft seal fitted?

Gehäuse auf ca. 80o C erwärmen.

Heat the housing to approx. 80o C.

Heißes Gehäuse bis zum Anschlag aufsetzen.

Push on the hot housing until the stop is reached.

Neue Montagestellung.

New assembly position.

1060 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.2
21

Triebwerk einbauen
Installing rotary group

Paßscheibe, O-Ring einlegen. Verschlußring

montieren.
O-Ring, Zwischenraum Wellendichtring einfetten
(siehe Serviceinfo).

Fit the shim and O-ring. Then fit the cover.

Grease the O-ring as well as the seal and dust
lipsof the shaft seal.

Triebwerk gegen Verschlußring ziehen.

Kontrolle: Verschlußring spielfrei.

Pull the rotary group against the cover.

Check: to see that the cover is free of play.

Befestigungsschraube ausbauen.
Steuerplatte lagerichtig aufsetzen.
Fertigmontage
Abstimmung Pos. D - siehe Serviceinfo

Remove fixing screw. Fit the control plate into its

correct location.
Final assembly
For adjustment of Pos. D - see service info

Abstimmung Pos. D / Adjustment item D

Pos. D

Anschlüsse mit Staubschutz abdichten.

Korrosionsschutz (innen/außen). Fertig!

Seal connections to protect against dust.

Corrosion proctection (internal/external).
Assembly complete.

008 914 20 BOMAG 1061

20.2 Bosch Rexroth AG | Mobile Hydraulics
22 A2F | RDE 91 001-03-R/05.03
Vibration motor

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metri- The values stated are valid for bolts with metric
schem ISO-Gewinde nach DIN 13 Teil 13, sowie ISO threads to DIN 13 part 13, as well as head
Kopfauflagemaßen nach DIN 912 Zylinder- areas to DIN 912 socked head cap screws, DIN
schrauben, DIN 931 Sechskantschrauben mit 931 hexagon bolt or DIN 933 hexagon bolts with
Schaft bzw. DIN 933 Sechskantschrauben mit threads up to the head.
Gewinde bis Kopf.

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240

1062 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.2
23

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

008 914 20 BOMAG 1063

20.2 Bosch Rexroth AG | Mobile Hydraulics
24 A2F | RDE 91 001-03-R/05.03
Vibration motor

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

7. Linsenschrauben 7. Oval head screw

mit Innen-TORX, Gewindevorbeschichtung mit "precote" with inner TORX, thread precoated with "precote"

Standard / Standard precote 80 - Rot / Red

precote 86 - Blau / Blue

Variante / Variant
*
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20

siehe Stückliste / as to parts list

* mit Unterkopfbeschichtung - farblos

* with head bottom coating - colorless

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7

1064 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.2
25

Sicherheitsbestimmungen
Safety regulations

Allgemein General advice

● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.

Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck-Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. heavy injuries.
Daher sofort einen Arzt aufsuchen, da anderenfalls Therefore immediately consult a doctor as otherwise
schwere Infektionen entstehen können! heavy infections can be caused.
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr 2. When searching leakages use appropriate auxiliary devices
geeignete Hilfsmittel verwenden! because of the danger of accidents.
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt 3. Before working at the hydraulic equipment, lower pressure
drucklos machen und angebaute Geräte absenken! to zero and lower working arms of the rnachine.
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor 4. When working at the hydraulic equipment, absolutely stop
abstellen und Traktor gegen Wegrollen sichern motor and secure tractor against rolling away
(Feststellbremse, Unterlegkeil)! (parking brake, shim)!
5. Beim Anschließen von Hydraulikzylindern und -motoren ist 5. When connecting hydraulic cylinders and motor pay
auf vorgeschriebenen Anschluß der Hydraulikschläuche attention to correct connection of hydraulic flexible hoses.
zu achten! 6. In case of exchanging the ports, the tunctions are vice versa
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen (f. ex. lift-up/lower) - danger of accidents!
(z.B. Heben/Senken) - Unfallgefahr! 7. Check hydraulic flexible hoses regularly and replace them in
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und case of dammage or wear! The new hose pipes must comply
bei Beschädigung und Alterung austauschen! Die with the technical requirements of the machine manufacturer!
Austausch schlauchleitungen müssen den technischen
Anforderungen des Geräteherstellers entsprechen! Orderly disposal or recycling of oil, fuel and
filters!
Öle, Kraftstoffe und Filter ordnungsgemäß
entsorgen!

008 914 20 BOMAG 1065

20.2 Bosch Rexroth AG | Mobile Hydraulics
26 A2F | RDE 91 001-03-R/05.03
Vibration motor

1066 BOMAG 008 914 20

RDE 91 001-03-R/05.03
Vibration motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.2
27

008 914 20 BOMAG 1067

20.2 Vibration motor

Bosch Rexroth AG
Mobile Hydraulics
Produktbereich Axialkolbenmaschinen
Werk / Plant Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
[email protected]
www.boschrexroth.com/brm

© 2003 by Bosch Rexroth AG, © 2003 by Bosch Rexroth AG,

Mobile Hydraulics, 89275 Elchingen Mobile Hydraulics, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Bosch Rexroth AG reproduziert oder
any form or by any means, without the unter Verwendung elektronischer
prior written authorization of Bosch Systeme gespeichert, verarbeitet,
Rexroth AG. In the event of vervielfältigt oder verbreitet werden.
contravention of the above provisions, Zuwiderhandlungen verpflichten zu
the contravening party is obliged to Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are zu beachten, dass unsere Produkte
subject to a natural process of wear einem natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.

Printed in Germany
RDE 91 001-03-R/05.03

1068 BOMAG 008 914 20

Vibration motor 20.2

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008 914 20 BOMAG 1069

20.2 Vibration motor

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1070 BOMAG 008 914 20

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008 914 20 BOMAG 1071

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1072 BOMAG 008 914 20

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008 914 20 BOMAG 1073

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TBGFUZ UIFTFBDUJWJUJFTNBZUIFSFGPSFPOMZCFDBSSJFEPVUCZRVBMJGJFEQFSTPOOFMPS
BOJOTUSVDUFEQFSTPOVOEFSUIFEJSFDUJPOBOETVQFSWJTJPOPGRVBMJGJFEQFSTPOOFM

1074 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
(FOFSBMTBGFUZJOTUSVDUJPOT

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UIFBQQSPQSJBUFTBGFUZNFBTVSFTEVFUPUIFJSQSPGFTTJPOBMUSBJOJOH LOPXMFEHF
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SFMFWBOUUPUIFTVCKFDUBSFB

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*OUIJTNBOVBM UIFSFBSFTBGFUZJOTUSVDUJPOTCFGPSFUIFTUFQTXIFOFWFSUIFSFJTB
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BWPJEUIFTFEBOHFSTNVTUCFPCTFSWFE
4BGFUZJOTUSVDUJPOTBSFTFUPVUBTGPMMPXT

4*(/"-803%Ý 5ZQFPGEBOHFSÝ
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È $POTFRVFODFTEFTDSJCFTXIBUPDDVSTJGUIFTBGFUZJOTUSVDUJPOTBSFOPU
DPNQMJFEXJUI
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5IFTJHOBMXPSETIBWFUIFGPMMPXJOHNFBOJOH
4JHOBMXPSEÝ "QQMJDBUJPO
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8"3//(Ý OEJDBUFTBQPUFOUJBMEBOHFSXIJDI JGOPUBWPJEFE DPVME

SFTVMUJOEFBUIPSTFSJPVTJOKVSZ

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FRVJQNFOU

*GUIJTJOGPSNBUJPOJTEJTSFHBSEFE UIFPQFSBUJOHQSPDFEVSF
NBZCFJNQBJSFE

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(FOFSBMJOTUSVDUJPOT È 0CTFSWFUIFSFHVMBUJPOTGPSBDDJEFOUQSFWFOUJPOBOEFOWJSPONFOUBMQSPUFDUJPO
GPSUIFDPVOUSZXIFSFUIFQSPEVDUJTVTFEBOEBUUIFXPSLQMBDF
È 0OMZVTF3FYSPUIBYJBMQJTUPOVOJUTJOHPPEUFDIOJDBMPSEFSBOEDPOEJUJPO
¾ *OTQFDUUIFQSPEVDUGPSPCWJPVTEFGFDUT
È %POPUNPEJGZPSSFUSPGJUUIFBYJBMQJTUPOVOJU
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EBUB

008 914 20 BOMAG 1075

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
(FOFSBMTBGFUZJOTUSVDUJPOT

È 1FSTPOTXIPBTTFNCMF DPNNJTTJPO PQFSBUF EJTBTTFNCMFPSNBJOUBJO3FYSPUI

QSPEVDUTNVTUOPUDPOTVNFBOZBMDPIPM ESVHTPSQIBSNBDFVUJDBMTUIBUNBZ
BGGFDUUIFJSBCJMJUZUPSFTQPOE
È 5IFXBSSBOUZPOMZBQQMJFTUPUIFEFMJWFSFEDPOGJHVSBUJPO
È 5IFXBSSBOUZSFOEFSFEWPJEJGUIFQSPEVDUJTJODPSSFDUMZBTTFNCMFE
DPNNJTTJPOFEPSPQFSBUFE PSJGJUJTOPUVTFEBTJOUFOEFEBOEPSIBOEMFE
JNQSPQFSMZ
È %POPUFYQPTFUIFQSPEVDUUPBOZNFDIBOJDBMMPBETVOEFSBOZDJSDVNTUBODFT
/FWFSVTFUIFQSPEVDUBTBIBOEMFPSTUFQ
%POPUQMBDFMBZBOZPCKFDUTPOJU
È 5IFOPJTFFNJTTJPOPGBYJBMQJTUPOVOJUTEFQFOETPOTQFFE PQFSBUJOHQSFTTVSF
BOEJOTUBMMBUJPODPOEJUJPOT5IFTPVOEQSFTTVSFMFWFMNBZSJTFBCPWFE#"
EVSJOHOPSNBMPQFSBUJOHDPOEJUJPOT5IJTDBODBVTFIFBSJOHEBNBHF
¾ "MXBZTXFBSIFBSJOHQSPUFDUJPOXIJMFXPSLJOHJOUIFWJDJOJUZPGUIFPQFSBUJOH
BYJBMQJTUPOVOJU
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UIFBYJBMQJTUPOVOJUHFUTPIPUEVSJOHPQFSBUJPOUIBUZPVNBZCVSOZPVSTFMG
¾ "MMPXUIFBYJBMQJTUPOVOJUUPDPPMEPXOTVGGJDJFOUMZCFGPSFUPVDIJOHJU
¾ 8FBSIFBUSFTJTUBOUQSPUFDUJWFDMPUIJOH FHHMPWFT

%VSJOHUSBOTQPSU È .BLFDFSUBJOUIBUUIFMJGUJOHHFBSIBTBEFRVBUFMJGUJOHDBQBDJUZ5IFXFJHIUDBO
CFGPVOEJODIBQUFSÜ5SBOTQPSUBOETUPSBHFÜ

%VSJOHBTTFNCMZ È #FGPSFBTTFNCMJOH NBLFTVSFUIBUBMMGMVJETIBWFCFFODPNQMFUFMZSFNPWFE

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TZTUFN
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WPMUBHFGSFFCFGPSFZPVBTTFNCMFUIFQSPEVDU1SPUFDUUIFTZTUFNBHBJOTUCFJOH
TXJUDIFEPO
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PWFSUIFN
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BSFMFBLQSPPGBOEGMVJETBOEDPOUBNJOBOUTBSFQSFWFOUFEGSPNQFOFUSBUJOHUIF
QSPEVDU
È 8IFOBTTFNCMJOH QSPWJEFGPSBCTPMVUFDMFBOMJOFTTJOPSEFSUPQSFWFOU
DPOUBNJOBOUT TVDIBTXFMEJOHCFBETPSNFUBMDVUUJOHT GSPNHFUUJOHJOUPUIF
IZESBVMJDMJOFTBOEDBVTJOHQSPEVDUXFBSPSNBMGVODUJPOT

%VSJOHDPNNJTTJPOJOH È &OTVSFUIBUBMMFMFDUSJDBMBOEIZESBVMJDDPOOFDUJPOTBOEQPSUTBSFPDDVQJFEPS
QMVHHFE0OMZDPNNJTTJPOBDPNQMFUFMZJOTUBMMFEQSPEVDU

%VSJOHDMFBOJOH È 1MVHBMMPQFOJOHTXJUIUIFBQQSPQSJBUFQSPUFDUJWFFRVJQNFOUJOPSEFSUPQSFWFOU
EFUFSHFOUTGSPNQFOFUSBUJOHUIFTZTUFN
È /FWFSVTFTPMWFOUTPSBHHSFTTJWFEFUFSHFOUT6TFPOMZXBUFSBOE JGOFDFTTBSZ
BNJMEEFUFSHFOUUPDMFBOUIFBYJBMQJTUPOVOJU
È %POPUQPJOUUIFIJHIQSFTTVSFDMFBOFSBUTFOTJUJWFDPNQPOFOUT FHTIBGUTFBM
SJOH FMFDUSJDBMDPOOFDUJPOTBOEFMFDUSJDBMDPNQPOFOUT

1076 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
(FOFSBMTBGFUZJOTUSVDUJPOT

%VSJOHNBJOUFOBODFBOESFQBJS È 1FSGPSNUIFQSFTDSJCFENBJOUFOBODFXPSLBUUIFJOUFSWBMTTQFDJGJFEJOUIF
PQFSBUJOHJOTUSVDUJPOT TFFDIBQUFSÜ.BJOUFOBODFÜ
È .BLFTVSFUIBUOPMJOFT DPOOFDUJPOTPSDPNQPOFOUTBSFEJTDPOOFDUFEBTMPOH
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%JTQPTBM È %JTQPTFPGUIFQSPEVDUBOEUIFIZESBVMJDGMVJEJOBDDPSEBODFXJUIUIFDVSSFOUMZ
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0QFSBUPSÁTPCMJHBUJPOT
5IFPQFSBUPSPGUIFBYJBMQJTUPOVOJUGSPN3FYSPUINVTUQSPWJEFQFSTPOOFMUSBJOJOH
POBSFHVMBSCBTJTSFHBSEJOHUIFGPMMPXJOHTVCKFDUT
È 0CTFSWBUJPOBOEVTFPGUIFPQFSBUJOHJOTUSVDUJPOTBOEUIFMFHBMSFHVMBUJPOT
È *OUFOEFEVTFBOEPQFSBUJPOPGUIFBYJBMQJTUPOVOJU
È 0CTFSWBUJPOPGUIFJOTUSVDUJPOTGSPNUIFGBDUPSZTFDVSJUZPGGJDFTBOEPGUIFXPSL
JOTUSVDUJPOTGSPNUIFPQFSBUPS

3FYSPUIPGGFSTUSBJOJOHTVQQPSUGPSTQFDJBMGJFMET:PVDBOGJOEBOPWFSWJFXPG
UIFUSBJOJOHDPOUFOUTPOUIF*OUFSOFUBUhttp://www.boschrexroth.de/
didactic

008 914 20 BOMAG 1077

20.2#PTDI3FYSPUI"(
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%FMJWFSZDPOUFOUT

%FMJWFSZDPOUFOUT
3

'JH"YJBMQJTUPOVOJUXJUITFSWJDFMJOFQPSUTBUCPUUPN

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5IFGPMMPXJOHQBSUTBSFBMTPBTTFNCMFEPOEFMJWFSZ
È 1MBTUJDUSBOTQPSUQSPUFDUJPOGPSESJWFTIBGUFOE
È 1MBTUJDQSPUFDUJWFDPWFST
È 1MBTUJDQMVHTMPDLJOHTDSFXT

1078 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
1SPEVDUEFTDSJQUJPO

1SPEVDUEFTDSJQUJPO

1FSGPSNBODFEFTDSJQUJPO
"GJYFEQMVHJONPUPSDPOWFSUTIZESPTUBUJDGMPXJOUPNFDIBOJDBMSPUBUJPO*UJT
EFTJHOFEQSJNBSJMZGPSJOTUBMMBUJPOJONFDIBOJDBMHFBSCPYFT FHUSBDLESJWF
HFBSCPYFT
3FGFSUPUIFEBUBTIFFUBOEPSEFSDPOGJSNBUJPOGPSUIFUFDIOJDBMEBUB PQFSBUJOH
DPOEJUJPOTBOEPQFSBUJOHMJNJUTPGUIFBYJBMQJTUPOVOJU

%FWJDFEFTDSJQUJPO
5IF"'&JTBGJYFEQMVHJONPUPSXJUIBYJBMUBQFSFEQJTUPOSPUBSZHSPVQPGCFOU
BYJTEFTJHOGPSIZESPTUBUJDESJWFTJOPQFOBOEDMPTFEDJSDVJUT%VFUPUIFCFOUBYJT
EFTJHO UIFUPSRVFJTEFWFMPQFEEJSFDUMZBUUIFESJWFTIBGU5IFQJTUPOT MPBEUIF
DZMJOEFST CVUXJUIPOMZWFSZMJUUMFSBEJBMGPSDF5IJTIBTBQPTJUJWFJNQBDUPO
XFBS FGGJDJFODZBOETUBSUJOHUPSRVF
0QFODJSDVJU *OBOPQFODJSDVJU UIFIZESBVMJDGMVJEGMPXTGSPNUIFUBOLUPUIFIZESBVMJDQVNQ
XIFSFJUJTQVNQFEUPUIFGJYFENPUPS'SPNUIFGJYFENPUPS UIFNFEJVNUIFO
GMPXTJOBOVOQSFTTVSJ[FETUBUFCBDLUPUIFUBOLXIFSFJUJTSFUVSOFEUPUIF
IZESBVMJDQVNQ
5IFPVUQVUEJSFDUJPOPGUIFGJYFENPUPSDBOCFDIBOHFEXJUIBEJSFDUJPOBMWBMWF
$MPTFEDJSDVJU *OBDMPTFEDJSDVJU UIFSFUVSOJOHIZESBVMJDGMVJEGMPXTGSPNUIFGJYFENPUPSEJSFDUMZ
UPUIFIZESBVMJDQVNQ
5IFPVUQVUEJSFDUJPOPGUIFGJYFENPUPSJTDIBOHFECZSFWFSTJOHUIFGMPXEJSFDUJPO
JOUIFWBSJBCMFQVNQ

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1 2
3

'JH"TTFNCMZPGUIF"'&TFSJFT

%SJWFTIBGU $POUSPMQMBUF
1JTUPO 1PSUQMBUF
$ZMJOEFS

008 914 20 BOMAG 1079

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
1SPEVDUEFTDSJQUJPO

'PSGJYFENPUPSTXJUICFOUBYJTEFTJHO UIFQJTUPOT BSFBSSBOHFEEJBHPOBMMZ

XJUISFTQFDUUPUIFESJWFTIBGU 5IFQJTUPOTQFSGPSNBTUSPLFNPWFNFOUXIJDI
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DZMJOEFS JTNPWFECZUIFQJTUPOT

'VODUJPOBMEFTDSJQUJPO
.PUPSGVODUJPO "GJYFEQMVHJONPUPSDPOWFSUTIZESPTUBUJDFOFSHZJOUPNFDIBOJDBMFOFSHZ
)ZESBVMJDGMVJEJTEJSFDUFEWJBUIFQPSUQMBUF BOEUIFDPOUSPMQMBUF UPUIF
DZMJOEFSCPSFT5IFQJTUPOT JOUIFDZMJOEFSCPSFTQFSGPSNBTUSPLFNPWFNFOU
XIJDIJTDPOWFSUFEJOUPSPUBUJPOCZUIFQJTUPOKPJOUPOUIFGMBOHFPGUIFESJWF
TIBGU %VSJOHUIJTQSPDFTT UIFQJTUPOTNPWFUIFDZMJOEFS BOEHFOFSBUF
BOPVUQVUUPSRVFBUUIFESJWFTIBGU5IFPVUQVUUPSRVFJTQSPEVDFECZUIFGPSDF
SFTVMUJOHGSPNUIFQSFTTVSFBOEQJTUPOTVSGBDF5IFPVUQVUTQFFEJTQSPQPSUJPOBM
UPUIFJOXBSEGMPXBOEUIFEJTQMBDFNFOU5IFPVUQVUUPSRVFJODSFBTFTXJUIUIF
QSFTTVSFEJGGFSFODFCFUXFFOUIFIJHIBOEMPXQSFTTVSFTJEFT

1SPEVDUJEFOUJGJDBUJPO
5IFBYJBMQJTUPOVOJUDBOCFJEFOUJGJFEXJUIUIFOBNFQMBUF5IFGPMMPXJOHFYBNQMF
TIPXTBO"'&OBNFQMBUF

Rexroth 3
D-89275 Elchingen

11 TYP: A2FE28/61W-VAL100
4
10 MNR: R90XXXXXXX SC: X
7202
9 SN: 12345678
5
8 FD: 08W38 Rotation:
m: XXX kg

6
Made in Germany

'JH/BNFQMBUFPGGJYFEQMVHJONPUPS

.BOVGBDUVSFS #BSDPEF
*OUFSOBMQMBOUEFTJHOBUJPO 1SPEVDUJPOEBUF
4BNQMFDBUFHPSZ PQUJPOBM 4FSJBMOVNCFS
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ESJWFTIBGU ¾IFSFBMUFSOBUJOH BYJBMQJTUPOVOJU
4QFDJGJFEBSFBGPSUFTUTUBNQ 0SEFSJOHDPEF
8FJHIU PQUJPOBM

1080 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
5SBOTQPSUBOETUPSBHF

5SBOTQPSUBOETUPSBHF

5SBOTQPSUJOHUIFBYJBMQJTUPOVOJU

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%POPUIJUUIFDPVQMJOHPSESJWFTIBGUPGUIFBYJBMQJTUPOVOJU
%POPUTFUQMBDFUIFBYJBMQJTUPOVOJUPOUIFESJWFTIBGU
%FUBJMTPOUIFQFSNJTTJCMFBYJBMBOESBEJBMGPSDFTDBOCFGPVOEJOUIFEBUB
TIFFU

"YJBMQJTUPOVOJUTDBOCFUSBOTQPSUFEXJUIBGPSLMJGUUSVDLPSXJUIBMJGUJOHEFWJDF
.BLFDFSUBJOUIBUUIFGPSLMJGUUSVDLPSMJGUJOHEFWJDFIBTBEFRVBUFMJGUJOH
DBQBDJUZ

%JNFOTJPOTBOEXFJHIUT 5BCMF%JNFOTJPOTBOEXFJHIUT

4J[F
8FJHIU LH
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)FJHIU NN
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4J[F

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)FJHIU NN
SFRVFTUJGOFDFTTBSZ
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5IFXFJHIUTQFDJGJDBUJPOTNBZWBSZEFQFOEJOHPOUIFVOJUUZQF5IFFYBDUXFJHIU
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OFDFTTBSZ

5SBOTQPSUJOHXJUIMJGUJOHEFWJDF
'PSUSBOTQPSUJOH UIFBYJBMQJTUPOVOJUDBOCFDPOOFDUFEUPBMJGUJOHEFWJDFWJBB
SJOHTDSFXPSBMJGUJOHTUSBQ
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PVUXBSEBYJBMGPSDFTPDDVS5IVT ZPVDBOTVTQFOEUIFBYJBMQJTUPOVOJUGSPNUIF
ESJWFTIBGU
5PEPUIJT TDSFXBSJOHTDSFXDPNQMFUFMZJOUPUIFUISFBEPOUIFESJWFTIBGU
5IFUISFBEFETJ[FJTTUBUFEJOUIFJOTUBMMBUJPOESBXJOH
.BLFTVSFUIBUFBDISJOHTDSFXDBOCFBSUIFUPUBMXFJHIUPGUIFBYJBMQJTUPO
VOJUQMVTBQQSPY

:PVDBOIPJTUUIFBYJBMQJTUPOVOJUBTTIPXOJO'JHVTJOHUIFSJOHTDSFX
TDSFXFEJOUPUIFESJWFTIBGUXJUIPVUBOZSJTLPGEBNBHF

008 914 20 BOMAG 1081

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
5SBOTQPSUBOETUPSBHF

'JH'JYJOHUIFSJOHTDSFX

5SBOTQPSUXJUIMJGUJOHTUSBQ 1MBDFUIFMJGUJOHTUSBQBSPVOEUIFBYJBMQJTUPOVOJUJOTVDIBXBZUIBUJUQBTTFT
PWFSOFJUIFSUIFBUUBDINFOUQBSUT FHWBMWFT OPSTVDIUIBUUIFBYJBMQJTUPO
VOJUJTIVOHGSPNBUUBDINFOUQBSUT TFF'JH

8"3/*/(Ý 3JTLPGJOKVSZÝ
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MJGUJOHTUSBQ
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'JH5SBOTQPSUXJUIMJGUJOHTUSBQ

1082 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
5SBOTQPSUBOETUPSBHF

4UPSJOHUIFBYJBMQJTUPOVOJU
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È 5IFTUPSBHFBSFBTNVTUCFESZ
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È "WPJEJOUFOTFMJHIUT
È %POPUTUBDLBYJBMQJTUPOVOJUTBOETUPSFUIFNTIPDLQSPPG
È 'PSPUIFSTUPSBHFDPOEJUJPOT TFF5BCMF

$IFDLUIFBYJBMQJTUPOVOJUNPOUIMZUPFOTVSFQSPQFSTUPSBHF

"GUFSEFMJWFSZ 5IFBYJBMQJTUPOVOJUJTQSPWJEFEFYXPSLTXJUIBDPSSPTJPOQSPUFDUJPOQBDLBHJOH
DPSSPTJPOQSPUFDUJPOGJMN
-JTUFEJOUIFGPMMPXJOHUBCMFBSFUIFNBYJNVNQFSNJTTJCMFTUPSBHFUJNFTGPSBO
PSJHJOBMMZQBDLFEBYJBMQJTUPOVOJU
5BCMF4UPSBHFUJNFXJUIGBDUPSZTVQQMJFEDPSSPTJPOQSPUFDUJPO
4UPSBHFDPOEJUJPOT 4UBOEBSEDPSSPTJPO -POHUFSN
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OPUBEIFSFEUPPSBGUFSFYQJSZPGUIFNBYJNVNTUPSBHFUJNF TFF5BCMF

1SPDFEVSFBGUFSFYQJSBUJPOPGUIFNBYJNVNTUPSBHFUJNF
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JOTUBMMBUJPO
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BYJBMQJTUPOVOJUJOTQFDUFECZZPVSSFTQPOTJCMF3FYSPUI4FSWJDFQBSUOFS

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GVSUIFSJOGPSNBUJPO

008 914 20 BOMAG 1083

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
5SBOTQPSUBOETUPSBHF

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'PSTUPSBHFUJNFVQUPNPOUITGJMMUIFBYJBMQJTUPOVOJUXJUIDPSSPTJPO
QSPUFDUJPO7$* NM
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1084 BOMAG 008 914 20

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Vibration motor #PTDI3FYSPUI"(
20.2
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008 914 20 BOMAG 1085

20.2#PTDI3FYSPUI"(
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1086 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
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1 2a2)

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3 2b3)

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5 TJ[FTUP

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008 914 20 BOMAG 1087

20.2#PTDI3FYSPUI"(
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4 T (NG28–180) 5
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1088 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
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1SFQBSBUJPO
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JOUIFPSEFSDPOGJSNBUJPO
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008 914 20 BOMAG 1089

20.2#PTDI3FYSPUI"(
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1090 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
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BTTPDJBUFEXFBS
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¾ 'PSGMBOHFJOTUBMMBUJPO BMJHOUIFTVQQPSUGPSUIFBYJBMQJTUPOVOJUXJUIUIF
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BDDFTT
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008 914 20 BOMAG 1091

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
"TTFNCMZ

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MPDLJOHTDSFXT5IFTFNVTUCFSFNPWFECFGPSFDPOOFDUJOH6TFBQQSPQSJBUF
UPPMT
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NBEF UIFTFQPSUTNVTUCFQMVHHFEXJUIBTVJUBCMFNFUBMMPDLJOHTDSFXTJODF
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1092 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
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5IFNBDIJOFPSTZTUFNNBOVGBDUVSFSJTSFTQPOTJCMFGPSEJNFOTJPOJOHUIFMJOFT
5IFBYJBMQJTUPOVOJUNVTUCFDPOOFDUFEUPUIFSFTUPGUIFIZESBVMJDTZTUFN
JOBDDPSEBODFXJUIUIFIZESBVMJDDJSDVJUEJBHSBNPGUIFNBDIJOFPSTZTUFN
NBOVGBDUVSFS

$"65*0/Ý %BNBHFUPUIFBYJBMQJTUPOVOJUÝ
8IFOJOTUBMMJOHIZESBVMJDMJOFTBOEIPTFTVOEFSNFDIBOJDBMTUSFTT UIFZBSF
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TFSWJDFMJGFPGUIFBYJBMQJTUPOVOJUBOEUIFFOUJSFNBDIJOFPSTZTUFN
"TTFNCMFIZESBVMJDMJOFTBOEIPTFTXJUIPVUNFDIBOJDBMTUSFTT

0OMZDPOOFDUIZESBVMJDMJOFTUPUIFTFSWJDFBOEGVODUJPOQPSUT

$"65*0/Ý 8FBSBOENBMGVODUJPOT
5IFDMFBOMJOFTTPGUIFIZESBVMJDGMVJEIBTBDPOTJEFSBCMFJNQBDUPOUIFDMFBOMJOFTT
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"CTPMVUFDMFBOMJOFTTJTSFRVJSFE
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.BLFTVSFUIBUBMMQPSUT IZESBVMJDMJOFTBOEBEEPOVOJUT FHNFBTVSJOH
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5BLFDBSFUIBUOPEFUFSHFOUTFOUFSUIFIZESBVMJDTZTUFN
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%POPUVTFIFNQBTTFBMBOUVOEFSBOZDJSDVNTUBODFT

/PUFTPOSPVUJOHUIFMJOFT 0CTFSWFUIFGPMMPXJOHOPUFTXIFOSPVUJOHUIFQSFTTVSFBOEDBTFESBJOMJOFT
0CTFSWFUIFBJSUJHIUOFTTPGUIFKVODUJPOTBOEUIFQSFTTVSFSFTJTUBODFPGUIF
IPTF BMTPXJUISFTQFDUUPUIFFYUFSOBMBJSQSFTTVSF
8JUIUIFQSFTTVSFMJOFT NBLFDFSUBJOUIBUUIFQJQFT IPTFTBOEDPOOFDUJOH
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XJUIIZESBVMJDGMVJEBOEUPFOTVSFUIBUOPBJSHFUTUISPVHIUIFTIBGUTFBMSJOH
FWFOEVSJOHFYUFOEFETUBOETUJMMQFSJPET5IFDBTFJOUFSOBMQSFTTVSFNVTUOPU
FYDFFEUIFMJNJUWBMVFTMJTUFEGPSUIFBYJBMQJTUPOVOJUJOUIFEBUBTIFFUVOEFS
BOZPQFSBUJOHDPOEJUJPOT5IFDBTFESBJOMJOFJOUIFUBOLNVTUFOEVQCFMPX
UIFNJOJNVNGMVJEMFWFMVOEFSBMMDPOEJUJPOT TFFDIBQUFSÜ*OTUBMMBUJPO
QPTJUJPOÜ

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EBUBTIFFU5IFNBDIJOFPSTZTUFNNBOVGBDUVSFSNVTUFOTVSFUIBUUIF
DPOOFDUJOHFMFNFOUTBOEMJOFTDPSSFTQPOEUPUIFTQFDJGJFEPQFSBUJOH
DPOEJUJPOT QSFTTVSF GMPX IZESBVMJDGMVJE UFNQFSBUVSF XJUIUIFOFDFTTBSZ
TBGFUZGBDUPST

008 914 20 BOMAG 1093

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
"TTFNCMZ

1SPDFEVSF 5PDPOOFDUUIFBYJBMQJTUPOVOJUUPUIFIZESBVMJDTZTUFN
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NBEFBDDPSEJOHUPUIFIZESBVMJDDJSDVJUEJBHSBN
6TFPOMZDMFBOIZESBVMJDMJOFT
$POOFDUUIFMJOFTBDDPSEJOHUPUIFIZESBVMJDDJSDVJUEJBHSBN
&JUIFSQJQFTPSIPTFTNVTUCFDPOOFDUFEUPBMMQPSUTBDDPSEJOHUPUIF
JOTUBMMBUJPOESBXJOHBOENBDIJOFPSTZTUFNDJSDVJUEJBHSBNPSUIFQPSUT
QMVHHFEVTJOHTVJUBCMFMPDLJOHTDSFXT
5IFJOTUBMMBUJPOESBXJOHDPOUBJOTUIFEJNFOTJPOTGPSBMMDPOOFDUJPOTBOEQPSUT
POUIFBYJBMQJTUPOVOJU"MTPPCTFSWFUIFJOTUSVDUJPOTQSPWJEFECZUIF
NBOVGBDUVSFSTPGUIFPUIFSIZESBVMJDDPNQPOFOUTXIFOTFMFDUJOHUIFSFRVJSFE
UPPMT

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PCTFSWFUJHIUFOJOHUPSRVFTÝ .BSLBMMDIFDLFEGJUUJOHTVTJOHFHBQFSNBOFOU
NBSLFS
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DPOOFDUJOHQJFDF DPVQMJOHPSDPOOFDUJOHQPJOUXJUIIPTFTPSQJQFTIBWFCFFO
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PSt
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UIFTFUUJOHPGUIFBEKVTUJOHTDSFXPOUIFQSFTTVSFSFMJFGWBMWFXJMMSFOEFSUIF
XBSSBOUZWPJE

1094 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor 20.2
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"TTFNCMZ

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UIFDPVOUFSCBMBODFWBMWFBOENPUPSBSFEFMJWFSFETFQBSBUFMZ UIFDPVOUFSCBMBODF
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5BCMF5JHIUFOJOHUPSRVFTPGUIFGJYJOHTDSFXT
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B1
B2
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DPOUFOUT

008 914 20 BOMAG 1095

20.2#PTDI3FYSPUI"(
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5BCMF5ISFBEFETJ[FTBOEEJNFOTJPOT
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S1 PSt
PSt
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T21)

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1096 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
"TTFNCMZ

MA
T

T
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S
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T21) MB

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B
A
T2

'JH1PSUPWFSWJFX"'& TJ[FTUP QPSUQMBUF TFSWJDFMJOFQPSUTBUSFBS

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%FTJHOBUJPO 1PSUGPS 4UBOEBSE 1FBL 4UBUF
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5 $BTFESBJOGMVJE %*/ 9
5 $BTFESBJOGMVJE %*/ 0
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4 4VQQMZ POMZXJUIQPSUQMBUF %*/ 9

14U 1JMPUQSFTTVSF POMZGPSQPSU %*/*40 0
QMBUF
#SJFGQSFTTVSFTQJLFTNBZPDDVSEFQFOEJOHPOUIFBQQMJDBUJPO,FFQUIJTJONJOEXIFOTFMFDUJOH

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0OMZEJNFOTJPOTBDDPSEJOHUP4"&+

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7BMJEGPSTJ[FTUP

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0.VTUCFDPOOFDUFE QMVHHFEXJUIQMBTUJDQMVHTPOEFMJWFSZ
91MVHHFE JOOPSNBMPQFSBUJPO

008 914 20 BOMAG 1097

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
"TTFNCMZ

5JHIUFOJOHUPSRVFT 5IFGPMMPXJOHUJHIUFOJOHUPSRVFTBQQMZ
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0CTFSWFUIFNBOVGBDUVSFSTJOTUSVDUJPOSFHBSEJOHUIFUJHIUFOJOHUPSRVFTPGUIF
VTFEBSNBUVSFT
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'PSUIFNFUBMMPDLJOHTDSFXTTVQQMJFEXJUIUIFBYJBMQJTUPOVOJU UIFSFRVJSFE
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UBCMF

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8"'IFYBHPOTPDLFUGPS
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.Y %*/ /N /N NN
.Y %*/ /N /N NN
.Y %*/ /N /N NN
.Y %*/ /N /N NN
.Y %*/ /N /N NN
.Y %*/ /N /N NN
.Y %*/ /N /N NN
.Y %*/ /N /N NN
.Y %*/ /N /N NN
.Y %*/ /N /N NN
( %*/*40 /N

3JTLPGNJYVQTXJUI 5IFBYJBMQJTUPOVOJUTBSFVTFEJOBQQMJDBUJPOBSFBTXJUINFUSJDBTXFMMBTXJUI
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#PUIUIFTZTUFNPGVOJUTBOEUIFTJ[FPGUISFBEFEIPMFBOEUISFBEFEQMVH
FHMPDLJOHTDSFX NVTUNBUDI
%VFUPMJNJUFEQPTTJCJMJUJFTGPSWJTVBMMZEFUFDUJOHEJGGFSFODFT UIFSFJTBSJTLPG
NJYVQT

8"3/*/(Ý 3JTLPGEBNBHFUPQFSTPOTBOEQSPQFSUZÝ
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SFTQFDUUPUIFUISFBEFEIPMFJTQSFTTVSJ[FE UIFUISFBEFEQMVHNBZMPPTFOJUTFMGPS
FWFOCFFKFDUFEGSPNUIFIPMFJOBQSPKFDUJMFMJLFNBOOFS
5IJTDBOSFTVMUJOTFSJPVTJOKVSZBOEEBNBHFUPFRVJQNFOU)ZESBVMJDGMVJEDBOCF
EJTDIBSHFEGSPNUIJTMFBLBHFQPJOU
6TFUIFESBXJOHT JOTUBMMBUJPOESBXJOHEBUBTIFFU UPEFUFSNJOFUIFSFRVJSFE
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TDSFXTBOEMPDLJOHTDSFXT
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PGUIFDPSSFDUTJ[F

1098 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
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$PNNJTTJPOJOH
8"3/*/(Ý %BOHFSXIJMFXPSLJOHJOUIFEBOHFS[POFPGBNBDIJOFPSTZTUFNÝ
*UJTOPUQFSNJTTJCMFUPXPSLJOUIFEBOHFS[POFPGBNBDIJOFPSTZTUFN
5IFNBDIJOFPSTZTUFNNVTUPOMZCFPQFSBUFEJGTBGFXPSLJOHJTFOTVSFE
1BZBUUFOUJPOUPBOESFDUJGZQPUFOUJBMEBOHFSTPVSDFTCFGPSFPQFSBUJOHUIF
NBDIJOFPSTZTUFN
/PCPEZNBZTUBOEJOUIFEBOHFS[POFPGUIFNBDIJOFPSTZTUFN
5IFFNFSHFODZTUPQCVUUPOGPSUIFNBDIJOFPSTZTUFNNVTUCFXJUIJOUIF
PQFSBUPSÁTSFBDI
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DPNNJTTJPOJOH

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BVUIPSJ[FEUPDPNNJTTJPOUIFBYJBMQJTUPOVOJU

8"3/*/(Ý 3JTLPGUPYJDBUJPOBOEJOKVSZÝ
$POUBDUXJUIIZESBVMJDGMVJETNBZEBNBHFZPVSIFBMUI FHFZFJOKVSJFT TLJO
EBNBHF UPYJDBUJPOVQPOJOIBMBUJPO
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8IJMFQFSGPSNJOHUIFTFDIFDLT XFBSTBGFUZHMPWFT TBGFUZHMBTTFTBOE
TVJUBCMFXPSLJOHDMPUIFT
*GIZESBVMJDGMVJETIPVME OFWFSUIFMFTT DPNFJOUPDPOUBDUXJUIZPVSFZFTPS
QFOFUSBUFZPVSTLJO DPOTVMUBEPDUPSJNNFEJBUFMZ
8IFOXPSLJOHXJUIIZESBVMJDGMVJET TUSJDUMZPCTFSWFUIFTBGFUZJOTUSVDUJPOT
QSPWJEFECZUIFIZESBVMJDGMVJENBOVGBDUVSFS

8"3/*/(Ý 'JSFIB[BSEÝ
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,FFQPQFOGMBNFTBOEJHOJUJPOTPVSDFTGSPNUIFBYJBMQJTUPOVOJU

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1SJPSUPBTTFNCMZ NBLFTVSFUIBUBMMTFBMTBOEDPOOFDUPSTBSFUJHIU

008 914 20 BOMAG 1099

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
$PNNJTTJPOJOH

'JSTUDPNNJTTJPOJOH

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$"65*0/Ý 3JTLPGEBNBHFUPUIFQSPEVDUÝ
*GZPVDPNNJTTJPOUIFBYJBMQJTUPOVOJUXJUIPVUPSXJUIJOTVGGJDJFOUIZESBVMJDGMVJE
UIFBYJBMQJTUPOVOJUJTEBNBHFEJNNFEJBUFMZPSFWFOEFTUSPZFE
8IFODPNNJTTJPOJOHPSSFDPNNJTTJPOJOHBNBDIJOFPSTZTUFN NBLFTVSF
UIBUUIFDBTFJOUFSJPSBOEUIFTFSWJDFMJOFTPGUIFBYJBMQJTUPOVOJUBSFGJMMFEXJUI
IZESBVMJDGMVJEBOESFNBJOGJMMFEEVSJOHPQFSBUJPO

8IFODPNNJTTJPOJOHUIFBYJBMQJTUPOVOJU PCTFSWFUIFCBTJDTBGFUZ
JOTUSVDUJPOTBOEJOUFOEFEVTFQSPWJEFEJODIBQUFSÜ(FOFSBMTBGFUZ
JOTUSVDUJPOTÜ

'JMMJOHUIFBYJBMQJTUPOVOJU
:PVXJMMSFRVJSFBOBQQSPWFEIZESBVMJDGMVJE
5IFNBDIJOFPSTZTUFNNBOVGBDUVSFSDBOQSPWJEFZPVXJUIQSFDJTFEFUBJMTPOUIF
IZESBVMJDGMVJE%FUBJMTPONJOJNVNSFRVJSFNFOUTGPSNJOFSBMPJMCBTFEIZESBVMJD
GMVJET FOWJSPONFOUBMMZBDDFQUBCMFIZESBVMJDGMVJETPS)'IZESBVMJDGMVJETGPSUIF
BYJBMQJTUPOVOJUBSFBWBJMBCMFJOUIF3FYSPUIQVCMJDBUJPOT3& 3&
BOE3& SFTQFDUJWFMZ
5PFOTVSFUIFGVODUJPOBMSFMJBCJMJUZPGUIFBYJBMQJTUPOVOJU DMFBOMJOFTTMFWFM
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WFSZIJHIIZESBVMJDGMVJEUFNQFSBUVSFT m$UPNBYJNVN m$ DMFBOMJOFTT
MFWFMBDDPSEJOHUPBUMFBTU*40JTOFDFTTBSZ'PSQFSNJTTJCMF
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1100 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
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MJOF
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5FTUJOHUIFIZESBVMJDGMVJETVQQMZ
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'PSUIJTSFBTPO UIFTVQQMZPGIZESBVMJDGMVJENVTUCFFOTVSFEBUUIFTUBSUPGUIF
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5PUFTUUIFIZESBVMJDGMVJETVQQMZ
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008 914 20 BOMAG 1101

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
$PNNJTTJPOJOH

1FSGPSNJOHGVODUJPOBMUFTU

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8IFODPOOFDUJOHIZESBVMJDDPNQPOFOUT PCTFSWFUIFTQFDJGJFEQJQJOH
BDDPSEJOHUPUIFIZESBVMJDDJSDVJUEJBHSBNPGUIFNBDIJOFPSTZTUFN
NBOVGBDUVSFS

0ODFZPVIBWFUFTUFEUIFIZESBVMJDGMVJETVQQMZ ZPVNVTUQFSGPSNBGVODUJPOBM
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UPUIFJOTUSVDUJPOTPGUIFNBDIJOFPSTZTUFNNBOVGBDUVSFS
5IFBYJBMQJTUPOVOJUJTDIFDLFEGPSGVODUJPOBMDBQBCJMJUZCFGPSFEFMJWFSZBDDPSEJOH
UPUIFUFDIOJDBMEBUB%VSJOHDPNNJTTJPOJOH JUNVTUCFFOTVSFEUIBUUIFBYJBM
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1FSGPSNJOHGMVTIJOHDZDMF
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5IFGMVTIJOHDZDMFDBOCFQFSGPSNFE FHCZVTJOHBOBEEJUJPOBMGMVTIJOHVOJU
'PMMPXUIFJOTUSVDUJPOTPGUIFGMVTIJOHVOJUÁTNBOVGBDUVSFSGPSUIFFYBDU
QSPDFEVSFEVSJOHUIFGMVTIJOHDZDMF

3FDPNNJTTJPOJOHBGUFSTUBOETUJMM
%FQFOEJOHPOUIFJOTUBMMBUJPODPOEJUJPOTBOEBNCJFOUDPOEJUJPOT DIBOHFTNBZ
PDDVSJOUIFTZTUFNXIJDINBLFSFDPNNJTTJPOJOHOFDFTTBSZ
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1102 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
0QFSBUJPO

3VOOJOHJOQIBTF
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EFWFMPQNFOUXIJDIEFDSFBTFTXJUIJODSFBTJOHPQFSBUJOHIPVST5IFWPMVNFUSJD
BOENFDIBOJDBMIZESBVMJDFGGJDJFODZJODSFBTFTBTXFMMUISPVHIUIFDPODMVTJPOPG
UIFSVOOJOHJOQIBTFPGBQQSPYPQFSBUJOHIPVST

$"65*0/Ý 3JTLPGEBNBHFCZJOTVGGJDJFOUWJTDPTJUZÝ
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DBVTFUIFWJTDPTJUZUPESPQUPJNQFSNJTTJCMFMFWFMT
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3FEVDFUIFMPBEJOH QSFTTVSF SQN PGUIFBYJBMQJTUPOVOJUJGJNQFSNJTTJCMF
PQFSBUJOHUFNQFSBUVSFTBOEPSWJTDPTJUJFTPDDVS

0QFSBUJPO
5IFQSPEVDUJTBDPNQPOFOUXIJDISFRVJSFTOPTFUUJOHTPSDIBOHFTEVSJOH
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JOGPSNBUJPOPOBEKVTUNFOUPQUJPOT0OMZVTFUIFQSPEVDUXJUIJOUIFQFSGPSNBODF
SBOHFQSPWJEFEJOUIFUFDIOJDBMEBUB5IFNBDIJOFPSTZTUFNNBOVGBDUVSFSJT
SFTQPOTJCMFGPSUIFQSPQFSQSPKFDUQMBOOJOHPGUIFIZESBVMJDTZTUFNBOEJUTDPOUSPM

008 914 20 BOMAG 1103

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
.BJOUFOBODFBOESFQBJS

.BJOUFOBODFBOESFQBJS

$MFBOJOHBOEDBSF

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UIFNUPBHFGBTUFS
/FWFSVTFTPMWFOUTPSBHHSFTTJWFEFUFSHFOUT

$"65*0/Ý %BNBHFUPUIFIZESBVMJDTZTUFNBOEUIFTFBMTÝ
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BOEUIFTFBMTPGUIFBYJBMQJTUPOVOJU
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*OTQFDUJPO
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5BCMF*OTQFDUJPOTDIFEVMF
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EPXO

1104 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
.BJOUFOBODFBOESFQBJS

.BJOUFOBODF
5IFBYJBMQJTUPOVOJUJTMPXNBJOUFOBODFXIFOVTFEBTJOUFOEFE
5IFTFSWJDFMJGFPGUIFBYJBMQJTUPOVOJUJTIFBWJMZEFQFOEFOUPOUIFRVBMJUZPGUIF
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MFBTUPODFQFSZFBSPSFWFSZPQFSBUJOHIPVST XIJDIFWFSPDDVSTGJSTU PS
IBWJOHJUBOBMZ[FECZUIFIZESBVMJDGMVJENBOVGBDUVSFSPSBMBCPSBUPSZUPEFUFSNJOF
JUTTVJUBCJMJUZGPSGVSUIFSVTF
5IFTFSWJDFMJGFPGUIFBYJBMQJTUPOVOJUJTMJNJUFECZUIFTFSWJDFMJGFPGUIFCVJMUJO
CFBSJOHT5IFTFSWJDFMJGFDBOCFSFRVFTUFEGSPNUIFSFTQPOTJCMF3FYSPUI4FSWJDF
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IZESBVMJDTZTUFN

3FQBJS
3FYSPUIPGGFSTBDPNQSFIFOTJWFSBOHFPGTFSWJDFTGPSUIFSFQBJSPG3FYSPUIBYJBM
QJTUPOVOJUT
3FQBJSTPGUIFBYJBMQJTUPOVOJUNBZPOMZCFQFSGPSNFECZBVUIPSJ[FE TLJMMFEBOE
JOTUSVDUFEQFSTPOOFM
0OMZVTFHFOVJOFTQBSFQBSUTGSPN3FYSPUIGPSSFQBJSJOHUIF3FYSPUIBYJBM
QJTUPOVOJUT

5FTUFEBOEQSFBTTFNCMFEPSJHJOBM3FYSPUIBTTFNCMZHSPVQTBMMPXGPSTVDDFTTGVM
SFQBJSSFRVJSJOHPOMZMJUUMFUJNF

008 914 20 BOMAG 1105

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
.BJOUFOBODFBOESFQBJS

4QBSFQBSUT

$"65*0/Ý %BNBHFUPQFSTPOTBOEQSPQFSUZEVFUPGBVMUZTQBSFQBSUTÝ
4QBSFQBSUTUIBUEPOPUNFFUUIFUFDIOJDBMSFRVJSFNFOUTTQFDJGJFECZ3FYSPUINBZ
DBVTFEBNBHFUPQFSTPOTPSQSPQFSUZ
6TFPOMZPSJHJOBMTQBSFQBSUTGSPN3FYSPUI

5IFTQBSFQBSUTMJTUTGPSBYJBMQJTUPOVOJUTBSFPSEFSTQFDJGJD8IFOPSEFSJOHTQBSF
QBSUT RVPUFUIFNBUFSJBMBOETFSJBMOVNCFSPGUIFBYJBMQJTUPOVOJUBTXFMMBTUIF
NBUFSJBMOVNCFSTPGUIFTQBSFQBSUT
1MFBTFBEESFTTBMMRVFTUJPOTSFHBSEJOHTQBSFQBSUTUPZPVSSFTQPOTJCMF3FYSPUI
4FSWJDFQBSUOFSPSUIFTFSWJDFEFQBSUNFOUPGUIFNBOVGBDUVSFÁTQMBOUGPSUIFBYJBM
QJTUPOVOJU
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(MPDLFSBVTUSBF
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www.boschrexroth.com/addresses

1106 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
%FDPNNJTTJPOJOH

%FDPNNJTTJPOJOH
5IFBYJBMQJTUPOVOJUJTBDPNQPOFOUUIBUEPFTOPUSFRVJSFEFDPNNJTTJPOJOH
'PSUIJTSFBTPO UIJTDIBQUFSPGUIFNBOVBMEPFTOPUDPOUBJOBOZJOGPSNBUJPO
'PSEFUBJMTBCPVUIPXUPEJTBTTFNCMFPSSFQMBDFZPVSBYJBMQJTUPOVOJU QMFBTF
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OFDFTTBSZ

1SFQBSJOHGPSEJTBTTFNCMZ

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PSWPMUBHF

%FDPNNJTTJPOUIFFOUJSFTZTUFNBTEFTDSJCFEJOUIFPWFSBMMNBOVBMGPSUIF
NBDIJOFPSTZTUFN
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TZTUFNNBOVGBDUVSFS

%JTBTTFNCMJOHUIFBYJBMQJTUPOVOJU
1SPDFFEBTGPMMPXTUPEJTBTTFNCMFUIFBYJBMQJTUPOVOJU
.BLFTVSFUIBUUIFIZESBVMJDTZTUFNJTEFQSFTTVSJ[FE
$IFDLXIFUIFSUIFBYJBMQJTUPOVOJUIBTDPPMFEEPXOGBSFOPVHITPUIBUJUDBO
CFEJTBTTFNCMFEXJUIPVUEBOHFS
1MBDFBDBUDIQBOVOEFSUIFBYJBMQJTUPOVOJUUPDPMMFDUBOZIZESBVMJDGMVJEUIBU
NBZFTDBQF

$"65*0/Ý %BOHFSPGFOWJSPONFOUBMDPOUBNJOBUJPOÝ
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VOJUDBOMFBEUPFOWJSPONFOUBMQPMMVUJPOBOEDPOUBNJOBUJPOPGUIFHSPVOEXBUFS
8IFOESBJOJOHUIFIZESBVMJDGMVJE BMXBZTQMBDFBDBUDIQBOVOEFSUIFBYJBM
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TQFDJGJDBUJPOTQSPWJEFECZUIFTZTUFNNBOVGBDUVSFS

008 914 20 BOMAG 1107

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
%JTBTTFNCMZBOESFQMBDFNFOU

-PPTFOUIFMJOFTBOEDPMMFDUUIFFTDBQJOHIZESBVMJDGMVJEJOUIFDPMMFDUPS

3FNPWFUIFBYJBMQJTUPOVOJU6TFBOBQQSPQSJBUFMJGUJOHEFWJDF
$PNQMFUFMZFNQUZUIFBYJBMQJTUPOVOJU
1MVHBMMPQFOJOHT

1SFQBSJOHUIFDPNQPOFOUTGPSTUPSBHF
PSGVSUIFSVTF
1SPDFFEBTEFTDSJCFEJODIBQUFSÜ4UPSJOHUIFBYJBMQJTUPOVOJUÜ

1108 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
%JTQPTBM

%JTQPTBM
0CTFSWFUIFGPMMPXJOHQPJOUTXIFOEJTQPTJOHPGUIFBYJBMQJTUPOVOJU
$PNQMFUFMZFNQUZUIFBYJBMQJTUPOVOJU
%JTQPTFPGUIFIZESBVMJDGMVJEBDDPSEJOHUPUIFOBUJPOBMSFHVMBUJPOTPGZPVS
DPVOUSZ
%JTBTTFNCMFUIFBYJBMQJTUPOVOJUJOUPJUTJOEJWJEVBMQBSUTBOEQSPQFSMZSFDZDMF
UIFTFQBSUT
4FQBSBUFQBSUTCZ
¾ $BTUQBSUT
¾ 4UFFM
¾ /POGFSSPVTNFUBM
¾ &MFDUSPOJDXBTUF
¾ 1MBTUJD
¾ 4FBMT

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NBUFSJBMDPVMEMFBEUPQPMMVUJPOPGUIFFOWJSPONFOU
5IFSFGPSF EJTQPTFPGUIFBYJBMQJTUPOVOJU UIFIZESBVMJDGMVJEBOEUIF
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TIFFUTGPSUIFTFIZESBVMJDGMVJET

&YUFOTJPOBOEDPOWFSTJPO
%POPUDPOWFSUUIFBYJBMQJTUPOVOJU5IJTBMTPJODMVEFTBNPEJGJDBUJPOPGUIF
BEKVTUJOHTDSFXT
5IFXBSSBOUZGSPN3FYSPUIPOMZBQQMJFTUPUIFEFMJWFSFEDPOGJHVSBUJPO*ODBTF
PGFYUFOTJPOTPSDPOWFSTJPOT UIFXBSSBOUZXJMMCFSFOEFSFEWPJE

5IFBEKVTUJOHTDSFXTBSFQSPUFDUFEBHBJOTUVOBVUIPSJ[FESFTFUUJOHCZNFBOT
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OFFEBNPEJGJDBUJPOPGUIFTFUUJOH QMFBTFDPOUBDUZPVSSFTQPOTJCMF3FYSPUI
4FSWJDF GPSBEESFTT TFFDIBQUFSÜ4QBSFQBSUTÜ

008 914 20 BOMAG 1109

20.2#PTDI3FYSPUI"(
"'&TFSJFT]3&#
Vibration motor
5SPVCMFTIPPUJOH

5SPVCMFTIPPUJOH
5IFGPMMPXJOHUBCMFXJMMBTTJTUZPVEVSJOHUSPVCMFTIPPUJOH5IFUBCMFEPFTOPU
DMBJNUPCFDPNQMFUF
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JOBCJMJUZUPBTDFSUBJOUIFPSJHJOBMFSSPSDBVTF
'JSTUPCUBJOBHFOFSBMPWFSWJFXPGIPXZPVSQSPEVDUXPSLTJODPOKVODUJPOXJUI
UIFFOUJSFTZTUFN
5SZUPGJOEPVUXIFUIFSUIFQSPEVDUIBTXPSLFEQSPQFSMZJODPOKVODUJPOXJUIUIF
FOUJSFTZTUFNCFGPSFUIFUSPVCMFTPDDVSSFEGJSTU
5SZUPEFUFSNJOFBOZDIBOHFTPGUIFFOUJSFTZTUFNJOXIJDIUIFQSPEVDUJT
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¾ 8FSFUIFSFBOZDIBOHFTUPUIFQSPEVDUÁTPQFSBUJOHDPOEJUJPOTPSPQFSBUJOH
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CFGPVOEVOEFS
www.boschrexroth.com/addresses

1110 BOMAG 008 914 20

3&#]"'&TFSJFT
Vibration motor #PTDI3FYSPUI"(
20.2
5SPVCMFTIPPUJOH

.BMGVODUJPOUBCMF
5BCMF.BMGVODUJPOUBCMFGPSGJYFENPUPST
'BVMU 1PTTJCMFDBVTF 3FNFEZ
6OVTVBMOPJTFT 0VUQVUTQFFEUPPIJHI .BDIJOFPSTZTUFNNBOVGBDUVSFS

*NQSPQFSGJYJOHPGUIFBYJBMQJTUPOVOJU $IFDLGJYJOHPGUIFBYJBMQJTUPOVOJU
BDDPSEJOHUPUIFTQFDJGJDBUJPOTPGUIF
NBDIJOFPSTZTUFNNBOVGBDUVSFS0CTFSWF
UJHIUFOJOHUPSRVFT
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DPVQMJOHBOEIZESBVMJDMJOFT JOGPSNBUJPOQSPWJEFECZUIFDPVQMJOHPS
BSNBUVSFNBOVGBDUVSFS
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DPOUBDU3FYSPUI4FSWJDF
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The pressure compensator option features a low

pressure rise (short ramp) to provide optimal power
A complete family of controls and regulators is avai-
lable to fulfill the requirements of a wide range of utilization throughout the entire displacement range
applications. of the motor. The pressure compensator is also
available as a stand-alone regulator.

● The Series 51 - Advanced Technology Today

● The Most Technically Advanced Hydraulic Units in the Industry

● SAE Flange and Cartridge Motors

● Cartridge Motors designed for Direct Installation in Compact

Planetary Drives

● Large Displacement Ratio (5:1)

● Complete Family of Control Systems

● Proven Reliability and Performance

● Optimum Product Configurations

● Compact, Lightweight

Front page: Option - hydraulic two-position control

1120 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Contents

Introduction ......................................................................................................................................................4
Basic Hydraulic Circuits ...................................................................................................................................4
General Description of the Series 51 Variable Displacement Motors ..............................................................5
Functional Description ......................................................................................................................................6
Technical Specifications and Data - Variable Displacement Motors .............................................................. 20
Safety Precautions .........................................................................................................................................21
Gauge Installation ..........................................................................................................................................23
Start-Up Procedure and Maintenance ............................................................................................................25
Component Inspection and Adjustment .........................................................................................................27
Troubleshooting ............................................................................................................................................. 37
Exploded View of the Series 51 Variable Motor .............................................................................................41
Minor Repair and Replacement - Variable Motor ........................................................................................... 51
General .....................................................................................................................................................51
Shaft Seal (SAE Flange Configuration) .................................................................................................... 52
Shaft Seal (Cartridge Configuration) .........................................................................................................53
Loop Flushing Shuttle Valve (Option)........................................................................................................54
Charge Pressure Relief Valve ...................................................................................................................55
Minimum Angle Servo Cover .................................................................................................................... 55
Hydraulic 2-Position Control (Type N2) .....................................................................................................56
Electrohydraulic 2-Position Controls (Types E1•E2 and F1•F2) ...............................................................57
Electric 2-Position Controls (Type S1) ......................................................................................................58
Hydraulic Proportional Control (Type HZ) .................................................................................................59
Hydraulic Proportional Control (Type HS) .................................................................................................60
Hydraulic Proportional Control with Maximum Angle Over-ride (Types H1•H2 or K1•K2) ........................61
Two Connection Hydraulic Proportional Control (Type HP) ......................................................................62
Two Connection Hydraulic Proportional Control for “Dual Path” Vehicles (Type HC) ...............................64
Electrohydraulic Proportional Control (Types EP and EQ)........................................................................68
Pressure Control Pilot (PCP) Valve for Electrohydraulic Proportional Control (Types EP and EQ) .......... 70
Multi-function Block ...................................................................................................................................71
Pressure Compensator Regulator (Type PC) ........................................................................................... 76
Control Orifices .........................................................................................................................................77
Plug / Fitting Torques ................................................................................................................................77

0-1 3

008 914 20 BOMAG 1121

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Introduction
The purpose of this manual is to provide information Dirt or contamination is the greatest enemy of any
necessary for the normal servicing of the Series 51 type of hydraulic equipment. The greatest possible
family of variable displacement hydrostatic motors. cleanliness is necessary when starting up the sys-
tem, changing filters, or performing any other service
This manual includes unit and component descrip- procedure.
tion, troubleshooting, adjustments, and minor repair
procedures. By following the procedures in this For Technical Information on Series 51 motors, refer
manual, inspections and minor repairs may be per- to publication BLN-10042 or 368753.
formed without affecting the unit warranty.
For Fluid Quality Requirements, refer to publication
A Series 51 motor does occasionally require servic- BLN-9987 or 697581.
ing, and these units are designed to meet this require-
ment. Sauer-Sundstrand provides a complete repair serv-
ice for its products. Contact any Sauer-Sundstrand
Many repairs or adjustments can be completed with- Authorized Service Center for details. Sauer-Sund-
out removing the unit from the vehicle or machine, strand Authorized Service Center locations are listed
provided the unit is accessible and can be thoroughly in publication BLN-2-40527 or 698266.
cleaned before beginning any procedures.

Basic Hydraulic Circuits

CASE Closed Circuit
DRAIN
LINE The main ports of the pump are connected by hydrau-
lic lines to the main ports of the motor. Fluid flows in
either direction from the pump to the motor then back
to the pump in this closed circuit. Either of the hydrau-
INPUT PV MV OUTPUT lic lines can be under high pressure. The direction
and speed of fluid flow (and the motor output shaft
rotation) depends on the position of the pump swash-
plate. The system pressure is determined by the
machine load.

FLOW (BI-DIRECTIONAL) Open Circuit

RESERVOIR The outlet port of the pump is connected by a hydrau-
51000001 lic line to a directional control valve. The working ports
Fig. 0-1 - Basic Closed Circuit of this valve are connected to the main ports of the
motor. When the valve is actuated, fluid flows first
FLOW FLOW from the pump to the valve. The valve then directs the
(UNI-DIRECTIONAL) (BI-DIRECTIONAL) fluid to the motor in either direction. The direction of
fluid flow (and motor output shaft rotation) depends
CONTROL VALVE

on the direction the control valve is shifted. The speed

INPUT PUMP of fluid flow (and motor output shaft speed) depends
MV OUTPUT on pump output volume and the distance the control
valve is shifted. The system pressure is determined
by the machine load.
CASE Fluid returning from the motor is routed through the
DRAIN
RESERVOIR LINE
control valve to the reservoir. Additional components
may be necessary to provide dynamic braking and to
51000002 deal with over-running loads.
Fig. 0-2 - Basic Open Circuit

4 0-2

1122 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
General Description of the Series 51 Variable Displacement Motors
The Series 51 variable displacement hydraulic mo- Various hydraulic and electrohydraulic controls may
tors use spherical pistons and piston rings. The angle be mounted on the motor end cap to control the servo
between the cylinder block and the output shaft can piston and the motor displacement. Servo pressure
be set between 32° and 6°, providing a 5 to 1 oil may either be supplied internally from the motor, or
maximum to minimum displacement ratio. externally.

At maximum displacement, the motor will provide a For all controls except the N2 and PC, servo pressure
certain maximum output shaft torque and minimum oil is supplied to a four (4) way spool valve in the motor
speed corresponding to the pressure and flow sup- end cap. When a combination of pilot pressure (or
plied to the motor. Under the same input conditions force) from an external control assembly and internal
but at minimum displacement, the shaft speed will be spring force shifts this valve, servo pressure is routed
approximately five (5) times faster while the available to move the servo piston and change the motor’s
output torque will decrease to approximately one-fifth displacement.
(1/5) the full displacement value. The displacement
is changed by a servo piston which is connected to A synchronizing shaft, with spherical rollers, synchro-
the valve segment. nizes the rotation of the output shaft and the cylinder
block. The ball end of each piston runs in a socket
bushing, pressed into the output shaft. There are no
other parts used to connect the pistons to the shaft.
Two tapered roller bearings support the output shaft.
Minimum
Displacement Limiter
Hydraulic Pressure Compensator
Proportional Override
Control Valve Segment
Control
Pressure Bearing Plate
Port

Tapered Roller Bearings

Synchronizing
Piston Shaft

Servo Piston
Cylinder

Charge Pressure
Relief Valve
P001 196
Fig. 10-1 - Sectional view of Series 51 variable displacement motor (SAE Flange
Configuration) with Hydraulic Proportional Control

10 - 1 5

008 914 20 BOMAG 1123

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Functional Description
Loop Flushing
Series 51 motors used in closed circuit applications
incorporate an integral loop flushing valve as stan-
dard equipment. Installations that require additional
fluid to be removed from the main hydraulic circuit
because of fluid cooling requirements, or circuits
requiring the removal of excessive contamination
from the high pressure circuit, can benefit from loop
flushing. Series 51 motors used in open circuit appli-
51000003 51000004
Fig. 10-2 - Loop Fig. 10-3 - Loop cations may have the optional loop flushing defeat
components installed.
Flushing Flushing Defeat
Components Components Series 51 motors equipped with an integral loop
flushing valve also include a charge pressure relief
valve. The setting of the motor charge relief valve
affects the function of the flushing circuit. Higher
motor charge relief settings reduce the loop flushing
flow and increase the flow over the pump charge
pressure relief valve when the circuit is operating.
Lower motor charge relief settings increase the loop
flushing flow and may increase the motor case pres-
sure when the circuit is operating.

An appropriate combination of pump and motor charge

pressure settings should be maintained to insure the
proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all condi-
tions of operation to maintain pump control perfor-
mance in closed loop systems.

NOTE: An optional orifice may be installed between

the motor charge relief and the motor case to
limit the maximum flushing oil flow.

6 10 - 2

1124 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Displacement Limiters
All Series 51 motors incorporate mechanical dis-
placement limiters. The minimum displacement of
the motor can be limited within the standard range by
a set screw in the motor housing. The maximum
displacement can be limited with spacers installed on
the servo piston.

51000005
Fig. 10-4 - Minimum Displacement Limiter
with Tamper Resistant Cap (Cartridge
Motor Configuration Shown)

51000006
Fig. 10-5 - Maximum Displacement Limiter
Screw

Controls - General
A wide range of control options is available for the
Series 51 motors. These include pilot operated
Electrohydraulic 2-Position Controls, Hydraulic Pro-
portional Controls (single or two [2] connection), and
Electrohydraulic Proportional Controls. A directly op-
erated Hydraulic 2-Position Control and a Pressure
Compensator regulator are also available.

The Series 51 variable motor servo piston (except 5100007

when equipped with N2 control or the PC regulator) Fig. 10-6 - Internal Servo Pressure Supply
may be operated either by servo pressure oil supplied Screen with Multi-function Block and/or
internally from the main ports of the motor, or by servo Control Removed (Plug for External
pressure oil supplied from an external source. (The Supply)
N2 control uses servo pressure supplied by an exter-
nal control valve. The PC regulator obtains servo
pressure from the main ports of the motor.)

Orifice plugs are installed in the control spool sleeve

in the end cap to regulate the flow of oil from the servo
piston to the motor housing. Orifice plugs may be
installed in the end cap to regulate the flow of servo
pressure supply oil to the control valve, and to regu-
late the flow of oil from the control valve to the servo
piston. 51000008
Fig. 10-7 - External Servo Pressure Supply
Fitting (Plug for Internal Supply)
10 - 3 7

008 914 20 BOMAG 1125

U4 (opt.) T3

T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
B
Servo
Pressure
internal L1

X1 M7
51000017
Fig. 10-19 - HZ Control Schematic

10 - 7 11

008 914 20 BOMAG 1129

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Hydraulic Proportional Control (Type HS)
The HS control consists of a cover plate (with a
hydraulic port) mounted on the multi-function block.
Servo pressure may be supplied from an external
source or internally by the shuttle spool in the multi-
function block. PCOR is available with this control.

The function of the HS control is identical to the

function of the HZ control.
51000018
Fig. 10-20 - Series 51 Motor with HS
Control

51000019
Fig. 10-21 - HS Control Components
L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
B1
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1

M7 X1 HS

H1•H2
M7 X1

K1•K2
M7 X1
51000022
Fig. 10-22 - HS, H1•H2, and K1•K2 Control
Schematic

12 10 - 8

1130 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Hydraulic Proportional Control with
Electric Override (Types H1•H2 and K1•K2)
The function of the H1•H2 and K1•K2 controls is
similar to the function of the HS control. A 12 or 24
VDC solenoid valve is installed between the external
pilot pressure source and the control spool.

With the H1•H2 controls, energizing the solenoid

allows the control to function as an HS control. When
the solenoid is not energized, pilot pressure is blocked 51000020

and the end of the control spool is drained to the motor Fig. 10-23 - Series 51 Motor with H1•H2
case, causing the motor to shift to maximum displace- Control
ment.

With the K1•K2 controls, energizing the solenoid

blocks pilot pressure and drains the end of the control
spool to the motor case, causing the motor to shift to
maximum displacement. When the solenoid is not
energized, the control functions as an HS control.

51000167
Fig. 10-24 - Series 51 Motor with K1•K2
Control

51000021
Fig. 10-25 - H1•H2 and K1•K2 Control
Components

10 - 9 13

008 914 20 BOMAG 1131

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51

Functional Description (Continued)

Two Line Hydraulic Proportional Control
(Type HP)
This control consists of a valve block with two (2)
hydraulic ports mounted on the multi-function block.
The valve block incorporates a shuttle spool and a
pilot piston with centering springs. A pin transmits
force from the pilot piston to the control spool in the
end cap. Feedback springs (single spring for 060,
51000023
080, and 110) and a threshold spring are installed in
Fig. 10-26 - Series 51 Motor with HP the end cap. These springs function similar to the HS
control. Servo pressure may be supplied from an
Control
external source or internally by the shuttle spool in the
multi-function block. PCOR is available with this
control.

Two pilot pressures are provided to the control. The

shuttle spool directs the higher pilot pressure to the
end of the pilot piston opposite the feedback spring,
and the lower pressure to the opposite side of the pilot
piston. The rod transmits a force, proportional to the
difference of the pilot pressures, to the control spool.

51000024
An increase in the difference between the pilot pres-
Fig. 10-27 - HP Control Components sures will result in a decrease in motor displacement,
while a decrease will result in an increase in displace-
ment.
L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
B1
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
Servo B
Press,
internal
L1

X2 X1
51000025
Fig. 10-28 - HP Control Schematic

14 10 - 10

1132 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Two Line Hydraulic Proportional Control
for “Dual-Path” Vehicles (Type HC)
The HC control operates in a similar manner to the HP
control, however the HC control is optimized for use
in “dual-path” drive vehicles. This control consists of
a valve block with two (2) hydraulic ports mounted on
the end cap. The valve block incorporates a shuttle
spool and a pilot piston with centering springs. A pin
transmits force from the pilot piston to the control
51000158
spool in the end cap. Fig. 10-29 - Series 51 Motor with HC
A bleed valve is provided to eliminate any air which Control
might become trapped in the pilot piston oil passages.

Feedback springs are installed in the end cap. Servo

pressure is supplied internally by a ball type shuttle
valve in the control housing. PCOR is not available
with this control.

Two pilot pressures are provided to the control. The

shuttle spool directs the higher pilot pressure to the
end of the pilot piston opposite the feedback springs,
and the lower pressure to the opposite side of the pilot
piston. The pin transmits a force, proportional to the
difference of the pilot pressures, to the control spool.

An increase in the difference between the pilot pres- 51000111

sures will result in a decrease in motor displacement, Fig. 10-30 - HC Control Components
while a decrease will result in an increase in displace-
ment. The feedback springs in the end cap have L2 M6 M4 M3
differing spring rates and operate in parallel (060,
A
080, and 110) or series (160 or 250) to provide a linear M1
relationship between motor displacement and pilot
pressure differential. max.
disp.

U4 (opt.) T3

T7,
T8 M9
T1
M5

M2
B

X2 X1
51000160
Fig. 10-31 - HC Control Schematic

10 - 11 15

008 914 20 BOMAG 1133

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Electrohydraulic Proportional Control
(Types EP and EQ)
This control consists of a valve block and PCP (Pres-
sure Control Pilot) valve mounted on the multi-func-
tion block. The valve block incorporates a pilot piston
with centering springs. A pin transmits force from the
pilot piston to the control spool in the end cap.
Feedback springs (single spring for 060, 080, and
110) and a threshold spring are installed in the end
51000026
cap. These springs function similar to the HS control.
Fig. 10-32 - Series 51 Motor with EP Control
Servo pressure may be supplied from an external
(EQ Similar) source or internally by the shuttle spool in the multi-
function block. PCOR is available with this control.

An external pilot pressure source is connected to the

inlet of the PCP valve, which produces differential
pilot pressures proportional to the current through it.
These pressures are applied to the pilot piston. The
operation of this control is similar to that of the HP
Control, with the motor displacement being propor-
tional to the current through the PCP valve.

An increase in current (above the threshold current)

will result in a decrease in motor displacement, while
a decrease will result in an increase in displacement.
51000027
Fig. 10-33- EQ Control Components (EP
Similar)

L2 M6 M4 M3

A
M1

A1
max.
disp.

U4 (opt.) T3

T2
B1
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1

M7 X1 M8
51000028
Fig. 10-34 - EP and EQ Control Schematic

16 10 - 12

1134 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Multi-function Block Components
The Multi-function Valve Block includes a shuttle
valve which provides internally supplied servo pres-
sure, and an optional Pressure Compensator Over-
Ride (PCOR) function with optional brake pressure
defeat.

51000029
Fig. 10-35 - Multi-function Block (Without
Control)

Servo Pressure Supply

For internal supply, the multi-function block incorpo-

rates a shuttle spool with internal check ball valve that
routes oil from the main circuit ports of the motor to the
control valve in the end cap. “High side” pressure is
provided to the servo control valve in the end cap.

For external supply, the connection between the

shuttle spool and the servo control valve is blocked in
51000030
the end cap. The external pressure supply to the Fig. 10-36 - Multi-function Block with Servo
servo control valve connects to a port (“M5”) on the
Pressure Supply Shuttle Spool
end cap.

Pressure Compensator Over-Ride (PCOR)

The Pressure Compensator Over-Ride (PCOR) sys-

tem includes a spool valve located in the PCOR block
which is attached to the multi-function block. This
system increases the motor displacement at system
pressures above the PCOR valve setting. (Pressure
Compensator Over-Ride is not available with the N2
and HZ controls, or the PC regulator.)

For bi-directional PCOR operation, the shuttle valve

in the multi-function block routes system high pres-
sure to the PCOR spool valve. For single direction
51000031
PCOR operation, the PCOR spool valve is connected Fig. 10-37 - Multi-function Block with PCOR
to one (1) side of the closed loop through passages in Block and Spool Valve (K1•K2 Control
the multi-function block
Shown)
When system pressure exceeds the PCOR setting,
the spool valve moves to connect the displacement
reducing end of the servo piston to the motor case,
and the displacement increasing end of the servo
piston to system pressure. This increases the motor
displacement, which reduces the motor output speed.
When the PCOR valve closes, control of the servo
piston returns to the control spool in the motor end
cap.

10 - 13 17

008 914 20 BOMAG 1135

20.3 Axle drive motor

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Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
An optional “brake pressure defeat” spool may be
installed in the multi-function block. When used with
the PCOR, this spool assures that the PCOR does
not cause the motor displacement to increase during
deceleration (which could cause pump overspeed).
Pressure from a source such as the pump servos or
an external valve, shifts the defeat spool to block the
high pressure supply to the PCOR valve from the
“deceleration” side of the closed loop. Either bi-
51000032 directional or single direction PCOR operation can be
Fig. 10-38 - Multi-function Block with PCOR specified when PCOR defeat is installed.
Defeat Spool Components

Shuttle Valve Shuttle Valve PCOR Brake Pressure Defeat Operation

A1 T4 A1
Rotation High pressure Control pressure
Defeat
Spool
port on port

CW A XB
T5
CCW B XA
U7 U7

U6 U6
B1 T6
B1

PCOR PCOR
Valve Valve

XA XB

Standard with Defeat

Pressure Compensator Override
51000033
Fig. 10-39 - PCOR and PCOR with Defeat
Schematic

18 10 - 14

1136 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Functional Description (Continued)
Pressure Compensator Regulator (Type
PC)
In this regulator, the Pressure Compensator system
in the multi-function block assembly controls the
motor displacement. At system pressures below the
compensator setting, the servo piston is maintained
in the minimum motor displacement position. When
system pressure exceeds the POR setting, hydraulic
pressure acts on the servo piston to increase the
motor displacement.

With the Pressure Compensator regulator, an in- 51000034

crease in system pressure (above the setting pres- Fig. 10-40 - Series 51 Motor with PC
sure) will result in an increase in motor displacement Regulator
and output torque, and a decrease in motor shaft
speed.

51000035
Fig. 10-41 - PC Regulator Components

L2 M6 M4 M3

A
M1

max.
disp.
T5
U7

U4 (opt.)

U6 T7

T1
M9
M5

M2
B

L1
51000036
Fig. 10-42 - PC Regulator Schematic

10 - 15 19

008 914 20 BOMAG 1137

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Technical Specifications and Data - Variable Displacement Motors
Design Hydraulic Fluid
Piston motor with variable displacement, bent axis Refer to Sauer-Sundstrand publication BLN-9887 or
construction. 697581.
Type of Mounting Temperature 1)

SAE four (4) bolt flange – SAE Flange Configuration. ϑ min = -40°C (-40°F), intermittent, cold start
Two (2) bolt flange – Cartridge Motor Configuration. ϑ nominal = 104°C (220°F), continuous
ϑ max = 115°C (240°F), intermittent
Pipe Connections
1)
at the hottest point, normally the case drain line.
Main pressure ports: SAE flange
Hydraulic fluid viscosity must be as shown below.
Remaining ports: SAE O-ring thread
Fluid Viscosity Limits
Direction of Rotation
ν min = 5 mm2/s (42 SUS) intermittent
Clockwise and counter-clockwise.
ν min = 6.4 mm2/s (47 SUS) min. continuous
Installation Position ν min = 13 mm2/s (70 SUS) optimum
ν max = 110 mm2/s (510 SUS) max. continuous
Installation position discretionary. The housing must ν max = 1600 mm2/s (7400 SUS) intermittent, cold start
always be filled with hydraulic fluid.
Filtration
System Pressure Range, Input
Acceptable contamination level: ISO Code 18/13 or
Max: 480 bar (6960 psi) better. Refer to Sauer-Sundstrand publication BLN-9887
Min: 10 bar (145 psi) or 697581.
Case Pressure
Max. Continuous: 3 bar (44 psi)
Intermittent (Cold start): 5 bar (73 psi)

Frame Size
Dimension 060 080 110 160 250
Displacement maximum cm3 60.0 80.7 109.9 160.9 250.0
in3 3.66 4.92 6.71 9.82 15.26
minimum cm3 12.0 16.1 22.0 32.2 50.0
in3 0.73 0.98 1.34 1.96 3.05
Continuous speed at max disp min-1 (rpm) 3600 3100 2800 2500 2200
at min disp min-1 (rpm) 5600 5000 4500 4000 3400
Max. speed at max disp min-1 (rpm) 4400 4000 3600 3200 2700
at min disp min-1 (rpm) 7000 6250 5600 5000 4250
Theoretical at max disp Nm / bar 0.95 1.28 1.75 2.56 3.98
torque lbf•in / 1000 psi 583 784 1067 1563 2428
at min disp Nm / bar 0.19 0.26 0.35 0.51 0.80
lbf•in / 1000 psi 117 156 214 313 486
Max. continuous Q max L / min 216 250 308 402 550
flow gal / min 57 66 81 106 145
Max. corner power Pcorner max kW 336 403 492 644 850
hp 450 540 660 864 1140
Mass moment J kg • m2 0.0046 0.0071 0.0128 0.0234 0.0480
of inertia lbf • ft2 0.1092 0.1685 0.3037 0.5553 1.1580
Weight m kg 28 32 44 56 86
(with control N2) lb 62 71 97 123 190

20 10 - 16

1138 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Safety Precautions

● When Series 51 units are used in vehicular ● Use caution when dealing with hydraulic
hydrostatic drive systems, the loss of hy- fluid under pressure. Escaping hydraulic
drostatic drive line power in any mode of fluid under pressure can have sufficient
operation may cause a loss of hydrostatic force to penetrate your skin causing seri-
braking capacity. A braking system, redun- ous injury. This fluid may also be hot enough
dant to the hydrostatic transmission must, to burn. Serious infection or reactions can
therefore, be provided which is adequate to develop if proper medical treatment is not
stop and hold the system should the condi- administered immediately.
tion develop.
● Some cleaning solvents are flammable. To
● Certain service procedures may require the avoid possible fire, do not use cleaning
vehicle/machine to be disabled (wheels solvents in an area where a source of igni-
raised off the ground, work function discon- tion may be present.
nected, etc.) while performing them in order
to prevent injury to the technician and by-
standers.

20 - 1 21

008 914 20 BOMAG 1139

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Notes

22 20 - 2

1140 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Gauge Installation
Various pressure gauge readings can be a great Snubbers are recommended to protect pressure
asset in troubleshooting problems with the Series 51 gauges. Frequent gauge calibration is necessary to
motor or support system. insure accuracy.

Fig. 30-1 - Gauge Ports, Motor with N2 Control

Port "L1" Port Y2:
Servo press., external
(N2 Control Only) Gauge port M6:
Charge pressure
"X" Gauge port M3; 9/16 — 18 UNF-2B
Servo pressure
min. displacement Gauge port M2:
Port "B" system
pressure
A B
Gauge port M1:
Port "A" system M1
pressure Port Y1:
M2
Servo press., external
(N2 Control Only)
Port "L2"
Gauge port M4:
Servo pressure
max. displacement
Side Port End Cap Axial Port End Cap
Right Side View View in Direction "X"
51000037

Fig. 30-2- Gauge Ports, Motor with E1•E2, F1•F2, H1•H2, and K1•K2 Controls
Port X3:
servo press., external
Gauge port M5:
servo press., internal Control • E1/E2 • F1/F2
XA
Control • E1/E2•F1/F2 Control • H1/H2 • K1/K2
Gauge port M8 Gauge port M7
Control • H1/H2 control pressure
Control pressure port X1 View"T"
Control • K1/K2
Control pressure port X1
XA
XB XB

"T" 51000038

Fig. 30-3 - Gauge Ports, Motor with HS and HZ Controls

Port X3:
servo press., ext.
Gauge port M5: Gauge port M7:
servo press., int. Control pressure
XA
Gauge port M7:
Control pressure
View"U" View"U"
(HS) (HZ)

XA XB
Control pressure Control pressure
XB
port X1 port X1
"U" 51000039

30 - 1 23

008 914 20 BOMAG 1141

20.3 Axle drive motor

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Bent Axis Variable Displacement Motors Series 51
Gauge Installation (Continued)
Fig. 30-4 - Gauge Ports, Motor with HP Control

Port X3:
servo press., ext.
Gauge port M5:
servo press., int. XA

View"V"

XA XB

XB X1 X2 Ports X1, X2:

Control pressure
9/16 — 18 UNF-2B
"V" 51000040

Fig. 30-5 - Gauge Ports, Motor with EP•EQ Control

Port X3:
servo press., ext.
Gauge port M5:
servo press., int. XA

View"W"

XA XB

XB
MS-Connector (MS3102C) Packard
7/8 — 20 UNEF Connector
Manual override
Port X1:
External PCP
"W" supply pressure 51000041

Gauge Information
System 600 bar or 10,000 psi Gauge Motor 60 bar or 1000 psi Gauge
M1 Pressure M6 Charge
Port “A” 9/16 — 18 O-Ring Fitting Pressure 9/16 — 18 O-Ring Fitting
System 600 bar or 10,000 psi Gauge M7 Control 60 bar or 1000 psi Gauge
M2 Pressure M8 Test Port 9/16 — 18 O-Ring Fitting
Port “B” 9/16 — 18 O-Ring Fitting L1 Case 60 bar or 1000 psi Gauge
Servo 600 bar or 10,000 psi Gauge L2 Pressure 060, 080, 110:
M3 Pressure 1-1/16 — 12 O-Ring Fitting
(Min. Angle) 9/16 — 18 O-Ring Fitting 160, 250:
Servo 600 bar or 10,000 psi Gauge 1-5/16 — 12 O-Ring Fitting
M4 Pressure X1 Control 60 bar or 1000 psi Gauge
(Max. Angle) 9/16 — 18 O-Ring Fitting X2 Pressure 9/16 — 18 O-Ring Fitting
Servo 600 bar or 10,000 psi Gauge X3
M5 Supply 9/16 — 18 O-Ring Fitting or XA Defeat 60 bar or 1000 psi Gauge
(M9) Pressure Tee into Control Pressure Line XB Pressure Tee into Defeat Pressure
Line(s)

24 30 - 2

1142 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Start-Up Procedure and Maintenance
Start-Up Precautions Fill the reservoir with recommended hydraulic fluid,
which should be passed through a 10 micron (nomi-
Cleanliness
nal, no bypass) filter prior to entering the reservoir.
Ensure that all system components, including fittings, The use of contaminated fluid will cause damage to
pipes, and hoses, are completely clean. If cloths are the components, which may result in unexpected
used for cleaning components, they must be made of vehicle/machine movement.
lint-free materials.
The inlet line leading from the reservoir to the pump
Follow the guidelines presented in Sauer-Sundstrand must be filled prior to start up. Check inlet line for
publication BLN-9887 or 697581 for required fluid properly tightened fittings and make sure it is free of
cleanliness levels at machine start-up. restrictions and air leaks.
Reservoir and Fluid Level Be certain to fill the pump and motor housing with
clean hydraulic fluid prior to start up. Fill the
The reservoir should be designed to accommodate
housing by pouring filtered oil into the upper case
maximum volume changes during all system operat-
drain port.
ing modes, and to promote de-aeration of the fluid as
it passes through the tank. The reservoir outlet (charge Install a 0 to 60 bar or 0 to 1000 psi pressure gauge
pump inlet) and the reservoir inlet (fluid return) must in the charge pressure gauge port to monitor the
always be below the normal fluid level. A sight glass charge pressure during start-up.
is the preferred method for checking fluid level.
The external control input signal should be discon-
The reservoir inlet (fluid return) should be positioned nected at the pump control during initial start-up. This
so that flow to the reservoir is directed into the interior will allow the pump to remain in its neutral position.
of the reservoir for maximum dwell and efficient de-
“Jog” or slowly rotate prime mover until charge pres-
aeration. A baffle (or baffles) between the reservoir
sure starts to rise. Start the prime mover and run at
inlet and outlet ports will promote de-aeration and
the lowest possible RPM until charge pressure is
reduce surging of the fluid.
established. Excess air may be bled from the high
No funnel-shaped eddying at the reservoir outlet pressure lines through the high pressure gauge ports.
(charge pump inlet) or formation of foam at the
Once charge pressure is established, increase speed
reservoir inlet (fluid return) is permitted.
to normal operating RPM. Note the charge pressure.
Start-Up Procedure If charge pressure is incorrect, shut down and deter-
mine cause for improper pressure.
The following start-up procedure should always be
followed when starting-up a new Series 51 installa- Shut down prime mover and connect external control
tion or when restarting an installation in which either input signal. Start prime mover, checking to be
the pump or motor has been removed from the certain pump remains in neutral. With prime mover at
system. normal operating speed, slowly check for forward and
reverse machine operation.
WARNING
Charge pressure should be maintained during for-
The following procedure may require the ve- ward or reverse operation. Continue to cycle slowly
hicle/machine to be disabled (wheels raised off between forward and reverse for at least five (5)
the ground, work function disconnected, etc.) minutes.
while performing the procedure in order to
prevent injury to the technician and bystand- Shut down prime mover, remove gauges, and plug
ers. Take necessary safety precautions before ports. Check reservoir level and add fluid if neces-
operating the vehicle/machine. sary.
Prior to installing the motor, inspect the unit for The transmission is now ready for operation.
damage incurred during shipping and handling. Make
certain all system components (reservoir, hoses,
valves, fittings, heat exchanger, etc.) are clean prior
to filling with fluid.

30 - 3 25

008 914 20 BOMAG 1143

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Start-Up Procedure and Maintenance (Continued)
Maintenance Changing the Fluid and Filter
Cleanliness To insure optimum service life on Series 51 products,
The reservoir breather air filter (if equipped) must be regular maintenance of the fluid and filter must be
kept clean. Clean the area around the filler cap before performed.
opening the reservoir. The hydraulic fluid should be The fluid and filter must be changed per the vehicle/
filtered before it enters the reservoir. machine manufacturer’s recommendations. In the
Follow the guidelines presented in Sauer-Sundstrand absence of such recommendations, the following
publication BLN-9887 or 697581 for required fluid intervals may be used:
cleanliness levels during machine operation. • System with a sealed type reservoir - 2000 hrs.
Recommended Fluids • System with a breathing type reservoir - 500 hrs.

Hydraulic fluids used with Sauer-Sundstrand prod- It may be necessary to change the fluid more fre-
ucts should be carefully selected with assistance quently if the fluid becomes contaminated with for-
from a reputable supplier, following the guidelines eign matter (dirt, water, grease, etc.) or if the fluid has
presented in Sauer-Sundstrand publication BLN-9887 been operating at temperature levels greater than the
or 697581. maximum recommended. Never reuse fluid.

Checking for Leaks The filter should be changed when changing the fluid,
or whenever the filter indicator shows that it is neces-
Check the system components for leakage at regular sary to change the filter.
intervals. Tighten any leaking connections while the
system is not under pressure. Replace any defective
seals and gaskets.

Check hydraulic hoses for damage or aging. When

installing replacements, be certain that the hoses are
clean and connected properly.

Checking the Fluid Level

Check the reservoir daily for proper fluid level, the

presence of water (noted by a cloudy or milky appear-
ance, or free water in bottom of reservoir), and rancid
fluid odor (indicating excessive heat).

26 30 - 4

1144 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Component Inspection and Adjustment

WARNING

The following procedures may require the ve-

hicle/machine to be disabled (wheels raised off
the ground, work function disconnected, etc.)
while performing the adjustments to prevent
injury to the technician and bystanders.

Charge Pressure Relief Valve Adjustment

An appropriate combination of pump and motor charge
pressure settings should be maintained to insure the
proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all
conditions of operation to maintain pump control
performance in closed loop systems.

To measure motor charge pressure, install a 0 to 60

bar or 0 to 500 psi pressure gauge in the motor charge 51000042

pressure gauge port. Install a gauge to measure case Fig. 30-6 - Adjusting Charge Pressure
pressure. Operate the system with the prime mover Relief Valve
at normal operating speed and the pump at half
stroke (forward or reverse) when measuring motor
charge pressure.

In most applications, the motor charge relief valve is

set 2 to 4 bar (29 to 58 psi) below the setting of the
pump charge relief valve (measured with the pump in
its “neutral” or zero-angle position). This setting as-
sumes a reservoir temperature of 50° C (122° F), and
is referenced to case pressure.
51000043
Series 51 motors are equipped with an external screw
adjustable charge pressure relief valve. To adjust the
Fig. 30-7 - Tighten Charge Pressure Relief
charge pressure, loosen the lock nut (with a 1-1/16" Valve Lock Nut
hex wrench) and turn the adjustment plug with a large
screwdriver. Clockwise rotation of the plug increases
the setting, and counter-clockwise rotation decreases
the setting (at a rate of approximately 3.4 bar [50 psi]
per turn). The lock nut should be torqued to 52 Nm (38
ft•lbsf).

Once the desired charge pressure setting is achieved,

remove the gauges and reinstall the port plugs.

30 - 5 27

008 914 20 BOMAG 1145

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Minimum Displacement Limiter Adjustment
The minimum displacement is set at the factory, and
the adjustment screw is covered with a tamper-
resistant cap
WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The sealing lock nut must be retorqued
510000434
Fig. 30-8 - Loosen Minimum Displacement after every adjustment to prevent an unex-
Limiter Lock Nut pected change in operating conditions and to
prevent external leakage during unit operation.
NOTE: Changes in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor, while maintaining the motor at
minimum displacement and monitoring the
motor output shaft speed. An increase in
displacement will result in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed.

To adjust the minimum displacement, first remove

51000045
Fig. 30-9 - Rotate Minimum Displacement and discard the cap covering the adjusting screw.
Adjusting Screw Using a 17 mm hex wrench for 060 and 080 frame
size motors or a 19 mm hex wrench for 110 through
250 frame size motors, loosen the lock nut retaining
Approximate Change in the minimum displacement limiter adjusting screw.
Minimum Displacement Using a 5 mm internal hex wrench for 060 and 080
Frame Per Revolution frame size motors or a 6 mm internal hex wrench for
Size of Adjusting Screw 110 through 250 frame size motors, rotate the adjust-
060 1.5 cc/Rev (.09 in3/Rev) ing screw to limit the minimum displacement of the
080 2.1 cc/Rev (.13 in3/Rev) motor.
110 3.1 cc/Rev (.19 in3/Rev) Rotating the adjusting screw clockwise will increase
180 4.0 cc/Rev (.24 in3/Rev) the minimum displacement of the motor, while rotat-
250 6.2 cc/Rev (.38 in3/Rev) ing the adjusting screw counter-clockwise will de-
crease the minimum displacement.
Min. Displacement Screw Size
Frame Range and Length For each full revolution, of the adjusting screw, the
Size cc/Rev (in /Rev)
3
mm (in) displacement will change according to the accompa-
nying chart.
060 12 to 29 (.73 to 1.77) M10x65 (2.56)
30 to 40 (1.83 to 2.44) M10x80 (3.15) Different minimum displacements may require differ-
080 16 to 35 (.98 to 2.14) M10x65 (2.56) ent length adjusting screws. The various lengths are
36 to 54 (2.20 to 3.20) M10x80 (3.15) shown in the accompanying chart.
110 22 to 46 (1.34 to 2.81 ) M12x70 (2.76) After establishing the desired minimum displacement
47 to 74 (2.87 to 4.52) M12x80 (3.15) setting, tighten the lock nut on the adjusting screw to
160 32 to 72 (1.95 to 4.39) M12x75 (2.95) 51 Nm (38 ft•lbsf) for 060 and 080 frame size motors
73 to 107 (4.45 to 6.53) M12x90 (3.54) or 86 Nm (63 ft•lbsf) for 110 through 250 frame size
250 50 to 90 (3.05 to 5.49) M12x75 (2.95) motors. Install a new tamper-resistant cap on the
91 to 130 (5.55 to 7.93) M12x90 (3.54) adjusting screw.
131 to 167 (7.99 to 10.19) M12x100 (3.94)

28 30 - 6

1146 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Maximum Displacement Limiter
Adjustment
The maximum displacement of the Series 51 motors
can be limited by limiting the stroke of the setting
piston, and the resulting movement of the valve
segment. A displacement stop screw is installed on
the setting piston (under the minimum angle servo
cover) to limit the stroke of the piston.

Spacers may be installed on the displacement stop

screw to limit the stroke. A longer or shorter screw
must be used to retain a thicker or thinner spacer.

WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The stop screw must be retorqued
after adjustment to prevent an unexpected
change in operating conditions.
NOTE: Changes in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor, while maintaining the motor at 51000046
maximum displacement and monitoring the Fig. 30-10 - Remove Minimum Angle Servo
motor output shaft speed. An increase in Cover Screws
displacement will result in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed. Approximate Change in
Frame Maximum Displacement
To adjust the maximum displacement, first remove Size with Change in Spacer Thickness
the screws retaining the minimum angle servo cover cc/mm (in3/.1 in)
to the end cap with an 8 mm internal hex wrench (060,
080, 110, and 160 units), or a 10 mm internal hex 060 0.98 (.15)
wrench (250 units). Remove the minimum angle 080 1.14 (.18)
servo cover and O-rings. Remove the displacement 110 1.48 (.23)
limiter screw with an 8 mm internal hex wrench. 160 1.93 (.30)
Installing a thicker spacer on the end of the setting 250 2.63 (.41)
piston will reduce the maximum displacement of the
motor. Installing a thinner spacer will increase the
maximum displacement. The displacement will
change according to the accompanying chart.

Torque the displacement limiter screw to 54 Nm (40

ft•lbsf).

Install the minimum angle servo cover and its O-rings.

Install the cover screws and torque to 78 Nm (58
ft•lbsf) for 060, 080, 110, and 160 motors, or 110 Nm
(81 ft•lbsf) for 250 motors.
51000070
Fig. 30-11 - Torque Maximum Displacement
Limiter Screw

30 - 7 29

008 914 20 BOMAG 1147

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Displacement Control Adjustments
NOTE: A change in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor and monitoring the motor output
shaft speed while adjusting the control. An
increase in displacement will result in a de-
crease in shaft speed, while a decrease in
displacement will result in an increase in shaft
speed.

Hydraulic 2-Position Control (Type N2)

No adjustments are provided for the N2 control.

A minimum of 25 bar (360 psi) servo pressure is

required to change the motor displacement with the
motor shaft turning. A minimum of 70 bar (1015 psi)
servo pressure is required to change the motor dis-
placement with the motor shaft locked.
50000009
Fig. 30-12 - Hydraulic 2-Position Control,
Type N2)

Electrohydraulic 2-Position Control (Types E1•E2

and F1•F2) and Electric 2-Position Control (Type
S1)

These controls do not require adjustment.

CAUTION

Do not tamper with the adjusting screw in the

end cap (opposite the control).
50000012
Fig. 30-13 - Electrohydraulic 2-Position Pilot pressure for the E1•E2 or F1•F2 electric sole-
Control, Types E1•E2 and F1•F2 noid valve is internally supplied. When the solenoid is
energized, motor charge pressure should be present
at test ports M7 and M8. When the solenoid is not
energized, test port M8 should drop to case pressure.

The S1 control utilizes a direct acting solenoid to

operate the control valve spool in the end cap.

Servo pressure supply oil is usually provided inter-

nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
50000162 displacement with the motor shaft turning, and a
Fig. 30-14 - Electric 2-Position Control, minimum of 70 bar (1015 psi) is required with the
Type S1 motor shaft locked.

30 30 - 8

1148 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Hydraulic Proportional Control (Types HZ, HS,
H1•H2, and K1•K2)
The control start pressure for these controls may be
adjusted with the adjusting screw on the end cap
(opposite the control block). Control start is that pilot
pressure at which the motor displacement starts to
decrease.
To check the control start setting, install a gauge to
monitor the pilot pressure (connect to port M7 or tee 51000015
into the pilot line connected to port X1), and the Fig. 30-15 - Hydraulic Proportional Control,
minimum angle servo pressure (port M3). If adjusting Type HZ
an H1 or H2 control, the override solenoid must be
energized. If adjusting a K1 or K2 control, the sole-
noid must not be energized.
NOTE: The pilot signal may be determined by prime
mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.
Increase the pilot signal to the required control start
pressure. An increase in minimum angle servo pres-
sure will be noted as the motor displacement starts to 51000018
decrease. Fig. 30-16 - Hydraulic Proportional Control,
To adjust the control start pressure, loosen the lock Type HS
nut using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm internal hex wrench. Turning the
screw clockwise increases the control start pressure.
Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjust-
ing.
For the H1•H2 controls, the pilot signal pressure
supplied to port X1 should also be present at test port
M7 when the solenoid is energized. When the sole-
noid is not energized, test port M7 should drop to case
pressure.
51000020
For the K1•K2 controls, the pilot signal pressure Fig. 30-17 - Hydraulic Proportional Control
supplied to port X1 should also be present at test port with Electric Override, Type H1•H2 (K1•K2
M7 when the solenoid is not energized. When the Similar)
solenoid is energized, test port M7 should drop to
case pressure.
Shut down the prime mover. Remove the gauges and
install the gauge port plugs. Return the pump and
motor controls to their normal operation.
Servo pressure supply oil is usually provided inter-
nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
51000047
displacement with the motor shaft turning, and a Fig. 30-18 - Adjusting Control Threshold,
minimum of 70 bar (1015 psi) is required with the Types HS, HZ, H1•H2, and K1•K2
motor shaft locked.

30 - 9 31

008 914 20 BOMAG 1149

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Two Line Hydraulic Proportional Control
(Type HP)
The differential control start pressure for this control
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
differential pilot pressure at which the motor displace-
ment starts to decrease.

To check the control start setting, install gauges to

51000023 monitor the pilot pressures (tee into the pilot lines
Fig. 30-19 - Two Line Hydraulic connected to ports X1 and X2), and the minimum
Proportional Control, Type HP angle servo pressure (port M3).

NOTE: The pilot signals may be determined by prime

mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.

Increase the pilot signal differential to the required

control start pressure. An increase in minimum angle
servo pressure will be noted as the motor displace-
ment starts to decrease.
51000047 The differential control start pressure should be the
Fig. 30-20 - Adjusting Control Threshold same no matter which pilot pressure is higher. Differ-
(Type HP) ences in control operation when the pilot pressure
differential is reversed indicate a problem with the
shuttle spool in the control block.

To adjust the control start differential pressure, loosen

the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm internal hex wrench.
Turning the screw clockwise increases the control
start pressure. Torque the lock nut to 9 Nm (6.6 ft•lbsf)
after adjusting.

Shut down the prime mover. Remove the gauges and

install the gauge port plugs. Return the pump and
motor controls to their normal operation.

Servo pressure supply oil is usually provided inter-

nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
displacement with the motor shaft turning, and a
minimum of 70 bar (1015 psi) is required with the
motor shaft locked.

32 30 - 10

1150 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Two Line Hydraulic Proportional Control
for “Dual Path” Vehicles (Type HC)
The differential control start pressure for this control
may be adjusted with the adjusting screw on the
control housing. Control start is that differential pilot
pressure at which the motor displacement starts to
decrease.

To check the control start setting, install gauges to

monitor the pilot pressures (tee into the pilot lines 51000158

connected to ports X1 and X2), and the minimum Fig. 30-21 - Two Line Hydraulic
angle servo pressure (port M3). Proportional Control, Type HC

NOTE: The pilot signals may be determined by prime

mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.

Increase the pilot signal differential to the required

control start pressure. An increase in minimum angle
servo pressure will be noted as the motor displace-
ment starts to decrease.

The differential control start pressure should be the 51000159

same no matter which pilot pressure is higher. Differ- Fig. 30-22 - Adjusting Control Threshold
ences in control operation when the pilot pressure (Type HC)
differential is reversed indicate a problem with the
shuttle spool in the control block.

To adjust the control start differential pressure, loosen

the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm internal hex wrench.
Turning the screw counter-clockwise (CCW) increases
the control start pressure. Torque the lock nut to 9 Nm
(6.6 ft•lbsf) after adjusting.

Shut down the prime mover. Remove the gauges and

install the gauge port plugs. Return the pump and
motor controls to their normal operation.

Servo pressure supply oil is provided internally from

the main system ports of the motor.

30 - 11 33

008 914 20 BOMAG 1151

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Electrohydraulic Proportional Control
(Types EP and EQ)
The control start current for the EP and EQ controls
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
current supplied to the PCP (Pressure Control Pilot)
valve at which the motor displacement starts to de-
crease.
51000026 To check the threshold setting, install instruments to
Fig. 30-23 - Electrohydraulic Proportional monitor the PCP current, and the minimum angle
Control, Type EP (EQ Similar) servo pressure (port M3).

NOTE: The current supplied to the PCP may be

determined by prime mover speed, other
shaft speeds, control pressures, or other elec-
trical signals, depending upon the design of
the vehicle / machine control circuit.

Increase the PCP current to the required control start

current. An increase in minimum angle servo pres-
sure will be noted as the motor displacement starts to
decrease.
51000047
Fig. 30-24 - Adjusting Control Threshold To adjust the control start current, loosen the lock nut
(Type EP•EP) using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm internal hex wrench. Turning the
screw clockwise increases the control start current.
Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjust-
ing.

PCP supply pressure oil is provided externally. PCP

supply pressure must be a minimum of 20 bar (290
psi) and no more than 70 bar (1015 psi).

Shut down the prime mover. Remove the gauges and

install the gauge port plugs. Return the pump and
motor controls to their normal operation.

Servo pressure supply oil is usually provided inter-

34 30 - 12

1152 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Pressure Compensator Over-Ride (PCOR)
and Pressure Compensator Regulator
(Type PC) Adjustment
The PCOR or PC regulator valve setting may be
adjusted with the adjusting screw on the PCOR/PC
valve block attached to the multi-function block. The
regulator start pressure is that system pressure at
which the PCOR or PC regulator starts to increase
the motor displacement.
In order to measure the regulator start pressure
setting of the PCOR or the PC regulator, the motor
output shaft must be loaded to increase the system 51000031

working pressure. This can accomplished by apply- Fig. 30-25 - PCOR Block on Multi-Function
ing the vehicle’s brakes or by loading the work func- Block (K1•K2 Control Shown)
tion.
WARNING

The following procedures may require the ve-

hicle/machine to be disabled (wheels raised off
the ground, work function disconnected, etc.)
while performing the adjustment to prevent
injury to the technician and bystanders.
Install gauges to monitor system pressure (connect
to ports M1 and M2), the minimum angle servo
pressure (port M3), and the maximum angle servo
pressure (port M4).
51000034
Start the prime mover and operate at normal speed.
Fig. 30-26 - Pressure Compensator
Provide a signal to the pump control to provide a
Regulator (Type PC)
constant flow of hydraulic fluid to the motor. Provide
a signal to the motor control to maintain the motor at
its minimum displacement.
Increase the load on the motor to increase the system
pressure to the required regulator start pressure. The
maximum angle servo pressure (M4) will increase
and the minimum displacement servo pressure (M3)
will decrease as the PCOR or PC regulator operates.
The servo pressures will equalize, and the maximum
angle servo pressure continue to increase, as the
motor displacement starts to increase.
51000048
During the transition from minimum to maximum Fig. 30-27 - System Pressure Gauge Ports
displacement, an additional 10 bar (145 psi) increase (Side Port End Cap)
in system pressure may be noted.
Once the motor is at maximum displacement, further
increases in load will result in increasing system
pressure until the maximum system pressure (deter-
mined by the system relief valve or pump pressure
limiter) is reached.

30 - 13 35

008 914 20 BOMAG 1153

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Component Adjustment (Continued)
Allow the pump to return to its neutral position.
Repeat the procedure for the other side of the closed
circuit if so configured. The PCOR or PC regulator
must operate at the same start pressure as noted
previously. Any noticeable difference in operation
from side to side may indicate a problem with the
pressure supply shuttle spool or brake pressure de-
feat spool in the multi-function block.
NOTE: Some motors may be configured for the
PCOR or PC regulator to function on only
one (1) side of the closed loop. Refer to the
nomenclature on the motor nameplate.
In order for the PCOR or PC regulator to function
properly on motors equipped with a brake pressure
defeat spool, the defeat spool must be positioned
correctly. The control pressure for the defeat spool
should be applied to the appropriate port (XA or XB)
as shown in the following table to shift the defeat
spool and permit PCOR or PC regulator operation.
Maximum pressure across the brake pressure defeat
ports XA and XB is 50 bar (725 psi).
51000049 Pressure Compensator Override Defeat Operation
Fig. 30-28 - Loosen PCOR/PC Lock Nut Rotation High system Control
pressure port pressure on port
CW A XB
CCW B XA
The PCOR or PC regulator valve is screw adjustable.
To adjust, loosen the locknut with a 1-1/16" hex
wrench. Turn the adjusting screw with a large screw-
driver until the desired pressure setting is estab-
lished. Clockwise rotation of the adjustment screw
will increase the pressure setting at a rate of approxi-
mately 70 bar (1000 psi) per turn.
51000050
Fig. 30-29 - Rotate PCOR/PC Adjusting CAUTION
Screw A stop pin is installed in the adjusting screw to
prevent “overtravel” of the PCOR/PC valve
spool. The stop pin must protrude (distance
"X" “X”) 19 mm (.75 in.) from the spring seat for
settings of 270 to 370 bar (3900 to 5350 psi), or
24 mm (.94 in.) for settings of 110 to 260 bar
(1600 to 3750 psi). Refer to the appropriate
Service Parts Manual for further information.
While holding the adjusting screw from turning, torque
the lock nut to 52 Nm (38 ft•lbsf). Recheck the PCOR
or PC regulator setting.
51000051
Shut down the prime mover. Remove the gauges and
Fig. 30-30 - PCOR/PC Adjusting Screw Stop install the gauge port plugs. Return the pump and
Pin motor controls to their normal operation.

36 30 - 14

1154 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Troubleshooting
Fault-Logic Diagrams • Closed Circuit

Check Oil Level Check System Check Pump Check Prime Mover
OK OK OK Speed
in Reservoir Relief Valve Inlet Pressure
Pressure Low
Low Low OK
Settings

Fill to Proper Defective Inspect Inlet Filter Adjust

Level and Replace if
Adjust or Necessary
Replace

Replace Check System Check Charge and

Transmission OK Internal Leakage OK Control Pressures
(Pump and Motor)
High Incorrect

Repair as Required Repair as Required

SYSTEM RESPONSE IS SLUGGISH

Check Oil Air in System OK Check Pump Inspect Shaft Inspect Shaft
Level in
OK Inlet Pressure
OK Couplings
OK Alignment
Reservoir
Loose Fitting Low Defective Defective
Low

Fill to Proper Purge Air and Inspect Inlet Filter Repair or Align Shafts
Level Tighten and Replace if Replace
Fittings Necessary

EXCESSIVE NOISE AND/OR VIBRATION

Check Oil Level Inspect Heat Check Charge Check Pump Inlet
in Reservoir
OK Exchanger
OK Pressure
OK Pressure
Low Defective Incorrect Low OK

Fill to Proper Clean, Repair Repair as Inspect Inlet Filter

Level or Replace Required and Replace if
Necessary

Replace Check System Check for Internal Check System Relief

Transmission OK Pressure OK System Leakage OK Pressure Settings
(Pump and Motor)
High High Low

Reduce Load on Repair as Required Adjust or Replace

Transmission

SYSTEM OPERATING HOT

30 - 15 37

008 914 20 BOMAG 1155

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Troubleshooting (Continued)
Fault-Logic Diagrams • Closed Circuit (Continued)

Check Charge Check Pump Interchange System Replace

Pressure OK Control System OK Relief Valves and/or OK Transmission
Charge Check (Pump and
Decays in One Defective Valves Motor)
Direction (Forward
Problem Changes
or Reverse) Only
Direction

Inspect and Repair Repair or Replace Repair or Replace

Loop Flushing Appropriate Valve
Valve

MOTOR OPERATES NORMALLY IN ONE DIRECTION ONLY

Check Inlet Check Outlet Motor at Incorrect Repair or Replace

Pressure at OK Pressure at OK (Minimum) Displacement OK Motor
Motor Motor

Low High / Low Incorrect

Correct System Correct System Check Control Supply

Pressure and/or Repair
LOW MOTOR OUTPUT TORQUE Displacement Control

Check Oil Check Charge Check Pump

Level in OK Pressure OK Output Flow OK Check Motor Displacement
Reservoir
Low Incorrect Improper Incorrect OK

Fill to Proper Repair Charge Repair Pump Check and Repair

Level System Control and/or Control System and
Pump Displacement Controls
(Pump and Motor)

Repair or Replace
Motor
IMPROPER MOTOR OUTPUT SPEED

38 30 - 16

1156 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Notes

30 - 17 39

008 914 20 BOMAG 1157

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Notes

40 30 - 18

1158 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor
The following information is for general parts identi-
fication ONLY. Refer to the applicable Service Parts
List when ordering service parts.
Base Unit
L35

W10 OPTION
WNNT L40
W50
L50
B71
W25 B80
B71A B80
L70 L80

L75

L40
L50

B70
B70A

B70A

Y10
B70
Y20
W25
Y30

Y20

W50
Y10 Y10
W10 B70A
OPTION Y20
WNNS B70
Y30

Name Plate
saue
Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ

51V160 RF1N
E1A2 ANE1 NNN Model Code
050AA210322
Model No. Ident Nr
Model Number
516-40104 786673
Serial Number N 91 25 67890
Serial No. Fabr Nr
MADE IN GERMANY

Place of Manufacture
Name Plate (German Production)
40 - 1 41

008 914 20 BOMAG 1159

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
End Cap
(....) = Applies to the indicated
G30 frame size(s).
G24

G30A
J70
G26
J60 G38

J50 G36

M18/M98 F10N, F10A–G

M16/M96 F20A–G
K90
K50
J40
K10
OR
K16 K70 OR
(250) K90N
G20
G20A K80
Q40 K90A
K14
K16 G50
(060—160)
G12 G50A G12
G12A G30 G30A K18N
(250) (250)
G80
(060, 080) G12A OR
G80A K16
G30 K18
(060, 080) (060—160) K16
(250)
G30A (250)
G30
(250) G30A K14
G20A
M11/T3A1-A9
T3B0-B6 G20
G12 T3C2-C7
G12A S20 OR
G12A
G12 S10
M11/T1A1-A9
T1B0-B6 (060, 080,
T1C2-C7 G30A 110)
G18 (250) OR S10
G90 (160, 250)
G12A G30
Y40 G12 (250)
N1U5 J30
T8A1-A9
Y50 T8B0-B6 J10A-D
T8C2-C7
J20/S70
G30A
G30 T7A1-A9
G42
G36 T7B0-B6
T7C2-C7
M11/T2A1-A9 G44
T2B0-B6
T2C2-C7 G38
F33
G38

G38
G42 F32

42 40 - 2

1160 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Multi-Function Valve
N28 Q50
N28A N84
N84A

N52 OR

N32 N34
N34A
N72 N46/T5
N66 N72A N52/T4
N66A
N34
N34A N84
N30
N34
N34A OR
N52/T6
N34A N84A
N34
N34
N34A

N1A1-A6 N28
OR N28A
N90A
N66A
N90 OR N66
N26A
N26

N34
N34A
N58
N24
N82
N11

N29

Z10 & Z20

N82 N22 & N20

U7 N24
U6 N11 & N21
N14

N16
N18
N27A
N27 N29

N23
N27A
N23A
N27

Q60

40 - 3 43

008 914 20 BOMAG 1161

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Controls

M28

M30
M24
M38

M36

M10 M30
M18
M28
M32A M32 M26 M14
M32
M24
M26
M30 M28
M1HS
M1HP
M16 M18
M16
M20 M22
M1EP•EQ
M14 M18 M16 M16
M12 M14
M12
EP•EQ M10 HS M18
M10

M36

M16 M1S1
M10

M20 M14
M22
M1E1•E2•E5 M22A S1
M1F1•F2
M1H1•H2
M1K1•K2 M18A

M14
M18

M2E5

E1•E2•E5 / F1•F2 / H1•H2 / K1•K2

44 40 - 4

1162 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Controls (Continued)
(....) = Applies to the indicated
frame size(s).
S50
S30
S20
S40
S60
S11T
(060, 080,
110)
OR
S11T
S10 (160, 250)
(060, 080, S10
110) (160, 250)
S10T S10T
M10 (060, 080, (160, 250)
M12 110)

S70

M44 M32
M34
M34A
M14
M40 M1HC
M1N2 M16
M38 M47
M16A M14 M46
N2
M18
M50A
M18A
M50
M10 M34A M48A
M18 M12 M11 M34
M18A M48
(060, 080, 110) M26

M18A M34A
M22 M10
M18 M16A J10 M34
M1HZ M16 M25
HZ
M24

M22

M20

M14

M12

M28 M18

M16
HC

40 - 5 45

008 914 20 BOMAG 1163

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
PC Regulator

F33
F32
M84
M28
M84A
M28A
M52
M34
M34A
M72 T5
M66 T4
M66A M72A
M34
M34A
M30
M34
M34A
T6 M84
M34A M84A
M34
M34 M34A

M10 M28
M28A
M90A
M90 M28A
M26 M28
M26A

M34A
M34
M58

Z10 & Z20

M24 M82 M22 & M20

U7
U6
M1PC & M21
M14

M16
M18
M27A
M27 M29

M23
M27A
M23A
M27
Q60

46 40 - 6

1164 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
B000 COMMON PARTS GROUP (SAE FLNG) J00A-K CONTROL START SETTING
B80 O-RING 1 J10A-K SPRING-HEL COMP- CONT START 1
L35 FLANGE- SAE 1 J20 SEAT-SPRING 1
L40 SEAL- SHAFT 1 J30 SEAT-SPRING 1
L50 O-RING 1 J40 SCREW-ADJUSTING 1
L70 SCREW- SOC HD 8 J50 O-RING 1
J60 NUT-ADJUSTING SCREW 1
C000 COMMON PARTS GROUP (CARTRIDGE) J70 NUT-LOCK 1
L40 SEAL- SHAFT 1
L50 O-RING 1 J00N CONT START N/A (FOR 2 POS CONT)
L75 COVER- SEAL 1
L80 RING- RETAINING 1 M0EP CONTROL- ELHYD PRP, PACKARD
M0EQ CONTROL- ELHYD PRP, MS
F••• MAXIMUM DISPLACEMENT F32 BUSHING- VALVE ASSY 1
F10 SPACER- MAX DISPL LMTR 1 M1EP PCP VALVE, PACKARD CONN 1
F20 SCREW-SOC HD - MAX DISPL LMTR 1 M1EQ PCP VALVE, MS CONN 1
M10 HOUSING- CONTROL 1
G00A END CAP-AXIAL (160-250) M12 SCREW- SOC HD 4
G00B END CAP-AXIAL, CODE 61 (160-250) M14 COVER 1
G00R END CAP-SIDE, LOOP FL M16 GASKET 1
G00S END CAP-SIDE, LOOP FL, CODE 61 M18 SCREW- SOC HD 4
G12 PLUG-STR THD HEX 7 M24 PISTON- SHUTTLE, DELTA P 1
G14 PLUG-EXP 1 M26 SPRING- HEL COMPRESSION 1
G16 PLUG-MANDREL 2 M28 PIN 1
G18 SCREW-SET, FLAT PT 2 M30 O-RING 1
G20 PLUG- SPECIAL 2 M32 PLUG-SOC HD 2
G20N PLUG- STR THD HEX 2 M34 PLUG-MANDREL 6
G24 SCREW-SOC HD 4 M36 O-RING 1
G26 COVER-SERVO PISTON 1 M38 O-RING 1
G30 PLUG-STR THD HEX 3 M40 CONTROL SCREEN FILTER 1
G36 O-RING 2 M42 PLUG-SOC HD 1
G38 O-RING 4 M44 PLUG-PLASTIC 1
G42 O-RING 2 N90 PLUG-STR THD HEX 1
G44 O-RING 1
G50 PLUG-ST THD HEX 2 M0E1/E2 CONTROL- ELHYD 2 POS
G70 COVER-PORT 2 M0F1/F2 CONTROL- ELHYD 2 POS, MAX ANG
G90 CONTROL SCREEN FILTER 1 F32 BUSHING- VALVE ASSY 1
K10 ADJ PLUG ASSY-CHG RLF 1 M1E1 VALVE ASSY- SOLENOID,12V 1
K14 SPRING-HELICAL COMP 2 M1E2 VALVE ASSY- SOLENOID,24V 1
K16 GUIDE-SPRING (060 — 160) 2 M10 HOUSING-CONT, ELHYD, 2 POS (E) 1
K16 GUIDE-SPRING (250) 2 M10 HOUSING-CONT, ELHYD, 2 POS (F) 1
K18 SHUTTLE VALVE SPOOL 1 M12 PLUG-EXP 7
K18N LOOP FLUSH SPOOL- DEFEAT 1 M14 SCREW-SOC HD 4
K50 O-RING 1 M16 O-RING 2
K70 SPRING-HELICAL COMPRESSION 1 M18 PLUG-STR THD HEX 1
K80 POPPET-CHG RELIEF 1 M20 O-RING 1
K90 NUT-HEX LOCK 1 M22 PLUG-STR THD HEX 1
K90N PLUG- ST THD HEX 1 N90 PLUG-STR THD HEX 1

40 - 7 47

008 914 20 BOMAG 1165

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
M0HC CONTROL- HYD PRPNL 2LN, DUAL PATH M0HS CONTROL- HYD PRP, 1 LN
F32 BUSHING- VALVE ASSY 1 F32 BUSHING-VALVE ASSY 1
M1HC HOUSING- HYD PRPNL (2LN),DUAL 1 M1HS HOUSING- VALVE, HYD PRPRNL 1 LN 1
M10 SCREW-SOC HD 4 M10 SCREW-SOC HD 4
M11 WASHER, FLAT (060, 080, 110) 4 M12 O-RING 1
M12 COVER 1 M14 PLUG-STR THD HEX 1
M14 GASKET 1 M16 PLUG-PLASTIC 1
M16 NUT-SEAL LOCK 1 N90 PLUG-STR THD HEX 1
M18 SCREW-SET, FL PT 1
M20 GUIDE- SPRING 1 M0HZ CONTROL- HYD PRP, 1 LN, CMPCT
M22 SPRING-HELICAL COMPRESSION 1 F32 BUSHING- VALVE ASSY 1
M24 PISTON- DELTA P 1 M1HZ HOUSING- VALVE, HYD PRP, 1 LN, CPT 1
M25 SEAT- SPRING 1 M10 VALVE ASSY- DBL CHECK 1
M26 PIN 1 M12 SCREW- SOC- DRILLED 1
M28 SCREW-SOC HD 4 M14 CONTROL SCREEN FILTER 2
M32 CONTROL SCREEN FILTER 2 M16 PLUG-STR THD HEX 2
M34 PLUG-SOC HD 4 M18 PLUG-STR THD HEX 3
M38 VALVE- BLEED 1
M40 NUT- SEAL LOCK 1 M0H1/H2 CONTROL- HYD PRP, 1 LN, MAX ANG
M44 VALVE, SHUTTLE- DELTA P 1 M0K1/K2 CONTROL- HYD PRP, 1 LN, MIN ANG
M46 SEAT- BALL CHECK 1 F32 BUSHING-VALVE ASSY 1
M47 BALL- SHUTTLE 1 M1H1 VALVE ASSY-SOLENOID,12V 1
M48 PLUG-STR THD HEX 1 M1H2 VALVE ASSY-SOLENOID,12V 1
M50 PLUG-STR THD HEX 1 M10 HSG-CONT,ELHYD, 2 POS 1
M12 PLUG-EXP 8
M0HP CONTROL- HYD PRPNL 2LN, W/BLD M14 SCREW-SOC HD 4
F32 BUSHING- VALVE ASSY 1 M16 O-RING 2
M1HP HOUSING- HYD PRPNL (2LN),W/BLD 1 M18 PLUG-STR THD HEX 1
M10 COVER 1 M20 O-RING 1
M12 GASKET 1 M22 PLUG-PLASTIC 1
M14 PISTON-SHUTTLE, DELTA P 1 N90 PLUG-STR THD,SOC HD 1
M16 SPRING-HELICAL COMPRESSION 1
M18 PIN 1 M0N2 CON-HYD, 2 POS, DIRECT
M24 O-RING 1 M1N2 COVER 1
M26 VALVE SHUTTLE,DELTA P 1 M10 PLUG 1
M28 PLUG-SEALING 1 M11 SCREW- SET,FLT PT 3
M30 O-RING 2 M12 O-RING 1
M32 PLUG-SEALING 1 M14 SCREW-SOC 4
M34 PLUG-EXP 6 M16 GASKET 1
M36 SCREW-SOC HD 4 M18 PLUG 1
N90 PLUG-STR THD HEX 1

48 40 - 8

1166 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
M0PC REGULATOR- PRESS COMP N0A1-6 SVO PRS SPLY, PCOR, DFT
F32 PLUG- VALVE BUSHING BORE 1 N1A1-6 HOUSING-MULTI FUNCTION BLOCK 1
F33 O-RING 1 N11 HOUSING-VALVE 1
M1PC HOUSING- VALVE 1 N14 NUT-HEX LOCK 1
M10 HOUSING- MULTI FUNCTION BLOCK 1 N16 O-RING 1
M14 NUT-HEX LOCK 1 N18 SPRING-HELICAL COMPRESSION 1
M16 O-RING 1 N20 SEAT-SPRING, PCOR 1
M18 SPRING-HELICAL COMPRESSION 1 N21 BUSHING-VALVE 1
M20 SEAT-SPRING, PC 1 N22 SPOOL-PCOR VALVE 1
M21 BUSHING-VALVE 1 N23 PLUG-STR THD HEX 1
M22 SPOOL-PC VALVE 1 N24 O-RING 5
M23 PLUG-STR THD HEX 1 N26 PLUG-SOC HD (W/PCOR) 1
M26 PLUG-SOC HD 1 N26 PLUG-STR THD HEX (WO/PCOR) 1
M27 PLUG-STR THD HEX 10 N27 PLUG-STR THD HEX 17
M28 PLUG-STR THD HEX 4 N28 PLUG-PLASTIC (W/DFT) 2
M29 SCREW-SOC 4 N28 PLUG-STR THD HEX (WO/DFT) 2
M30 SPOOL, BI-DIRECTIONAL CHECK 1 N29 SCREW-SOC 4
M34 PLUG-STR THD HEX 10 N30 SPOOL, BI-DIRECTIONAL CHECK 1
M36 SCREW-SET,FLT PT 5 N32 PISTON 1
M38 PLUG-EXP 11 N34 PLUG-STR THD HEX 10
M50 PLUG-EXP 8 N36 SCREW-SET,FLT PT 5
M52 CONTROL SCREEN FILTER 2 N38 PLUG-EXP (060 - 110 ONLY) 11
M54 PLUG-EXP 1 N50 PLUG-EXP (060 - 110 ONLY) 6
M58 SCREW-SOC HD 4 N52 CONTROL SCREEN FILTER 2
M62 PLUG-EXP 1 N54 PLUG-EXP 1
M66 PLUG-STR THD HEX 2 N58 SCREW-SOC HD 4
M72 PLUG-STR THD,SOC HD 1 N62 PLUG-EXP 1
M82 O-RING 1 N66 PLUG-STR THD HEX (060-110) 2
M84 PLUG-STR THD HEX 2 N66 PLUG-STR THD HEX (160-250) 1
M86 SCREW-FL PT 1 N72 PLUG-STR THD,SOC HD 1
M90 PLUG-STR THD HEX 1 N74 SCREW-SET, FL PT 3
M96 GASKET 1 N82 O-RING 1
M98 PLUG 1 N84 PLUG, SPECIAL 2
N24 O-RING 5 N84 PLUG-STR THD HEX 2
N86 SCREW-SET 1
M0S1 CONTROL- ELECTRIC 2 POS, DIRECT U5 PLUG- SOC (EXT SUPPLY) 1
F32 BUSHING- VALVE ASSY 1 U6 ORIFICE, PCOR DAMPING 1
M1S1 SOLENOID,12V 1 U7 ORIFICE, PCOR DAMPING 1
M10 ADAPTER PLATE- SOLENOID 1
M14 SCREW-SOC HD 4 N0NN SERVO PRESS SPLY- NONE
M16 O-RING 1
M18 O-RING 1 P0AA SYS PRESS PROTECT- NONE
M20 PIN 1
M22 O-RING 1
N90 PLUG-STR THD HEX 1

40 - 9 49

008 914 20 BOMAG 1167

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Exploded View of the Series 51 Variable Motor (Continued)
Item Description Quantity Item Description Quantity
S00D-G CONTROL RAMP- HP, HS, H1/H2, K1/K2 Y••• MINIMUM DISPLACEMENT
S10 GUIDE-SPRING (160-250) 1 Y10 SCREW- SET, FLT PT 1
S10D-G CONT RAMP SPRING (060-110) 1 Y20 NUT- HEX, SEAL LOCK 1
S10D-G CONT RAMP SPRING ASSY (160-250) 2 Y30 TAMPER RESISTANT CAP 1
S20 GUIDE-SPRING 1
S70 SEAT-SPRING 1 Z000 PRS COMP SET- NONE

S00N CONTROL RAMP-NONE Z0•• PCOR / PRESS COMP SETTING

Z10 ADJUSTER- THREADED 1
S00T CONTROL RAMP- HC Z20 PIN-STRAIGHT 1
S10 GUIDE-SPRING 1
S10T CONT RAMP SPRING 1
S11T CONT RAMP SPRING 1
S20 GUIDE-SPRING 1
S30 NUT- ADJUSTING SCREW 1
S40 O-RING 1
S50 NUT- LOCK 1
S60 SCREW- ADJUSTING 1
S70 SEAT-SPRING 1

S00U-Z CONTROL RAMP- EP/EQ

S10 GUIDE-SPRING (160-250) 1
S10U-Z CONT RAMP SPRING (060-110) 1
S10U-Z CONT RAMP SPRING ASSY (160-250) 1

T0A0 CON ORIFICE (A0)- NONE

T0A1 CON ORIFICE (A1)

T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 SCREW 2
T5 ORIFICE 1
T6 SCREW 1
T7 ORIFICE 2
T8 ORIFICE 1
U3 SCREW-FL PT 1

T0A2 CON ORIFICE (A2)

T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 ORIFICE 2
T5 SCREW 1
T6 ORIFICE 1
T7 ORIFICE 2
T8 ORIFICE 1

WNNN SPCL HDW-NONE

A10 SPEED SENSOR 51V 0
B70 PLUG-SOC HD 1
B71 PLUG-PLASTIC 1

50 40 - 10

1168 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor

Charge Pressure
Relief Valve
Loop Flushing
Valve

Shaft
Seal

Control
Orifices
Multi-function
Block

Control
Minimum Displacement
Limiter

51000052
Variable Displacement Motor (SAE Flange Configuration)
Fig. 50-1 - Minor Repairs

Minor Repairs may be performed, following the proce- Protect all exposed sealing surfaces and open cavi-
dures in this section, without voiding the unit war- ties from damage and foreign material.
ranty. Although specific products are illustrated,
these procedures apply to all units in the Series 51 It is recommended that all gaskets and O-rings be
family. replaced. All gasket sealing surfaces must be cleaned
prior to installing new gasket. Lightly lubricate all O-
General rings with clean petroleum jelly prior to assembly.
Cleanliness is a primary means of insuring satisfac-
tory transmission life, on either new or repaired units.
Cleaning parts by using a solvent wash and air drying
is adequate, providing clean solvent is used. As with
any precision equipment, the internal mechanism
and related items must be kept free of foreign mate-
rials and chemicals.

50 - 1 51

008 914 20 BOMAG 1169

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Shaft Seal (SAE Flange Configuration)
Lip type shaft seals are used on the Series 51 motors.

Replacement of the shaft seal usually requires re-

moval of the motor from the machine.

Remove the screws holding the flange to the housing,

using a 6 mm internal hex wrench (060 and 080 units),
an 8 mm internal hex wrench (110 units), a 10 mm
internal hex wrench (160 units), or a 12 mm internal
hex wrench (250 units).

Remove the flange from the housing using a suitable

puller. Care must be taken so as to not damage the
housing bore or shaft.
51000178 51000179 CAUTION
Fig. 50-2 - Remove Fig. 50-3 - Remove
Screws Holding Flange (SAE) Do not allow the output shaft to move out of the
Flange to Housing housing while removing the flange. After the
(SAE) flange is removed, do not attempt to remove
the shaft from the housing. If the output shaft
moves out of the housing, the synchronizing
shaft and rollers could fall out of position,
requiring major disassembly of the unit.

Remove the old seal from the flange. Once removed,

the seal is not reusable.

Inspect the flange and the new seal for any damage
or nicks.

Using an arbor press, press the new seal into the

flange. Be careful not to damage seal.

NOTE: The outside diameter of the seal may be

51000053 51000054 lightly coated with a sealant (such as Loctite
Fig. 50-4 - Remove Fig. 50-5 - New Seal High Performance Sealant #59231) prior to
Old Seal from Flange Installed in Flange installation. This will aid in preventing leaks
(SAE) (SAE) caused by damage to the seal bore in the
flange.

Inspect the sealing area on the shaft for rust, wear, or

contamination.

52 50 - 2

1170 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install a new O-ring on the flange. Prior to assembly,
lubricate the flange O-ring and the I.D. of the seal with
petroleum jelly.

Protect the seal lip from damage during installation by

wrapping the spline or key end of shaft with plastic
film, or by using a seal installation tool.

Assemble the flange and seal over the shaft and into
the housing bore. Install four (4) of the flange screws,
51000055 51000056
and tighten them evenly to pull the flange into posi- Fig. 50-6 - Install Fig. 50-7 - Torque
tion. Take care to not damage the O-ring or seal lip
Flange onto Housing Flange Screws (SAE)
during installation.
(SAE)
Install the flange screws and torque evenly to 32 Nm
(24 ft•lbsf) for 060 and 080 motors, 63 Nm (46 ft•lbsf)
for 110 motors, 110 Nm (81 ft•lbsf) for 160 motors,
and 174 Nm (128 ft•lbsf) for 250 motors.

Shaft Seal (Cartridge Configuration)

Lip type shaft seals are used on the Series 51 motors.
These seals can be replaced without major disas-
sembly of the unit. However, replacement of the shaft
seal requires removal of the motor from the wheel
drive or track drive gearbox.

Remove the seal carrier retaining ring from the hous-

ing.

Carefully pull the seal cover out of the housing. Care

must be taken so as not to damage the housing bore
or shaft.

Remove the O-ring from the housing.

Remove the old seal from the carrier. Once removed,

the seal is not reusable. 51000057 51000058
Fig. 50-8 - Remove Fig. 50-9 - Remove
Inspect the carrier and the new seal for any damage
Carrier Retaining Seal Carrier
or nicks.
Ring (Cartridge) (Cartridge)
Using an arbor press, press the new seal into the
carrier. Be careful not to damage seal.

NOTE: The outside diameter of the seal may be

lightly coated with a sealant (such as Loctite
High Performance Sealant #59231) prior to
installation. This will aid in preventing leaks
caused by damage to the seal bore in the seal
carrier.
51000059 51000060
Inspect the sealing area on the shaft for rust, wear, or
Fig. 50-10 - Seal Fig. 50-11 - Seal
contamination.
Carrier Removed Installed in Carrier
(Cartridge) (Cartridge)
50 - 3 53

008 914 20 BOMAG 1171

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install the carrier O-ring into the groove in the hous-
ing. Prior to assembly, lubricate the carrier O-ring and
the I.D. of the seal with petroleum jelly.

Protect the seal lip from damage during installation by

wrapping the spline or key end of shaft with plastic
film, or by using a seal installation tool.

Assemble the carrier and seal over the shaft and into
the housing bore. Take care to not damage the O-ring
51000061 51000057
Fig. 50-12 - Install Fig. 50-13 - Install or seal lip during installation.
Seal Carrier Carrier Retaining Install the seal carrier retaining ring.
(Cartridge) Ring (Cartridge)
Loop Flushing Shuttle Valve (Option)
Using an 11/16" wrench, remove the hex plugs from
both sides of end cap.
Remove springs and spring seat washers. Note the
orientation of the washers.
NOTE The 250 frame size motors use thicker spring
seat washers.

51000062 51000063 Remove flushing valve spool.

Fig. 50-14 - Remove Fig. 50-15 - Remove
Shuttle Valve Plugs Valve Spool

Inspect parts for damage or foreign material.

51000066
Fig. 50-16 - Loop Flushing Shuttle Valve
Components

Install flushing valve spool in end cap, then install the

spring seat washers (thick washers on 250 frame size
motors) on each end of the spool. The step on the
spring seat washers should face out, toward the
springs.
Install the spool springs and hex plugs. Torque the
plugs to 41 Nm (30 ft•lbsf).

51000064 51000065
Fig. 50-17 - Install Fig. 50-18 - Install
Valve Spool and Plugs and Springs
Washers
54 50 - 4

1172 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Charge Pressure Relief Valve
Before removing the screw adjustable relief valve
plug, mark the plug, lock nut, and end cap to allow
maintaining the original adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock nut (with a 1-1/16"
hex wrench), and unscrewing the plug with a large
screwdriver.

Remove the spring and relief valve poppet. 51000067 51000068

Fig. 50-19 - Remove Fig. 50-20 - Remove
Inspect the poppet and mating seat in the end cap for Charge Relief Valve Charge Relief Valve
damage or foreign material. Plug
Install the poppet and spring. Install the plug with its
lock nut, aligning the marks made at disassembly,
and torque the lock nut to 52 Nm (38 ft•lbsf).

Check and adjust, if necessary, the charge pressure.

51000069
Fig. 50-21 - Charge Relief Valve
Components

Minimum Angle Servo Cover

Thoroughly clean external surfaces prior to removal
of cover.

Remove the four (4) screws retaining the cover to the

end cap with an 8 mm internal hex wrench (060, 080,
110, and 160 units) or a 10 mm internal hex wrench
(250 units). Remove the cover. Remove the O-rings
between the cover and end cap.
51000046 51000006
Install new O-rings on the end cap and retain with Fig. 50-22 - Remove Fig. 50-23 - Install
petroleum jelly. Install the cover onto the end cap and Servo Cover Screws Servo Cover
install the screws. Torque the screws to 78 Nm (58
ft•lbsf) for 060, 080, or 110 units, or 110 Nm (81 ft•lbsf)
for 160 or 250 units.

The plug in the cover may be removed with a 7/16"

hex wrench. Torque this plug to 9 Nm (7 ft•lbsf).

50 - 5 55

008 914 20 BOMAG 1173

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic 2-Position Control (Type N2)
Thoroughly clean external surfaces prior to removal
of cover plate.

Remove the four (4) screws retaining the cover plate

to the end cap with an 8 mm internal hex wrench (060,
080, and 110 units) or a 10 mm internal hex wrench
(160 and 250 units). Remove the cover plate.

51000071 51000072 Remove the solid plug from the valve sleeve bore in
Fig. 50-24 - Remove Fig. 50-25 - Remove the end cap. (An 8 mm threaded hole is provided in
Cover Plate Screws Cover Plate the plug for a puller screw.) Remove the O-ring from
the plug.

Remove the O-rings from the end cap.

Install new O-rings on the end cap and retain with

petroleum jelly.

Install a new O-ring on the solid plug and install the

solid plug into the end cap.

51000168
Fig. 50-26 - Remove Valve Sleeve Bore
Plug Install the cover plate onto the end cap and install the
screws. Torque the screws to 78 Nm (58 ft•lbsf) for
060, 080, or 110 units, or to 110 Nm (81 ft•lbsf) for 160
or 250 units.

Set screws are installed in control orifice holes in the

end cap to plug the valve sleeve bore passages. To
gain access to the screw plugs, remove the outer
plugs from the end cap with a 7/16" or 11/16" hex
wrench. Remove the screw plugs with a 3 mm internal
hex wrench. When installing, torque the screw plugs
51000010
to 4 Nm (35 in•lbsf). Torque the 5/16" outer plugs to
Fig. 50-27 - N2 Control Components 9 Nm (7 ft•lbsf), and the 9/16" outer plugs to 37 Nm (27
ft•lbsf). Refer to the “Control Orifices” topic for addi-
tional information.

The special plug and seal washer on the end cap

opposite the control may be removed with a 13 mm
hex wrench. When installing, torque this plug to 20
Nm (15 ft•lbsf).

51000073 51000074
Fig. 50-28 - Torque Fig. 50-29 - Torque
Cover Plate Screws Plug in End Cap

56 50 - 6

1174 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Electrohydraulic 2-Position Controls
(Types E1•E2 and F1•F2)
Thoroughly clean external surfaces prior to removing
the control.

The solenoid may be removed from the valve by

removing the nut with a 3/4" hex wrench. The
solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.
51000075 51000076
Fig. 50-30 - Remove Fig. 50-31 - Remove
E1•E2 or F1•F2 Solenoid Valve
Control Solenoid
Remove the screws retaining the valve housing to the
multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.

The plugs on the control housing may be removed

with an 11/16" hex wrench. When reinstalling, torque
the plugs to 37 Nm (27 ft•lbsf).

51000013
Fig. 50-32 - E1•E2 and F1•F2 Control
Components

Install new O-rings onto the valve housing. Install the

valve housing onto the multi-function block, and
install the screws. Torque the screws to 6.4 Nm (4.7
ft•lbsf).

51000077
Fig. 50-33 - Install E1•E2 or F1•F2 Control
Valve Housing

When installing the solenoid valve into the valve

housing, the valve should be torqued to 20 Nm (15
ft•lbsf). When installing the solenoid onto the valve,
torque the nut to 15 Nm (11 ft•lbsf.).

51000078 51000079
Fig. 50-34 - Install Fig. 50-35 - Install
Solenoid Valve Solenoid

50 - 7 57

008 914 20 BOMAG 1175

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Electric 2-Position Controls (Type S1)
Thoroughly clean external surfaces prior to removing
the control.

Remove the screws retaining the solenoid and sole-

noid adapter plate to the multi-function block with a 4
mm internal hex wrench. Remove the solenoid and
the solenoid adapter plate from the multi-function
block.
51000164 51000165
Fig. 50-36 - Remove Fig. 50-37 - Remove Remove the solenoid pin from the multi-function
S1 Control Screws Adapter Plate and block.
Solenoid
Install new O-rings onto the adapter plate and the
solenoid.

51000163
Fig. 50-38 - S1 Control Components

Install the solenoid pin into the hole in the multi-

function block.

51000086
Fig. 50-39 - Install S1 Control Solenoid Pin

Install the adapter plate with O-rings onto the multi-

function block.

Install the solenoid with O-ring onto the adapter plate.

Install the screws and torque to 6.4 Nm (4.7 ft•lbsf).

51000165 51000166
Fig. 50-40 - Install Fig. 50-41 - Torque
Adapter Plate and Control Solenoid
Solenoid Screws

58 50 - 8

1176 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic Proportional Control (Type HZ)
Thoroughly clean external surfaces prior to removal
of control.

Remove the four (4) screws retaining the valve hous-

ing to the end cap with an 8 mm internal hex wrench
(060, 080, and 110 units) or a 10 mm internal hex
wrench (160 and 250 units). Remove the valve hous-
ing. Remove the O-rings between the valve housing
and end cap, and the O-ring on the valve spool 51000080 51000081

sleeve. Fig. 50-42 - Remove Fig. 50-43 - Remove

HZ Control Housing HZ Control Housing
The plugs on the control housing may be removed Screws
with a 7/16" or 11/16" hex wrench. When reinstalling,
torque the 5/16" plugs to 9 Nm (7 ft•lbsf), and the 9/16"
plugs to 37 Nm (27 ft•lbsf)

The valve housing is equipped with filter screens in

51000016
Fig. 50-44 - HZ Control Components

the passages between the housing and the end cap.

Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the valve
housing or end cap.

Units with external servo pressure supply have a plug 51000082 51000083
installed in the end cap passage leading to the valve Fig. 50-45 - HZ Fig. 50-46 - End Cap
spool sleeve. This plug may be removed with a 2.5 Control Housing O-Rings Installed
mm internal hex wrench. When installing this plug, Screens
torque to 2 Nm (18 in•lbsf).

Install a new O-ring onto the valve spool sleeve in the

end cap. Install new O-rings onto the end cap.

Install the valve housing onto the multi-function block,

and install the screws.

Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080,

or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250
units. 51000081 51000084
Fig. 50-47 - Install HZ Fig. 50-48 - Torque
Control Housing HZ Control Valve
Housing Screws
50 - 9 59

008 914 20 BOMAG 1177

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic Proportional Control (Type HS)
Thoroughly clean external surfaces prior to removal
of control.

Remove the screws retaining the valve housing to the

multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.

51000087
Fig. 50-49 - Remove HS Control Housing
Screws

The plug on the control housing may be removed with

an 11/16" hex wrench. When reinstalling, torque the
plug to 37 Nm (27 ft•lbsf).

Install a new O-ring onto the valve housing.

51000019
Fig. 50-50 - HS Control Components

Install the valve housing onto the multi-function block,

and install the screws.

Torque the screws to 6.4 Nm (4.7 ft•lbsf).

51000088
Fig. 50-51 - Torque HS Control Housing
Screws

60 50 - 10

1178 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Hydraulic Proportional Control with
Maximum Angle Over-ride (Types H1•H2 or
K1•K2)
Thoroughly clean external surfaces prior to removing
the control.

The solenoid may be removed from the valve by

removing the nut with a 3/4" hex wrench.

51000089 51000090
Fig. 50-52 - Remove Fig. 50-53 - Remove
H1•H2 or K1•K2 Solenoid Valve
Control Solenoid
The solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.

Remove the screws retaining the valve housing to the

multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.

The plugs on the control housing may be removed

with an 11/16" hex wrench. When reinstalling, torque
the plugs to 37 Nm (27 ft•lbsf).
51000091
Fig. 50-54 - Remove Control Housing
Screws

Install new O-rings onto the valve housing.

Install the valve housing onto the multi-function block,

and install the screws. Torque the screws to 6.4 Nm
(4.7 ft•lbsf).

51000021
Fig. 50-55 - H1•H2 and K1•K2 Control
Components

When installing the solenoid valve into the valve

housing, the valve should be torqued to 20 Nm (15
ft•lbsf).

When installing the solenoid onto the valve, torque

the nut to 15 Nm (11 ft•lbsf.).

51000092 51000093
Fig. 50-56 - Install Fig. 50-57 - Install
Solenoid Valve Solenoid

50 - 11 61

008 914 20 BOMAG 1179

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Two Connection Hydraulic Proportional
Control (Type HP)
Thoroughly clean external surfaces prior to removal
of control.

Hold the control housing in position, and remove the

screws retaining the cover and control housing to the
multi-function block with a 4 mm internal hex wrench.
Remove the housing cover and gasket. Remove the
51000094 51000095 valve housing with shuttle valve assembly and pilot
Fig. 50-58 - Remove Fig. 50-59 - Remove piston from the multi-function block.
HP Control Housing Control Housing
Screws Remove the O-rings from the valve housing. Remove
the pilot piston and spring from the valve housing.

Remove the pilot piston pin from the multi-function

block.

Remove the inner shuttle spool plug from the valve

housing. (A 5 mm threaded hole is provided in the
inner plug for a puller screw.) Remove the shuttle
spool from the valve housing. Remove the outer
shuttle spool plug. Remove the O-rings from the
51000096 51000086 plugs.
Fig. 50-60 - Remove Fig. 50-61 - Remove
Shuttle Spool Plug Pilot Piston Pin

Install new O-rings on the shuttle spool plugs.

Install new O-rings on the valve housing and retain

with petroleum jelly.

51000024
Fig. 50-62 - HP Control Components

62 50 - 12

1180 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install the pilot piston pin in the multi-function block.

Install the outer (thin) shuttle piston plug with the large
chamfer toward the shuttle valve bore. Install the
shuttle spool into its bore and install the inner (thick)
plug with the large chamfer toward the shuttle valve
bore.

51000097 51000098
Fig. 50-63 - Pilot Fig. 50-64 - Install
Piston Pin Installed Shuttle Spool and
Plugs
Position the valve housing (with O-ring) on the multi-
function block.

Install the pilot piston into the housing and over the
pin. The end of the piston with the cross drilled hole
should engage the pin.

51000099 51000100
Fig. 50-65 - Install Fig. 50-66 - Install
Control Housing Pilot Piston

Install the small spring in the outer end of the pilot

piston.

Install the control cover and gasket. Align the control

assembly with the multi-function block and install the
four (4) screws.

Torque the control screws to 6.4 Nm (4.7 ft•lbsf).

51000101 51000102
Fig. 50-67 - Install Fig. 50-68 - Install
Spring Cover, Gasket, and
Screws

50 - 13 63

008 914 20 BOMAG 1181

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Two Connection Hydraulic Proportional
Control for “Dual Path” Vehicles (Type HC)
Bleed Valve

Loosen the seal lock nut on the bleed valve with a 10

mm hex wrench, and remove the valve with a 4 mm
internal hex wrench.

Install the bleed valve and torque to 3 Nm (27 in•lbsf).

51000103 51000175
Fig. 50-69 - Remove Fig. 50-70 - Install
HC Control Bleed HC Control Bleed
Valve Valve
Install the seal lock nut and torque to 19 Nm (14
ft•lbsf).

Servo Pressure Shuttle Valve

Remove the servo pressure shuttle plug with an

11⁄16" hex wrench. Remove the shuttle ball seat with
a 5 mm internal hex wrench and remove the ball.

51000176 51000104
Fig. 50-71 - Install Fig. 50-72 - Remove
HC Control Bleed Servo Pressure Ball
Valve Seal Nut Shuttle Valve
Install the servo pressure shuttle ball.

Install the shuttle ball seat and torque to 11 Nm (8

ft•lbsf). Install the shuttle passage plug and torque to
37 Nm (27 ft•lbsf).

51000123 51000174
Fig. 50-73 - Install Fig. 50-74 - Torque
Servo Pressure Servo Pressure
Shuttle Ball Valve Shuttle Ball Seat
Control Pressure Shuttle Valve

Remove the shuttle spool plugs with a 1/4" internal

hex wrench. Remove the control pressure shuttle
spool.

Install the control pressure shuttle spool.

Install the shuttle spool plugs and torque to 20 Nm (15

ft•lbsf).
51000105 51000122
Fig. 50-75 - Install Fig. 50-76 - Torque
Control Pressure Shuttle Spool Plugs
Shuttle Spool
64 50 - 14

1182 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Pilot Piston and Control Housing

Thoroughly clean external surfaces prior to disas-

sembly of control.

Remove the four (4) screws retaining the cover to the

control housing with a 4 mm internal hex wrench.

Remove the housing cover and gasket (with the

adjusting screw and seal lock nut).
51000177 51000106
Fig. 50-77 - Remove Fig. 50-78 - Remove
HC Control Housing HC Control Housing
Cover Screws Cover
Remove the control start adjustor spring seat and
spring from the pilot piston.

Remove the pilot piston from the control housing.

Remove the pilot piston pin seat and pin from the
control housing (or pilot piston).

Remove the control start spring from the control

housing.
51000107 51000108
Fig. 50-79 - Remove Fig. 50-80 - Remove
Adjustment Spring Pilot Piston Pin and
and Pilot Piston Control Start Spring
Remove the four (4) screws (and washers for 060,
080, and 110 units) retaining the control housing to
the end cap with an 8 mm internal hex wrench (060,
080, and 110 units) or a 10 mm internal hex wrench
(160 and 250 units).

Remove the control housing from the end cap. Re-

move the O-rings between the control housing and
the end cap, and the O-ring on the valve spool sleeve.
51000109 51000110
Fig. 50-81 - Remove Fig. 50-82 - Remove
HC Control Housing HC Control Housing
Screws

50 - 15 65

008 914 20 BOMAG 1183

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
The plugs on the control housing may be removed
with a 7/16" hex wrench or a 1/4" internal hex wrench.
When reinstalling, torque the 5/16" plugs to 9 Nm (7
ft•lbsf), and the 9/16" plugs to 20 Nm (15 ft•lbsf).

51000111
Fig. 50-83 - HC Control Components

The control housing is equipped with filter screens in

the passages between the housing and the end cap.
Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the valve
housing or end cap.
51000112 51000113
Fig. 50-84 - HC Fig. 50-85 - End Cap Install a new O-ring onto the valve spool sleeve in the
Control Housing O-Rings Installed for end cap. Install new O-rings onto the end cap.
Screens HC Control

Install the valve housing onto the end cap, and install
the screws (with flat washers on 060, 080, and 110
units).

Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080,

and 110 units, or to 110 Nm (81 ft•lbsf) for 160 and
250 units.

51000110 51000114
Fig. 50-86 - Install Fig. 50-87 - Torque
HC Control Housing HC Control Housing
Screws
66 50 - 16

1184 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install the control start spring into the control housing.

Install the pilot piston pin. The end of the pin must
engage the recess in the end of the control valve
spool.

51000115 51000116
Fig. 50-88 - Install Fig. 50-89 - Install
HC Control Start Pilot Piston Pin
Spring
Install the pilot piston pin seat.

Install the pilot piston into the housing and over the
spring and spring seat. The end of the piston with the
deeper bore and the cross drilled hole should engage
the start spring and pin seat.

51000117 51000118
Fig. 50-90 - Install Fig. 50-91 - Install
Pilot Piston Pin Seat HC Control Pilot
Piston
Install the adjustor spring in the outer end of the pilot
piston.

Install the adjustor spring seat.

51000119 51000120
Fig. 50-92 - Install Fig. 50-93 - Install
HC Control Start HC Control Start
Adjuster Spring Adjuster Spring Seat
Install the control cover and gasket (with adjusting
screw and seal lock nut).

Torque the control cover screws to 6.4 Nm (4.7

ft•lbsf).

51000106 51000121
Fig. 50-94 - Install Fig. 50-95 - Torque
HC Control Cover Control Cover
and Gasket Screws
50 - 17 67

008 914 20 BOMAG 1185

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Electrohydraulic Proportional Control
(Types EP and EQ)
Thoroughly clean external surfaces prior to removal
of control.

The Pressure Control Pilot (PCP) valve may be

removed from the control valve housing, as de-
scribed under the following heading.

51000124 51000125 Remove the screws retaining the control housing

Fig. 50-96 - Remove Fig. 50-97 - Remove cover and control valve housing to the multi-function
PCP Valve EP•EQ Control block with a 4 mm internal hex wrench. Remove the
Housing Screws housing cover and gasket.

Remove the valve housing with the pilot piston from

the multi-function block.

Remove the O-rings from the valve housing. Remove

the pilot piston and spring from the valve housing.

Remove the pilot piston pin from the multi-function

block.

51000126 51000086
Fig. 50-98 - Remove Fig. 50-99 - Remove
EP•EQ Control Pilot Piston Pin
Housing
Install new O-rings on the valve housing and retain
with petroleum jelly.

The plugs on the control housing may be removed

with a 1/4" internal hex wrench. When reinstalling,
torque the 9/16" plugs to 20 Nm (15 ft•lbsf).

51000027
Fig. 50-100 - EQ Control Components (EP
Similar)

68 50 - 18

1186 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install the pilot piston pin in the multi-function block.

Position the valve housing (with O-rings) on the multi-

function block.

51000097 51000127
Fig. 50-101 - Pilot Fig. 50-102 - Install
Piston Pin Installed Control Housing

Install the pilot piston into the housing and over the
pin. The end of the piston with the cross drilled hole
should engage the pin.

Install the small spring in the outer end of the pilot

piston.

51000128 51000129
Fig. 50-103 - Install Fig. 50-104 - Install
Pilot Piston Spring

Install the control cover and gasket. Align the control

assembly with the multi-function block and install the
four (4) screws.

Torque the control screws to 6.4 Nm (4.7 ft•lbsf).

Reinstall the PCP valve, if removed.

51000130 51000131
Fig. 50-105 - Torque Fig. 50-106 - Install
Cover, Gasket, and PCP Valve
Screws

50 - 19 69

008 914 20 BOMAG 1187

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Pressure Control Pilot (PCP) Valve for
Electrohydraulic Proportional Control
(Types EP and EQ)
Thoroughly clean external surfaces of control.

Using a 4 mm internal hex wrench, remove the four

(4) screws and remove the PCP valve.

Check surfaces for nicks or damage. Clean internal

51000132 51000133 screens.
Fig. 50-107 - Remove Fig. 50-108 - PCP
PCP Valve Screws Valve Components

Install new O-rings on the PCP housing and retain

with petroleum jelly. Position the PCP on the control
valve housing and install the screws.

Torque the screws to 5.4 Nm (48 in•lbsf).

51000124 51000131
Fig. 50-109 - Install Fig. 50-110 - Torque
PCP onto Control PCP Valve Screws

70 50 - 20

1188 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Multi-function Block
Removal and Installation
Remove the external control assembly as described
in the instructions for the specific control.
Remove the four (4) screws (and washers for 060,
080, and 110 units) retaining the multi-function block
to the end cap with an 8 mm internal hex wrench (060,
080, and 110 units) or a 10 mm internal hex wrench
51000087 51000134
(160 and 250 units).
Fig. 50-111 - Remove Fig. 50-112 - Remove
Remove the multi-function block from the end cap. External Control (HS Multi-function Block
Remove the O-rings between the multi-function block Shown) Screws
and the end cap, and the O-ring on the valve spool
sleeve.
The multi-function block is equipped with filter screens
in the passages between the block and the end cap.
Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the multi- 51000135 51000136

function block or end cap. Fig. 50-113 - Remove Fig. 50-114 - Multi-
Multi-function Block function Block
Units with external servo pressure supply have a plug
Screens
installed in the end cap passage leading to the valve
spool sleeve. This plug may be removed with a 2.5
mm internal hex wrench. When installing this plug,
torque to 2 Nm (18 in•lbsf).
Install a new O-ring onto the valve spool sleeve in the
end cap.
Install new O-rings onto the end cap.
Install the multi-function block onto the end cap, and
install the screws. 51000083 51000135

Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080, Fig. 50-115 - End Fig. 50-116 - Install
or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250 Cap O-Rings Multi-function Block
units. Installed
Reinstall the external control assembly as described
in the instructions for the specific control.

51000137 51000088
Fig. 50-117 - Torque Fig. 50-118 - Install
Multi-function Block External Control (HS
Screws Shown)
50 - 21 71

008 914 20 BOMAG 1189

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Servo Pressure Supply Shuttle Spool

Remove the servo pressure supply shuttle spool plug

from the multi-function valve with a 9/16" hex wrench.

NOTE: If a pressure compensator valve block is

installed, the opposite end of the shuttle
spool bore in the multi-function valve is
plugged with an internal hex head plug lo-
cated under the valve block. If a pressure
51000138 51000139
Fig. 50-119 - Remove Fig. 50-120 - Remove compensator valve block is not installed, the
opposite end of the shuttle spool bore is
Servo Pressure Servo Pressure
plugged with a hex head plug.
Supply Spool Plug Supply Shuttle Spool
Remove the servo pressure supply shuttle spool from
the multi-function valve block.

Inspect the shuttle spool for burrs or scoring. The

spool must slide free in its bore. The shuttle ball in the
spool must be free to move.

51000030
Fig. 50-121 - Multi-function Block with
Servo Pressure Supply Shuttle Spool

Install the shuttle spool into the multi-function block.

Install the hex head plug into the multi-function valve

and torque to 37 Nm (27 ft•lbsf).

NOTE: If an internal hex head plug was removed

from the opposite end of the shuttle spool
bore, torque it to 20 Nm (15 ft•lbsf).

51000139 51000140
Fig. 50-122 - Install Fig. 50-123 - Torque
Servo Pressure Servo Pressure
Supply Shuttle Spool Supply Spool Plug

72 50 - 22

1190 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Blocking Plate for Multi-function Block Without
PCOR

The blocking plate may be removed by removing the

four (4) screws with a 5 mm internal hex wrench.
Remove the O-rings from the plate.

Install new O-rings on the blocking plate and retain

with petroleum jelly. Install the plate on the multi-
function block and install the screws. Torque the
51000170 51000171
screws to 11 Nm (8 ft•lbsf). Fig. 50-124 - Remove Fig. 50-125 - Torque
Blocking Plate (Less Blocking Plate
PCOR) Screws (Less PCOR)
Pressure Compensator Valve for Pressure
Compensator Over-Ride (PCOR) and Pressure
Compensator Regulator (Type PC)

Loosen the adjusting screw lock nut with a 1-1/16"

hex wrench. Remove the adjusting screw from the
valve block with a large screwdriver.

Remove the pressure compensator valve spring and

the spool assembly from the block.
51000142 51000143
Fig. 50-126 - Remove Fig. 50-127 - Remove
PCOR•PC Adjustor PCOR•PC Spring
and Spool Valve
Remove the valve block plug with a 1" hex wrench.

Remove the four (4) screws retaining the valve block

to the multi-function block with a 5 mm internal hex
wrench. Remove the valve block and O-rings.

51000144 51000145
Fig. 50-128 - Remove Fig. 50-129 - Remove
PCOR•PC Plug PCOR•PC Valve
Block
Install new O-rings on the pressure compensator
valve block and retain with petroleum jelly. Install a
new O-ring on the adjusting screw.

The plugs on the valve block may be removed with a

7⁄16" hex wrench. When reinstalling, torque the 5⁄16"
plugs to 9 Nm (7 ft•lbsf).

51000146
Fig. 50-130 - Pressure Compensator Valve
Block Components

50 - 23 73

008 914 20 BOMAG 1191

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Install the valve block on the multi-function block and
install the screws. Torque the screws to 11 Nm (8
ft•lbsf).

Install the valve block plug and torque to 54 Nm (40

ft•lbsf).

51000147 51000148
Fig. 50-131 - Install Fig. 50-132 - Install
PCOR•PC Valve PCOR•PC Valve Plug
Block
Install the pressure compensator spool assembly
and the valve spring.

Install the adjusting screw and lock nut. Perform the

PCOR or PC regulator pressure adjustment as de-
scribed under “Component Adjustment."

51000143 51000142
Fig. 50-133 - Install Fig. 50-134 - Install
PCOR•PC Spring PCOR•PC Adjusting
and Spool Valve Screw
PCOR and PC Regulator Orifices

To gain access to the PCOR or PC regulator orifices,

remove the three (3) plugs located between the
defeat spool stop plugs on the multi-function block,
using a 7/16" hex wrench. Remove the PCOR brake
pressure defeat spool (if installed). Remove the ori-
fice plug(s) and plain plug(s) with a 2.5 mm internal
hex wrench.
51000149
Fig. 50-135 - PCOR and PC Regulator Refer to the appropriate Service Parts Manual for
information on orifice locations and sizes.
Orifices
Install the orifice plug(s) and plain plug(s), and torque
to 4 Nm (35 in•lbsf). Install the outer plugs and torque
to 6 Nm (4 ft•lbsf). Reinstall the PCOR defeat spool (if
removed).

Additional orifices are installed in the passages under

the pressure compensator valve block.

51000172
Fig. 50-136 - PCOR and PC Regulator
Orifices

74 50 - 24

1192 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
PCOR Brake Pressure Defeat Spool

Remove the PCOR defeat spool bore plugs or fittings

with a hex wrench.

Remove the PCOR defeat spool stop plugs with a

7⁄16" hex wrench. Remove the defeat spool.

NOTE: The defeat spool may be removed from

either end of its bore in the multi-function block.
51000150 51000151
Fig. 50-137 - Remove Fig. 50-138 - Remove
PCOR Defeat Spool PCOR Defeat Spool
Plug or Fitting Stop Plug
Inspect the defeat spool for burrs or roughness. The
spool must slide freely in its bore. Inspect the pins in
the stop plugs for damage.

51000032
Fig. 50-139 - Multi-function Block With
PCOR Defeat Spool Components

Install the PCOR defeat spool into its bore in the multi-
function block.

Install the spool stop plugs into the multi-function

block. Torque the stop plugs to 6 Nm (4 ft•lbsf).

Install the defeat spool bore plugs or fittings and

torque to 27 Nm (20 ft•lbsf).

51000152 51000153
Fig. 50-140 - Install Fig. 50-141 - Install
PCOR Defeat Spool PCOR Defeat Spool
Stop Plug

50 - 25 75

008 914 20 BOMAG 1193

20.3 Axle drive motor

saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Pressure Compensator Regulator (Type
PC)
The PC regulator utilizes the multi-function block and
pressure compensator valve to control the motor
displacement.
Service procedures for these components are in-
cluded in the “Multi-function Block” section of this
manual.
51000035
Fig. 50-142 - PC Regulator Components

A valve sleeve bore plug is installed in the motor end

cap in place of the valve spool sleeve. Remove the
plug from the valve sleeve bore in the end cap. (An 8
mm threaded hole is provided in the plug for a puller
screw.) Remove the O-ring from the plug.
A single servo drain orifice is installed in the valve
sleeve bore plug. This orifice limits oil flow from the
maximum displacement end of the servo piston to the
motor case.
51000169 51000173
Fig. 50-143 - Remove Fig. 50-144 - Servo Install a new O-ring on the valve sleeve bore plug.
Valve Sleeve Bore Drain Orifice (T7) Install the bore plug into the end cap.
Plug
The special plug and seal washer on the end cap
opposite the multi-function block may be removed
with a 13 mm hex wrench. When installing, torque this
plug to 20 Nm (15 ft•lbsf).

76 50 - 26

1194 BOMAG 008 914 20

Axle drive motor 20.3
saue
Bent Axis Variable Displacement Motors Series 51
Minor Repair and Replacement - Variable Motor (Continued)
Control Orifices
Orifices are installed in the motor end cap to regulate
oil flow to the servo control valve and the servo piston.

To gain access to these orifice plugs, remove the

three (3) plugs located on the motor end cap nearest
the multi-function block or control, using a 7⁄16" or
9⁄16" hex wrench. Remove the orifice plugs (plain
plugs for N2 control) with a 3 mm internal hex wrench.
51000154 51000155
Install the orifice plugs, and torque to 4 Nm (35 Fig. 50-145 - Servo Fig. 50-146 - Servo
in•lbsf). Torque the 5⁄16" outer plugs to 9 Nm (7 Pressure Supply Orifice for Maximum
ft•lbsf), and the 9⁄16" outer plug to 37 Nm (27 ft•lbsf). Orifice (T1) Displacement (T2)
Orifices are also installed in the servo control valve
sleeve to control oil flow from the servo piston to the
motor case.

51000156 51000157
Fig. 50-147 - Servo Fig. 50-148 - Servo
Orifice for Minimum Drain Orifices (T7
Displacement (T3) and T8)
Plug / Fitting Torques
If any plugs or fittings are removed from the unit
during servicing, they should be torqued as indicated
in the accompanying table.

Item Torque
Pressure Gauge Ports 37 Nm
(9/16—18 O-Ring Hex) (27 ft•lbsf)
Construction Plugs 20 Nm
(9/16—18 O-Ring Int. Hex) (15 ft•lbsf)
Construction Plugs 9 Nm
(5/16—24 O-Ring) (7 ft•lbsf)
Screw Plugs 4 Nm
(M6 Int. Hex) (35 in•lbsf)

50 - 27 77

008 914 20 BOMAG 1195

1196
DO NOT REMOVE UNTIL CONTROL VALVE AND
20.3

SPRINGS ARE REMOVED!

Remove as an assembly to preserve adjustment.
INSTALL BEFORE INSTALLING SPRINGS AND
CONTROL VALVE!
J70 For Proportional Controls
J60 [Except HC]
J40 (060 — 110 Frame Sizes)
For Proportional Controls
Items T1, T2, and T3: [Except HC]
3 mm internal hex wrench; (160 — 250 Frame Sizes)
J50
Torque to 5 Nm (44 lbsf•in)
4 mm internal S20
hex wrench T2
saue

S10

S20
J30
J10
S10 S70

BOMAG
J30
J10
T1 S70
T3
Remove Item T1 BEFORE removing Item F32! T7
Install Item T1 AFTER installing Item F32! F32
J30
Install O-ring J10 F33
a
Genuine

on adjustor screw J20 T8

Service Parts

Minor Repair Instructions

13 mm hex wrench
Torque to 20 Nm Items T7 and T8:
(15 lbsf•ft) For 2-Position Controls 2.5 mm int. hex wrench
4-Way Valve and Feedback Springs

10 mm hex wrench [Except N2] Torque to 2 Nm (18 lbsf•in)

Torque to 9 Nm (6.6 lbsf•ft) 5 mm threaded holes
after adjustment for puller screws
FOR 2-POSITION CONTROLS,
Sheet 1 of 2

Install O-rings
DO NOT DISTURB ADJUSTMENT! on valve sleeve
Series 51 MV

008 914 20
Axle drive motor
DO NOT REMOVE UNTIL CONTROL VALVE AND

008 914 20
SPRINGS ARE REMOVED!
Remove as an assembly to preserve adjustment (060 — 110).
INSTALL BEFORE INSTALLING SPRINGS AND
CONTROL VALVE!
Axle drive motor

S50
S30
For 060 — 110 Frame Sizes
S60
Items T1, T2, and T3: For 160 — 250 Frame Sizes
S40 3 mm internal hex wrench;
Torque to 5 Nm (44 lbsf•in)
4 mm internal
hex wrench T2 S20
saue

S11T
S10
S20 S10T

BOMAG
S70
S11T
T1 S10
T3 S10T
S70
Remove Item T1 BEFORE removing Item F32!
T7
Install Item T1 AFTER installing Item F32!
F32
Install O-ring
a
Genuine

on adjustor screw F33

Service Parts

Minor Repair Instructions

T8
13 mm hex wrench
Torque to 20 Nm Items T7 and T8:
(15 lbsf•ft) 2.5 mm int. hex wrench
Torque to 2 Nm (18 lbsf•in)
10 mm hex wrench
Torque to 9 Nm (6.6 lbsf•ft) 5 mm threaded holes
Sheet 2

after adjustment. for puller screws

Install O-rings
4-Way Valve and Feedback Springs - HC Control

on valve sleeve
Series 51 MV

79
20.3

1197
20.3 Axle drive motor

saue
Hydraulic Power Systems
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saue 2800 East 13th Street • Ames IA 50010 • U.S.A.
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SM-VMV51E • 11/97 • 300 043A
BLN-10043 • November 1997

1198 BOMAG 008 914 20

20.4 Axle

008 914 20 BOMAG 1199

20.4 Axle

1200 BOMAG 008 914 20

Axle 20.4

008 914 20 BOMAG 1201

20.4 Axle

1202 BOMAG 008 914 20

Axle 20.4

008 914 20 BOMAG

1 1203
20.4 Axle

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 responsabiliteÂ pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.

1204 BOMAG
2 008 914 20
Axle 20.4

INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX

INTRODUCTION ..........................................................5 DIFFERENTIAL UNIT

GB MAINTENANCE AND LUBRICANTS . Removal and disassembly ....................................................44
. Definition of viewpoints............................................7 . Assembly and installation .....................................................54
. Data plate ..............................................................................7 REDUCTION GEAR AND BEVEL PINION
. Maintenance points ................................................................7 . Disassembly.........................................................................68
. Maintenance intervals.............................................................8 . Installation and adjustment ...................................................74
. Adjustment and checks ..........................................................8
. Conversion tables...................................................................9 SPECIAL TOOLS ......................................................................82
. Tightening torques .................................................................9
. Screw-locking, sealing, and lubricating materials ...................10
NOTES ON SAFETY PRECAUTIONS ........................................13
CHECKING WEAR AND REPLACING THE BRAKING DISKS
. Disassembling the braking units............................................14
. Assembling the braking units ................................................20
. Mechanical and manual release of the axle ...........................28
PLANETARY REDUCTION AND AXLE SHAFT
. Disassembly.........................................................................30
. Assembly .............................................................................38

INTRODUZIONE .......................................................5 GRUPPO DIFFERENZIALE

ITA . Rimozione e smontaggio.......................................................44
MANUTENZIONE E LUBRIFICANTI
. Definizione viste ..................................................7 . Assemblaggio ed installazione ..............................................54
. Targa matricola ......................................................................7 RIDUTTORE E PIGNONE CONICO
. Punti di manutenzione ............................................................7 . Smontaggio..........................................................................68
. Intervalli di manutenzione .......................................................8 . Installazione e registrazione..................................................74
. Registrazione e controlli .........................................................8 ATTREZZI SPECIALI.................................................................82
. Tabelle di conversione............................................................9
. Coppie di serraggio ................................................................9
. Materiali per bloccaggio viti, tenuta e lubrificazione................10
NOTE RIGUARDANTI LA SICUREZZA ......................................13
CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO
. Smontaggio gruppi di frenatura .............................................14
. Assemblaggio dei gruppi di frenatura ....................................20
. Sbloccaggio meccanico manuale dell'assale..........................28
RIDUTTORE EPICICLOIDALE E SEMIASSE
. Smontaggio..........................................................................30
. Assemblaggio ......................................................................38

VORAUSSETZUNG .................................................5 DIFFERENTIAL

D . Abmontieren und zerlegen ....................................................44
WARTUNG UND SCHMIERSTOFFE
. Definition der Ansichten......................................7 . Montieren und installieren.....................................................54
. Kennummernschild.................................................................7 REDUZIERER UND KEGELRAD
. Wartungsstellen .....................................................................7 . Abmontieren ........................................................................68
. Wartungsintervalle..................................................................8 . Installieren und einstellen .....................................................74
. Einstellungen und Kontrollen ..................................................8 SONDERWERZZEUGE ..............................................................82
. Umrechnungstabellen.............................................................9
. Anziehdrehmomente...............................................................9
. Material zur Blockierung von Schrauben und
fuÈr Dichtungen und Schmiermittel .........................................10
BEMERKUNGEN ZUR SICHERHEIT...........................................13
VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN
AUSWECHSELN
. Bremsaggregate abmontieren ...............................................14
. Bremsaggregate montieren ...................................................20
. Achse mechanisch manuell entsichern ..................................28
PLANETENGETRIEBE UND HALBACHSE
. Abmontieren ........................................................................30
. Montieren ............................................................................38

008 914 20 BOMAG

3 1205
20.4 Axle
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX

PROLOGO................................................................ 5 GRUPO DIFERENCIAL

ESP MANTENIMIENTO Y LUBRICANTES . Remocion y desmontaje ....................................................... 44
. Definicion vistas................................................... 7 . Montaje e instalacion ........................................................... 54
. Matricula ............................................................................... 7 REDUCTOR Y PINÄON CONICO
. Puntos de manutencion.......................................................... 7 . Remocion ............................................................................ 68
. Intervalos de manutencioÁn...................................................... 8 . Instalacion y ajuste .............................................................. 74
. Ajuste y controles .................................................................. 8 HERRAMIENTAS ESPECIALES................................................. 82
. Tablas de conversion ............................................................. 9
. Pares de torsion .................................................................... 9
. Materiales para el bloqueo, estanqueidad y lubricacion ......... 10
NORMAS CONCERNIENTES A LA SEGURIDAD ....................... 13
CONTROL DEL DESGASTE Y SUSTITUCION DE LOS
DISCOS DEL FRENO
. Montaje de los grupos de frenado......................................... 14
. Desmontaje de los grupos de frenado................................... 20
. Desbloqueo manual de los axal ............................................ 28
REDUCTOR EPICICLOIDAL Y SEMIEJES
. Desmontaje ......................................................................... 30
. Montaje ............................................................................... 38

INTRODUCTION ....................................................... 5 GROUPE DIFFERENTIEL

F ENTRETIEN ET LUBRIFIANTS . Depose et demontage .......................................................... 44
. DeÂfinition vues ..................................................... 7 . Assemblage et installation .................................................... 54
. Plaque d'immatriculation ........................................................ 7 REDUCTEUR ET PIGNON CONIQUE
. Points d'entretien................................................................... 7 . Depose................................................................................ 68
. Intervalle de service ............................................................... 8 . Installation et reglage ........................................................... 74
. Reglages et controles............................................................. 8 OUTILS SPECIAL ..................................................................... 82
. Tableaux de conversion ......................................................... 9
. Couples de serrage................................................................ 9
. MateÂriaux pour le blocage vis, eÂtancheÂiteÂ et lubrification........ 10
NOTES EN MATIERE DE SECURITE......................................... 13
CONTROLE D'USURE ET SUBSTITUTION DES
DISQUES DE FREINAGE
. Desassemblage des groupes de freinage .............................. 14
. Assemblage des groupes de freinage ................................... 20
. Deblocage mecanique manuel de l'essieu............................. 28
REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU
. Demontage.......................................................................... 30
. Assemblage......................................................................... 38

1206 BOMAG
4 008 914 20
Axle 20.4
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
008 914 20 BOMAG
5 1207
20.4 Axle
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION

der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos de
Spiele, Vorspannungen und Drehmomente strengstens ein- las herramientas especificas necesarias para la ejecucioÂn de las
gehalten werden. intervenciones de mantenimiento figuran al final del manual; los
recambios se pueden pedir al fabricante de la maÂquina o
È LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern directamente al Service Center o a Distribuidores autorizados de
GU DANA ITALIA S.p.A..
die Einheiten gehoÈren. Der Einfachheit halber sind die
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer

= ab Kennummer Le rendement et la continuiteÂ des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapiditeÂ d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂcessiteÂ de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
DANA ITALIA S.p.A. bezogen werden. toutes les informations et preÂcautions neÂcessaires pour un
deÂmontage correct et les veÂrifications et assemblage de
chaque composant. En ce qui concerne le deÂplacement du
pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels
El rendimiento y la duracioÂn de los oÂrganos mecaÂnicos
fournis par le constructeur du veÂhicule. En deÂcrivant les
ESP depende, ademaÂs que del constante y correcto opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mantenimiento, tambieÂn de la intervencioÂn inmediata enleveÂ du veÂhicule.
en caso de averõÂas o anomalõÂas.
Al proponer este manual, ha sido considerada la suposicioÂn de una IMPORTANT: Pour faciliter le travail en sauvegardant en
revisioÂn general del grupo, pero es el mecaÂnico quien tiene que meÃme temps les surfaces usineÂes et la seÂcuriteÂ des opeÂra-
valorar la necesidad de montar cada uno de los componentes en teurs, il est preÂconiseÂ d'utiliser des installations approprieÂes
caso de reparacioÂn. El manual es una guõÂa raÂpida y segura que telles que des eÂtais ou banc de support, maillets en plastique
permite intervenciones precisas por medio de fotografõÂas y de ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
planos que muestran las distintas fases de las operaciones. A
continuacioÂn figuran todas las informaciones y advertencias Avant de proceÂder au deÂmontage des parties et vidanger
necesarias para ejecutar un montaje correcto, para las comproba- l'huile, il vaut mieux nettoyer soigneusement le pont, en
ciones y el montaje de cada uno de los componentes. Para enlevant incrustations et blocs de gras.
remover el puente diferencial del vehõÂculo hay que consultar los
manuales de los fabricantes del vehõÂculo. En la descripcioÂn de las PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
operaciones siguientes se supone que el puente ya ha sido sacado doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
del vahõÂculo. approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
IMPORTANTE: Para facilitar el trabajo salvaguardando al mismo particulier, de toutes les parties en mouvement (paliers,
tiempo las superficies mecanizadas y la seguridad de los
operadores, se aconseja que se usen equipos y herramientas engrenages, couple conique, arbres) et l'eÂtancheÂiteÂ des
adecuados como caballetes y bancos de soporte, martillos de bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
plaÂstico o de cobre, palancas adecuadas, extractores y llaves sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
especõÂficas. substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
Antes de desmontar las partes y descargar el aceite, es effectue une reÂvision ou une reÂparation des composants. Au
conveniente que se haga una limpieza minuciosa del puente moment du montage, les bagues d'eÂtancheÂiteÂ doivent eÃtre
sacando las incrustaciones y acumulaciones de grasa. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
conique, la substitution de l'un de ses engrenages comporte
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados eÂgalement la substitution de l'autre. En phase de montage, il
tienen que ser limpiados minuciosamente con productos adecua-
dos y restaurados o sustituidos en el caso de que presenten danÄos, faut respecter scrupuleusement les jeux, les preÂcharges et les
desgaste, rajaduras, agarrotamientos, etc. En particular, compro- couples prescrits.
bar la integridad de todas las partes en movimiento (cojinetes,
engranajes, par coÂnico, ejes) y de estanqueidad (anillos OR, VALIDITE: Le manuel fournit la validiteÂ des groupes sous
detenedor de aceite) sujetas a mayores solicitaciones y desgaste. forme de matricule. Pour une meilleure interpreÂtation, les
Se aconseja, de todas formas, que se sustituyan los oÂrganos de validiteÂs sont indiqueÂes comme:
estanqueidad cada vez que se ejecute la revisioÂn o reparacioÂn de
los componentes. = jusqu'aÁ l'immatriculation
Al volver a montar, los segmentos de compresioÂn tienen que estar
lubricados en los bordes de estanqueidad. En el caso del par = aÁ partir de l'immatriculation et apreÁs
coÂnico, la sustitucioÂn de uno de sus engranajes comporta tambieÂn
la sustitucioÂn del otro. Al montar hay que tener en cuenta Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
escrupulosamente los juegos, las precargas y los pares descriptos.
deÂmontage et d'assemblage sont pareilles dans toutes les
VALIDEZ: El manual suministra la validez de los grupos en forma versions.
de matrõÂcula. Para poder tener una interpretacioÂn correcta, la
validez estaÂ indicada: INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
Les dessins des installations speÂcifiques neÂcessaires pour
= hasta la matrõÂcula effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
= desde la matrõÂcula en adelante constructeur de la machine ou directement aux Centres de
Services, ou Distributeurs agreÂeÂs de la SocieÂteÂ DANA ITALIA
S.p.A..

1208 BOMAG
6 008 914 20
Axle
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
20.4
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS

DEFINITION OF VIEWPOINTS - DEFINIZIONE VISTE - DEFINITION DER ANSICHTEN - DEFINICION VISTAS - DEÂFINITION VUES

LEFT SIDE RIGHT SIDE

LATO SINISTRO LATO DESTRO
LINKE SEITE RECHTE SEITE
LADO IZQUIERDO LADO DERECHO
COTE GAUCHE COTE DROITE

D1240138

DATA PLATE - TARGA MATRICOLA - KENNUMMERNSCHILD - MATRICULA - PLAQUE D'IMMATRICULATION

Type and model unit - modification index

1
Tipo e modello gruppo - indice di modifica
Typ und Modelleles Antriebes - AÈ nderungsverzeichnis
Tipo y modelo grupo - indice de modificacion
Type et modeÂle de ensemble - tableau des modifications

1 2 Serial number

2
Numero di serie
Seriennummer
3 NuÂmero de serie
Numero de serie
MFG. BY CLARK-HURTH COMPONENTS S.P.A. Lubricant

3
38062 Arco (Trento) Lubrificante
Schmieroel
MADE IN ITALY Lubricante
Lubrificant
D1240011

MAINTENANCE POINTS - PUNTI DI MANUTENZIONE - WARTUNGSSTELLEN - PUNTOS DE MANUTENCION - POINTS D'ENTRETIEN

3 1 1 1 3

2 2 2 2
2

1
Oil filling plug - Tappo di carico
EinfuÈllstopfen - Tapon de carga
Bouchon de ravitaillement

2
Oil draining plug - Tappo di scarico
1 3 Ablasstopfen - Tapon de descarga
Bouchon de vidange

2
3
Check level plug - Tappo controllo livello
È lpegelkontrolle -
Stopfen zur O
Tapon de contrl de nivel - Jauge de niveau
D1240139

008 914 20 BOMAG

7 1209
20.4 Axle

MAINTENANCE INTERVALS - INTERVALLI DI MANUTENZIONE - WARTUNGSINTERVALLE - INTERVALOS DE MANUTENCIOÁN - INTERVALLE DE SERVICE

OPERATION - OPERAZIONE - FREQUENCY - PERIODICITAÁ

LUBRICANTS - LUBRIFICANTI - SCHMIERSTOFFE -
ARBEITSVORGANG - - ZEITABSTAND -
LUBRICANTES - LUBRIFIANTS
OPERACION - OPERATION FRECUENCIA - PERIODICITE
Differential monthly
Differenziale mensile
Im differential monatlich . SAE85W90 (API GL4 - MIL L-2105)
. Check levels: Diferencial cada mes With additives for oil-bath brakes
. Controllo livelli: Differentiel mensuel Con additivi per freni a bagno d'olio
. È
Olstandkontrolle: Mit Zusatzmittel fuÈr Bremsen in OÈ lbad
. Control niveles: Planetary reduction every 200 hours
Con aditivos para frenos de banÄo de aceite
. ControÃle niveaux: Riduzione epicicloidale ogni 200 ore
Avec adjuvants pour freins en bain d'huile
Planetengetrieb alle 200 Std.
ReduccioÂn epicicloidal cada 200 horas . SAE85W90 (API GL5 - MIL 2105-B)
Reduction epicycloidale toutes les 200 heures With additives for oil-bath brakes, for units pre-
Differential every 800 hours ] senting hypoid crown wheel and pinion and /or
Differenziale ogni 800 ore self-locking differential gear
Im differential alle 800 Std. Per esecuzioni con coppia conica ipoide e/o con
Diferencial cada 800 horas differenziale autobloccante, con additivi per freni
Differentiel toutes les 800 heures a bagno d'olio
Bei AusfuÈhrungen mit Kegel- und Telleradpaar
. Oil change: Planetary reduction every 1000 hours ]
und/oder Selbstsperrdifferential, mit Zusatzmit-
. Cambio olio: Riduzione epicicloidale ogni 1000 ore È lbad
È lwechsel: teln fuÈr Bremsen in O
. O Planetengetrieb alle 1000 Std.
Para ejecuciones con par coÂnico hipoide y/o con
. Cambio aceite: ReduccioÂn epicicloidal cada 1000 horas
diferencial autobloqueante con aditivos para fre-
. Vidange huile: Reduction epicycloidale toutes les 1000 heures
nos de banÄo de aceite.
Self-locking differential gear every 700 hours ] r Pour exeÂcutions avec couple conique hypoõÈde et/
Differenziale autobloccante ogni 700 ore ou diffeÂrentiel autobloquant, avec adjuvants pour
Selbstsperrdifferential alle 700 Std. freins en bain d'huile
Diferencial autobloqueante cada 700 horas
Differentiel autobloquant toutes les 700 heures
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100 horas
de trabajo - Initialement apreÁs 100 heures de travail
r When it starts sounding noisy - Anche ai primi cenni di rumorositaÁ - Auch falls ungewoÈhnliche GeraÈusche zu bemerken sind - TambieÂn al primer
indicio de ruido - MeÃme aux premiers signaux de bruit
OPERATION - OPERAZIONE - MEMBER - ORGANO - CONDITIONS - CONDIZIONI - FREQUENCY - PERIODICITAÁ - LUBRICANTS - LUBRIFICANTI -
ARBEITSVORGANG - ELEMENT - BEDINGUNG - ZEITABSTAND - SCHMIERSTOFFE -
OPERACION - OPERATION ORGANO - ORGANE CONDICIONES - CONDITIONS FRECUENCIA - PERIODICITE LUBRICANTES - LUBRIFIANTS
Normal work monthly
Lavori normali mensile
Normale Arbeit monatlich
Greasing Articulations Trabajos normales cada mes
Ingrassaggio Snodi TaÃches ordinaires mensuel
Schmieren Gelenk MOLIKOTE
Engrase RoÂtula Awkward work Weekly
Graissage Articulations Lavori gravosi Settimanale
Schwere Arbeit WoÈchentlich
Trabajos pesados Semanal
TaÃches extraordinaires Hebdomadaire

ADJUSTMENT AND CHECKS - REGISTRAZIONE E CONTROLLI - EINSTELLUNGEN UND KONTROLLEN - AJUSTE Y CONTROLES - REGLAGES ET CONTROLES

UNIT - GRUPPO - OPERATION - OPERAZIONE FREQUENCY - PERIODICITAÁ - SERVICE BRAKE CIRCUIT - CIRCUITO COMANDO FRENI -
AGGREGAT - ARBEITSVORGANG - ZEITABSTAND - BREMSKREISLAUF - CIRCUITO MANDOS FRENOS -
GRUPO - GROUPE OPERACION - OPERATION FRECUENCIA - PERIODICITE CIRCUIT DE COMMANDE DES FREINS
Negative brake Adjustment every 1000 hours ]
Freno negativo Registrazione ogni 1000 ore Only for mineral oil use e.g. ATF Dexron II. Make sure
Federspeicherbremse Einstellen alle 1000 Std. that master cylinder seals are suitable for mineral oil.
Freno negativo Ajuste cada 1000 horas Usare esclusivamente olio minerale ATF Dexron II. Ac-
Frein neÂgatif ReÂglage toutes les 1000 hours certarsi che le guarnizioni del cilindro master siano
adatte a questo olio.
Service brake Adjustment every 500 hours È l verwenden, z.B.: ATF Dexron II.
Nur mineralisches O
Freni di servizio Registrazione ogni 500 ore
Achtung: Dichtringe des Hauptbremszylinders muÈs-
Hilfsbremse Einstellen alle 500 Std. È l geeignet sein.
sen fuÈr dieses O
Frenos de ejercicio Ajuste cada 500 horas
Usar exclusivamente aceite mineral ATF Dexron II.
Freins de service ReÂglage toutes les 500 hours
Asegurarse de que las juntas del cilindro principal
Wheel nuts Tightening every 200 hours son adecuadas para este aceite.
Dadi ruota Serraggio - ogni 200 ore Utiliser exclusivement huile mineÂrale ATF Dexron II.
Radmuttern Festziehen alle 200 Std. VeÂrifier que les joints du maõÃtre-cylindre, soien compa-
Tuercas rueda Apriete cada 200 horas tibles avec cette huile.
Ecrous de roue Serrage toutes les 200 hours
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100
horas de trabajo - Initialement apreÁs 100 heures de travail
1210 BOMAG
8 008 914 20
Axle 20.4

CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN

TABLAS DE CONVERSION - TABLEAUX DE CONVERSION

Units of pressure - UnitaÁ di pressione - Druckeinheiten

Unidad de presioÂn - UniteÂs de pression: 1 Atm%1 bar%105 PA%14.4 PSi

Units of weight - UnitaÁ di peso - Gewichtseinheiten Units of torque - UnitaÁ di coppia - Drehmomenteinheiten
Unidad de peso - UniteÂs de poids Unidad de par - UniteÂs de couple
N daN kN kg lbs Nm daNm kNm kgm lb-in
1N 1 0,1 0,001 0,102 0,225 1Nm 1 0,1 0,001 0,102 8,854
1daN 10 1 0,01 1,02 2,25 1daNm 10 1 0,01 1,02 88,54
1kN 1000 100 1 102 225 1kNm 1000 100 1 102 8854
1kg 9,81 0,981 0,00981 1 2,205 1kgm 9,81 0,981 0,00981 1 86,8
1lb-in 0,1129 0,01129 0,0001129 0,01152 1

TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE

PARES DE TORSION - COUPLES DE SERRAGE

Unit - UnitaÁ di misura - Meûeinheiten - Unidad de medida - UniteÂs de mesure: Nm

TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS
SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS 8.8 10.9 12.9
TAMAN Ä O TORNILLO
MESURE VIS Normali Normali Normali Normali Normali Normali
+ Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270
M6 x 1 9,5-10,5 10,5-11,5 14,3-15,7 15,2-16,8 16,2-17,8 18,1-20,0
COARSE PITCH - PASSO GROSSO - GROûER
SCHRITT - PASO GRUESO - GROS PAS

M8 x 1,25 23,8-26,2 25,6-28,4 34,2-37,8 36,7-40,5 39,0-43,0 43,7-48,3

M10 x 1,5 48-53 52-58 68-75 73-81 80-88 88-97
M12 x 1,75 82-91 90-100 116-128 126-139 139-153 152-168
M14 x 2 129-143 143-158 182-202 200-221 221-244 238-263
M16 x 2 200-221 219-242 283-312 309-341 337-373 371-410
M18 x 2,5 276-305 299-331 390-431 428-473 466-515 509-562
M20 x 2,5 390-431 428-473 553-611 603-667 660-730 722-798
M22 x 2,5 523-578 575-635 746-824 817-903 893-987 974-1076
M24 x 3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27 x 3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30 x 3,5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
FINE PITCH - PASSO FINE - KLEINER SCHRITT

M8 x 1 25,7-28,3 27,5-30,5 36,2-39,8 40,0-44,0 42,8-47,2 47,5-52,5

M10 x 1,25 49,4-54,6 55,2-61,0 71,5-78,5 78,0-86,0 86,0-94,0 93,0-103,0
M12 x 1,25 90-100 98-109 128-142 139-154 152-168 166-184
M12 x 1,5 86-95 94-104 120-132 133-147 143-158 159-175
PASO FINO - PAS FIN

M14 x 1,5 143-158 157-173 200-222 219-242 238-263 261-289

M16 x 1,5 214-236 233-257 302-334 333-368 361-399 394-436
M18 x 1,5 312-345 342-378 442-489 485-536 527-583 580-641
M20 x 1,5 437-483 475-525 613-677 674-745 736-814 808-893
M22 x 1,5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082

008 914 20 BOMAG

9 1211
20.4 Axle

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'eÂtancheÂiteÂ 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. UtiliseÂ pour le freinage
demi reÂsistant. Il doit eÃtre utiliseÂ apreÁs avoir enleveÂ 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 utiliseÂ apreÁs avoir
enleveÂ 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 adapteÂ 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.

1212 BOMAG
10 008 914 20
Axle 20.4

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'eÂtancheÂiteÂ des filetages des raccords coniques ou cylindriques
jusqu'aÁ M80. Il doit eÃtre utiliseÂ apreÁs qu'on ait enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
Une certaine difficulteÂ de deÂmontage se preÂsente apreÁs la polymeÂrisation, on peut donc avoir la neÂcessiteÂ 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'eÂtancheÂiteÂ des arbres rotatifs ayant une arma-
ture meÂtallique externe.

008 914 20 BOMAG

11 1213
20.4 Axle

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 utiliseÂ pour le scellage, remplissage et protection des eÂleÂments ambiants et phy-
siques. PolymeÂrise aÁ une humiditeÂ 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 degreÂ d'adheÂsiviteÂ eÂleveÂ, adjuveÂ de composeÂs au silicone.
AppliqueÂ sur les vis de reÂglage aÁ trou communiquant avec des fluides du type huileux.
UtiliseÂ 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.
. ComposeÂ lubrifiant contenant du bisulfure de molybdeÁne, utiliseÂ 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) . AppliqueÂ sur les paliers, parties coulissantes et pour lubrifier les garnitures ou pieÁces pendant la phase de
montage.

1214 BOMAG
12 008 914 20
Axle 20.4

NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR

SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
1 - During all operations described in this manual, the LoÈsemittel muÈssen als SondermuÈll und auf jeden Fall laut den
GB axle should be fastened onto a trestle, while the oÈrtlich geltenden Vorschriften entsorgt werden.
other parts mentioned should rest on supporting 9- Zur Reinigung ausschlieûlich schwache LoÈsemittel wie Petroleum,
benches. Terpentin oder wasserhaltige LoÈsemittel verwenden. Auf keinen
2 - When removing one of the arms, an anti-tilting safety trestle Fall TrichloraÈthylen, tuolol- oder xylolhlatige LoÈsemittel usw.
should be placed under the other arm. verwenden.
3 - When working on an arm that is fitted on the machine, make sure 10 - Um die ArbeitsvorgaÈnge verstaÈndlich abzubilden, werden in
that the supporting trestles are correctly positioned and that the einigen Fotos die Aggregate ohne Einzelteile gezeigt, die sonst
machine is locked lengthways. bei der Arbeit nicht abmontiert werden muÈssen.
4 - Do not admit any other person inside the work area; mark off the Nur die beschriebenen Teile abmontieren.
area, hang warning signs and remove the ignition key from the 11 - Unter RECHTS und LINKS versteht man in diesem Handbuch die
machine. Seite einer Person, die zur Achse schaut und zwar dem Antrieb
5 - Use only clean, quality tools; discard all worn, damaged, low- entgegengesetzt.
quality or improvised wrenches and tools. Ensure that all 12 - Nach beendeten Arbeiten und um Rostbildungen zu vermeiden,
dynamometric wrenches have been checked and calibrated. die Teile an denen der Lack ggf. beschaÈdigt worden ist,
6 - Always wear gloves and non-slip rubber shoes when performing anstreichen.
repair work. 1 - Las operaciones descritas se refieren al eje blo-
7 - Should you stain a surface with oil, remove marks straight away. ESP queado en un caballete y a algunas partes apoyadas
8 - Dispose of all lubricants, seals, rags and solvents once work has en el banco de trabajo.
been completed. Treat them as special waste and dispose of them 2- Cuando se saca un brazo del eje, colocar debajo del otro un
according to the relative law provisions obtaining in the country caballete de seguridad antivuelco.
where the axles are being overhauled. 3- Si se trabaja con un eje montado en la maÂquina, asegurarse de
9 - Make sure that only weak solvents are used for cleaning haber colocado caballetes soporte y de haber inmovilizado
purposes; avoid using turpentine, dilutants and toluol-, xylol- longitudinalmente la maÂquina.
based or similar solvents; use light solvents such as Kerosene, 4- No permitir que personas extranÄas entren en la zona de trabajo;
mineral spirits or water-based, environment friendly solvents. delimitar esta zona, colgar carteles de aviso de hombres
10 - For the sake of clarity, the parts that do not normally need to be trabajando y sacar las llaves de arranque de la maÂquina.
removed have not been reproduced in some of the diagrams. 5- Usar soÂlo y exclusivamente herramientas limpias y de buena
11 - The terms RIGHT and LEFT in this manual refer to the position of cualidad; descartar llaves o herramientas gastadas o danÄadas, de
the operator facing the axle from the side opposite the drive. calidad mediocre o improvisadas. Asegurarse de que las llaves
12 - After repair work has been completed, accurately touch up any dinamomeÂtricas han sido controladas y calibradas.
coated part that may have been damaged. 6- Durante las operaciones de reparacioÂn, llevar siempre guantes y
calzado antideslizamiento.
1 - Le operazioni descritte sono riferite all'assale bloc- 7- Limpiar inmediatamente las zonas que pudieran estar sucias de
ITA cato su cavalletto ed alcuni particolari appoggiati su aceite.
un banco di lavoro.
8- Los lubricantes, las juntas, los trapos para la limpieza y los
2 - Quando si asporta un braccio dell'assale, sistemare sotto l'altro disolventes usados hay que eliminarlos como desechos especia-
braccio un cavalletto di sicurezza antiribaltamento. les y, de todas formas, de acuerdo con las normativas vigentes en
3 - Se si opera su un'assale montato sulla macchina, assicurarsi di el paõÂs en el que se revisan los ejes.
aver sistemato dei cavalletti di sostentamento e di aver immobi- 9- Para limpiar, utilizar soÂlo disolventes deÂbiles excluyendo en
lizzato longitudinalmente la macchina. absoluto tricloroetileno, diluyentes y disolventes a base de toluol,
4 - Non permettere che persone estranee entrino nella zona di lavoro; silol, etc.; usar soÂlo disolventes ligeros como queroseno, aguarraÂs
delimitare questa zona, appendere dei cartelli di avviso di lavori in minerales o disolventes ecoloÂgicos a base de agua.
corso ed asportare le chiavi di avviamento della macchina. 10 - Para que resulte clara la exposicioÂn y la ilustracioÂn, en las figuras
5 - Usare solo ed esclusivamente attrezzi puliti e di buona qualitaÁ; de algunos grupos faltan algunas piezas que por lo general se
scartare chiavi od attrezzi usurati o danneggiati, di bassa qualitaÁ pueden dejar montadas. Sacar soÂlo las partes descritas.
od improvvisati. Assicurarsi che le chiavi dinamometriche siano 11 - Las palabras DERECHA E IZQUIERDA usadas en el manual se
state controllate e tarate. refieren a la persona que mira el eje del lado opuesto a la toma de
6 - Durante le operazioni di riparazione, indossare sempre guanti e movimiento.
scarpe antiscivolo. 12 - Al final de las reparaciones, para evitar oxidaciones, retocar
7 - Pulire immediatamente le zone eventualmente imbrattate d'olio. cuidadosamente las partes pintadas que estuvieran danÄadas.
8 - I lubrificanti, le guarnizioni, gli eventuali stracci di pulizia ed i
solventi usati devono essere smaltiti come rifiuti speciali e 1 - Les opeÂrations deÂcrites se rapportent aÁ l'essieu
comunque secondo le normative vigenti nel Paese ove vengono F bloqueÂ sur chevalet et de quelques pieÁces poseÂes
revisionati gli assali. sur un eÂtabli de travail.
9 - Per la pulizia, usare solo solventi deboli escludendo categorica- 2- Quand on enleÁve un essieu monteÂ sur la machine, ajuster sous
mente trielina, diluenti e solventi a base di toluolo, xilolo, ecc.; l'autre bras un chevalet de seÂcuriteÂ contre tout basculement.
usare solo solventi leggeri quali cherosene, ragie minerali o 3- Si on oeuvre sur un essieu monteÂ sur la machine, s'assurer
solventi ecologici a base d'acqua. d'avoir ameÂnageÂ des chevalets de soutien et d'avoir bloqueÂ la
10 - Per chiarezza di illustrazione ed esposizione, sulle figure di alcuni machine en longueur.
gruppi mancano dei particolari che, normalmente, possono essere 4- Ne jamais permettre aÁ des eÂtrangers de peÂneÂtrer dans la zone de
lasciati montati. Rimuovere solo i particolari descritti. travail; deÂlimiter cette zone, mettre des pancartes de signalisation
11 - I termini DESTRA e SINISTRA usati nel manuale sono riferiti alla de travaux en cours et enlever les cleÂs de contact de la machine.
persona che guarda l'assale dal lato opposto alla presa di moto. 5- N'utiliser que des outils propres et de bonne qualiteÂ; eÂliminer cleÂ
12 - Al termine delle riparazioni, per evitare dannose ossidazioni, ou autres outils useÂs, abõÃmeÂs, de mauvaise qualiteÂ ou improviseÂs.
ritoccare con cura le parti verniciate eventualmente danneggiate. Veiller aÁ ce que les cleÂs dynamomeÂtriques aient eÂteÂ controÃleÂes et
calibreÂes.
1 - Die beschriebenen VorgaÈnge werden an der Achse 6- Pendant les opeÂrations de reÂparation, endosser toujours gants et
D vorgenommen, wenn diese auf einem Bock blockiert chaussures antideÂrapantes.
ist. Zur Bearbeitung der Einzelteile, werden diese 7- Nettoyer tout de suite les eÂventuelles zones souilleÂes d'huile.
auf die Werkbank gelegt. 8- Les lubrifiants, les garnitures, les eÂventuels chiffons servant au
2- Wenn eine Achse abgenommen wird, einen Sicherheitsbock unter nettoyage et les solvants utiliseÂs devront eÃtre reÂcolteÂs et traiteÂs
den zweiten Arm legen. comme rebut speÂcial conformeÂment aux lois en vigueur dans le
3- Werden Arbeiten an der Achse vorgenommen, wenn diese noch pays ouÁ les essieux sont en reÂvision.
an der Maschine montiert ist, BoÈcke zur Halterung unter die 9- Pour le nettoyage, n'utiliser que des solvants aÁ base de toluol,
Achse stellen und die Maschine der LaÈnge nach blockieren. xylol, etc.; n'utiliser que des solvants leÂgers tels que keÂroseÁne,
4- Es duÈrfen sich keine fremde Personen in der NaÈhe der Maschine essences mineÂrales, ou solvants eÂcologiques aÁ base d'eau.
waÈhrend der Arbeiten aufhalten; diesen Bereich absperren und 10 - En ce qui concerne la clarteÂ en matieÁre d'illustration et exposition,
mit Schilder kennzeichnen, die auf die laufenden Arbeiten sur les figures de certains groupes, il y a des pieÁces manquantes
hinweisen. ZuÈndschluÈssel von der Maschine abnehmen. qui normalement peuvent rester monteÂes.
5- Nur saubere Werkzeuge guter QualitaÈt verwenden; alte, beschaÈ- Enlever uniquement les pieÁces deÂcrites.
digte oder improvisierte Hilfsmittel nicht verwenden. Sicher- 11 - Les termes DROITE et GAUCHE utiliseÂs dans ce manuel se
stellen, daû die Dynamometer gepruÈft und geeicht worden sind. rapportent aÁ la personne regardant l'essieu du coÃteÂ opposeÂ aÁ celui
6- Bei Reparaturen, stets Handschuhe und rutschfeste Schuhe tragen. de la prise de mouvement.
7- Mit OÈ l beschmutzte Stellen, sofort reinigen. 12 - A la fin des opeÂrations, afin d'eÂviter un risque d'oxydation
8- Gebrauchte Schmiermittel, Dichtungen, Reinigungslappen und nuisible, retoucher soigneusement les parties vernies eÂventuelle-
ment abõÃmeÂes.
008 914 20 BOMAG
13 1215
20.4 Axle
SIMBOLI

Disassembly of assembly groups

Smontaggio di sottogruppi
Zerlegen von Baugruppen
Desmontaje de subgrupos
Demontage des sous-groupes
Reassemble to from assembly groups
Montaggio di sottogruppi 1
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts T1
Smontaggio di particolari ingombri
Abbauen-Ausbauen
Desmontaje de componentes abultados
Demontage des pieces encombrante
Reinstall-remount parts which had obstructed disassembly
Montaggio di particolari ingombri
Einbauen-Ausbauen
Montaje de componentes abultados
Montage des pieces encombrante
Attention ! Important notice S
Attenzione, indicazione importante
Achtung, wichtiger Hinweis F1241070 F1241071
¡ Cuidado ! IndicacioÂn importante
Attention, indication importante
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc.
PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs.
Controlar y ajustar, por ej. pares, medidas, presiones, etc. CHECKING WEAR Introduce tool T1 between the disks and check shim "S".
Controler, regler p.e. couples, mesures, pressions ecc. CAUTION! Perform operations on both arms. Minimum size of "S": 4.5 mm.
T=Special tool P=page Remove the oil-level plug (1).
T=Attrezzature speciali P=Pagina
T=Spezialwerkzeug P=Seite
T=Herramientas especiales P=PaÂgina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccioÂn de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale P
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual
Controler, examiner, controle visuel 3
Possibly still serviceable, renew if necessary
Eventualmente riutilizzare (sostituire se necessario)
Bedingt weiderverwendbar
Puede volver a utilizarse (reemplazar, si es preciso)
Eventuellement a utiliser a noveau (remplacer si neÂcessaire)
Renew at each reassembly 2
Sostituire ad ogni montaggio
Beim Zusammenbau immer erneuern
Puede reemplazarse a cada ensamblaje
Remplacer avec chaque montage
Unlock - lock e.g. split pin, locking plate, etc.
Togliere-mettere la sicura F1241072 F1241073
Entsichern-Sichern
Quitar-colocar el seguro
Enlever-mettre la securite
Lock-adhere (liquid sealant)
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung) ADJUSTING THE BRAKES Remove screw (2) and safety plate (3).
Colocar el seguro, pegar (mastique lõÂquido) Connect an external pump to the union piece "P" of the negative
Mettre la securite, coller (mastic liquide) brake and introduce a pressure of 15 ± 30 bar to eliminate the
Guard against material damage, damage to parts pressure of the Belleville washers (11).
Evitare danni materiali, danni a pezzi
Materialschaden verhuÈten
Evitar danÄar los materials o las piezas
Eviter dommages au materiaux, dommages au pieces
Mark before disassembly, observe marks when reassembly
Marchiare prima dello smontaggio (per il montaggio)
Vor dem Ausbau markieren (fuÈr den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje) 6
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
7
EinfuÈllen - AuffuÈllen - NachfuÈllen (OÈl-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
4
Drain off oil, lubricant
Scaricare olio, lubrificante
OÈl, bzw. Schmiermittel Ablassen
Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
Apply pressure into hydraulic circuit
8
Inserire pressione nel circuito idraulico F1241074 F1241075
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique
To clean
Pulire Turn the brake clearance adjustment pinion (4) clockwise and as REPLACING THE BRAKING DISKS
Reinigen
Limpiar far as the limit stop. Sling the arm (6) to be removed and connect it to a hoist.
Nettoyer Release pressure and disconnect the tubes. Loosen and remove screws (7) and nuts (8).
Lubricate - grease NOTE. Remove the lower plug (5) and drain the oil.
Lubrificare - ingrassare
Schmieren - einfetten
Lubrificar - Engrasar
1216Lubrifier - Graisser BOMAG 008 914 20
Axle 20.4

CONTROLLO USURA Introdurre l'attrezzo T1 tra i dischi e controllare lo

ITA ATTENZIONE! Eseguire le operazioni per i due ITA spessore "S".
bracci. "S" minimo: 4,5 mm
Asportare il tappo (1) di livello olio.

VERSCHLEISS KONTROLLIEREN Werkzeug T1 zwischen den Scheiben einsetzen und

D D die StaÈrke "S" kontrollieren.
ACHTUNG! Die VorgaÈnge an beiden Armen vorneh-
men. "S" Minimum: 4,5 mm
È
OleinfuÈllstopfen (1) abnehmen.
a b
CONTROL DESGASTE Introducir la herramienta T1 entre los discos y
ESP ESP controlar el espesor "S".
ATENCION! Efectuar las operaciones por los dos
ejes. «S» minimo: 4,5 mm.
Sacar el tapon (1) de nivel aceite.

CONTROLE USURE Introduire l'outil T1 entre les disques et controÃler la

F F cale "S".
ATTENTION! Effectuer les opeÂrations aux deux bras.
Enlever le bouchon (1) du niveau d'huile. "S" minimum: 4,5 mm

REGISTRAZIONE FRENI Asportare la vite (2) e la piastrina di sicurezza (3).

ITA Collegare al raccordo "P" del freno negativo una pompa ITA
esterna ed immettere una pressione di 15v30 bar per
eliminare la pressione delle molle a tazza (11).

BREMSEN EINSTELLEN Schraube (2) und SicherheitsplaÈttchen (3) abnehmen.

D AnschluûstuÈck "P" der Federspeicherbremse an eine D
aÈuûere Pumpe anschlieûen und Druck bei 15v30 bar
einlassen, um Tellerfedern (11) zu entlasten.
c d
REGISTRACION FRENOS Sacar el tornillo (2) y la placa de securidad (3).
ESP Conectar al empalme «P» del freno negativo una ESP
pompa esterna y introducir una presion de 15v30 bar
para eliminar la presion de los muelles a taza (11).

REGLAGE DES FREINS Enlever les vis (2) et la plaquette de seÂcuriteÂ (3).
F Brancher au raccord "P" du frein neÂgatif une pompe F
externe et envoyer une pression de 15v30 bar pour
eÂliminer la pression des ressorts belleville (11).

Ruotare in senso orario il pignone (4) di regolazione SOSTITUZIONE DISCHI FRENO

ITA gioco freni fino a fondo corsa. ITA Imbragare il braccio (6) da asportare e collegarlo ad un
Rilasciare la pressione e scollegare i tubi. mezzo di sollevamento.
NOTA. Rimuovere il tappo inferiore (5) e scaricare l'olio. Allentare ed asportare le viti (7) ed i dadi (8).

Das Kegelrad (4) zur Einstellung des Bremsspiels bis BREMSSCHEIBEN AUSWECHSELN
D zum Endanschlag drehen. D Den abzunehmenden Arm (6) anschlagen und an eine
Druck ablassen und die Leitungen abtrennen. Hebezeug befestigen.
BEMERKUNG. Unteren Stopfen (5) abnehmen und das O È l. Schrauben (7) und Muttern (8) lockern und abschrauben.
e f
Girar en sentido horario el pinon (4) de regulacioÁn SUBSTITUCION DISCOS FRENOS.
ESP juego frenos hasta final carrera. ESP Atar el eje (6) de sacar y conectarlo a un medio de
Dejar la presion y desconectar los tubos. levantamiento.
NOTA. Remover el tapon inferior (5) y descargar el aceite. Aflojar y sacar los tornillos (7) y las tuercas (8).

Tourner le pignon de reÂglage du jeu des freins (4) dans Substitution des disques frein
F le sens des aiguilles d'une montre jusqu'en fin de F Elinguer le bras (6) aÁ enlever et brancher celui-ci aÁ un
course. moyen de relevage.
LibeÂrer la pression et deÂbrancher les tubes. Desserrer et enlever les vis (7), les eÂcrous (8).
REMARQUE: Enlever le bouchon infeÂrieur (5) et vidanger l'huile.

008 914 20 BOMAG

15 1217
20.4 CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS Axle
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS

F1241076 F1241077

GB a GB b
Remove arm (6) together with brakes and axle shafts; lay down the Loosen screws (9) in an alternate manner and remove them.
arm vertically.

11
12

10 10

F1241078 F1241079

GB c GB d
Move the cylinder (10) outwards while supporting the Belleville Remove the cylinder (10) complete with piston (12).
washers (11).
Remove the Belleville washers (11) and note down direction of
assembly.

12
13
12

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.

1218 BOMAG
16 008 914 20
Axle 20.4

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 comprimeÂ aÁ basse pression Enlever le piston (12), les anneaux O'RING (13) et
F aÁ travers le raccord du frein neÂgatif pour extraire le F (14).
piston (12). REMARQUE. Les anneaux O'RING (13) et (14) sont aÁ
ATTENTION! Tenir le piston (12) qui pourrait eÃtre expulser substituer aÁ chaque deÂmontage.
rapidement et endommager.

008 914 20 BOMAG

17 1219
20.4 CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS Axle
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS

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.

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

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.

1220 BOMAG
18 008 914 20
Axle 20.4

Rimuovere le viti (15) di ritegno e guida dello Rimuovere lo spingidisco (16).

ITA spingidisco (16). ITA
ATTENZIONE! Annotare il senso di montaggio; la
NOTA. Allentare le viti (15) in modo sequenziale ed in parete frangiflusso "A" e gli scarichi olio, devono
uguale misura. essere rivolti verso il tappo di scarico olio.

Befestigungsschrauben (15) und die FuÈhrung der Druckplatte (16) abnehmen.

D Druckplatte (16) abnehmen. D
ACHTUNG! Montagerichtung notieren; der Strahlreg-
BEMERKUNG. Abwechselnd Schrauben (15) im È lablaûoÈffnungen muÈssen in Richtung
ler "A" und die O
gleichen Maû lockern. È
des Olablaûstopfens gerichtet sein.
a b
Remover los tornillos (15) de retencioÁn y guõÁa del Remover el empuja-disco (16).
ESP empuya-disco (16). ESP
ATENCION. Anotar el sentido de montaje; la pared
NOTA. Aflojar los tornillos (15) de manera secuencial rompe-flujo "A" y los descarge aceite, deben de ser
y en la misma mesura. dirijidos hacia el tapon de descarga aceite.

Enlever vis (15) de fixation et guide du plateau de Enlever le plateau de pression (16).
F pression (16). F
ATTENTION! Prendre noter du sens du montage; la
REMARQUE: Desserrer les vis (15) en seÂquence et en paroi brise-jet "A" et les eÂcoulements d'huile sont
eÂgale mesure. tourneÂs vers le bouchon de vidange d'huile.

Rimuovere le molle (17). Rimuovere i dischi di frenatura (18) e (19) annotando

ITA ITA l'ordine di montaggio.
NOTA. Controllare attentamente lo stato delle molle
che non devono essere deformate. NOTA. Se i dischi non devono essere sostituiti, evitare
Ogni deformazione deve portare alla sostituzione. lo scambio di posizione.

Federn (17) abnehmen. Bremsscheiben (18) und (19) abnehmen und Monta-
D D gerichtung notieren.
BEMERKUNG. Die Federn sorgfaÈltig kontrollieren; sie
duÈrfen nicht verformt sein. Sollte dies der Fall sein, BEMERKUNG. Falls die Scheiben ausgewechselt
Federn auswechseln. werden muÈssen, ihre Position nicht verwechseln.
c d
Remover los muelles (17). Remover los discos de frenadura (18) y (19) anotando
ESP ESP el orden de montaje.
NOTA. Controlar atentamente el estado de los
muelles que no deben de ser deformes. NOTA. Si los discos no deben de ser sobstituidos,
A cada deformacioÁn deben de ser cambiados. evitar el cambio de possicioÁn.

Enlever les ressorts (17). Enlever les disques de freinage (18) et (19) et prendre
F F note de l'ordre du montage.
REMARQUE. ControÃler attentivement l'eÂtat des res-
sorts, ils ne doivent pas eÃtre deÂformeÂs. REMARQUE. Si les disques doivent eÃtre substitueÂs,
Toute deÂformation veut dire substitution. eÂviter d'eÂchanger leur position.

Rimuovere il pignone (4) completo di anello OR (20). Svitare ed asportare la corona (21) di regolazione del
ITA ITA gioco dischi di frenatura.
NOTA. L'anello OR deve essere sostituito ad ogni
smontaggio.

Das Kegelrad (4) samt O-Ring (20) entfernen. Den Kranz (21) zur Einstellung des Bremsscheibens-
D D piels abnehmen.
BEMERKUNG. Den O-Ring bei jedem Zerlegen aus-
wechseln.
e f
Remover el pinon (4) completo de anillo OR (20). Destornillar y sacar la corona (21) de regulacioÁn del
ESP ESP juego discos de frenadura.
NOTA. El anillo OR debe de ser sobstituido a cada
desmontaje.

Enlever le pignon (4) complet de l'anneau O'RING DeÂvisser et enlever la couronne (21) de reÂglage du jeu
F (20). F des disques de freinage.
REMARQUE. L'anneau O-Ring est aÁ remplacer aÁ
chaque deÂmontage.

008 914 20 BOMAG

19 1221
20.4 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOSAxle
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

11
13
12

10 14

9
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).

1222 BOMAG
20 008 914 20
Axle 20.4

ESP

ITA

Lubrificare la filettatura della corona (21) ed avvitarla a Sostituire l'anello OR (20) del pignone (4).
ITA fondo nel braccio (6). ITA Lubrificare il pignone e montarlo nella sede del braccio
(6) innestando la dentatura nella corona (21).

Das Gewinde des Kranzes (21) schmieren und in den O-Ring (20) des Kegelrads (4) auswechseln. Kegelrad
D Arm (6) festschrauben. D schmieren und in den Sitz des Arms (6) montieren;
dabei die ZaÈhne des Kranzes (21) einrasten.

a b
Lubrificar la rosca de la corona (21) y atornillar a Sobstituir el anillo OR (20) del pinon (4).
ESP hondo en el eje (6). ESP Lubrificar el pinon y montarlo en la sed del eje (6)
introduciendo la dentadura en la corona (21).

Lubrifier le filetage de la couronne (21), puis visser Substituer l'anneau O'RING (20) du pignon (4).
F celle-ci aÁ fond dans le bras (6). F Lubrifier le pignon, puis monter celui-ci dans le
logement du bras (6) en introduisant en meÃme temps
la denture dans la couronne (21).

008 914 20 BOMAG

21 1223
20.4 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOSAxle
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

19
18
B

F1241088 F1241089

GB a GB b
Lubricate the first friction disk (19) and install it on the axle shaft .
Lightly lubricate the first steel braking disk (18), then install it on the Complete the assembly, alternating steel disks and friction disks.
arm (6). CAUTION! Oval holes "B" of friction disks must be lined up.

16
17

6 A
F1241084 F1241083

GB c GB d
Position springs (17) in the appropriate slots of the arm (6). Fit the pressure plate (16).
CAUTION! Accurately check orientation: flow regulator "A" and oil
drains must be oriented towards the arm's oil drain plug.

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.

1224 BOMAG
22 008 914 20
Axle 20.4

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 cleÂ dynamomeÂtrique.
F vis (15). F Couple de serrage: 20v30 Nm.
ATTENTION! Serrer les vis en plusieurs temps en
ordre seÂquentiel.

008 914 20 BOMAG

23 1225
20.4 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOSAxle
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

14 12
12

13 10

10
F1241091 F1241092

GB a GB b
Fit O-rings (13) and (14) onto the piston (12). Using a plastic hammer, ram the piston (12) into the cylinder (10).
Lubricate the piston and the O-rings and install the unit into the NOTE. Lightly hammer all around the edge in an alternate
cylinder (10). sequence.
NOTE. Piston relief «C» must face downwards.

22 11

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.

1226 BOMAG
24 008 914 20
Axle 20.4

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 tourneÂ 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 cleÂ dynamomeÂtrique aÁ un couple de 86v89 Nm. F O'RING (23) du bras; installer le bras complet (6).
REMARQUE. Afin de rendre plus aiseÂ le centrage du
demi-essieu, bouger lentement le moyeu porte-roue.

008 914 20 BOMAG

25 1227
20.4 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOSAxle
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

T2
6

8
F1241095 F1241096

GB a GB b
Temporarily lock the arm (6) with nuts (8) previously coated with Check the flatness of the arms, using tool T2; then lock the arms
Loctite 242; tighten lightly to make the unit touch the main body. into their final position, using screws (7) adequately coated with
Loctite 242.
Torque wrench setting: 182 ± 202 Nm.
NOTE. Tighten using the criss-cross method.

F1241097 F1241074

bar GB c GB d
Connect an external pump to the union piece "A" of the negative Rotate the adjustment pinion (4) anticlockwise (±) to eliminate all
brake and introduce pressure to 15 ± 30 bar. existing clearance between the braking disks.
Rotate up to a torque of 8 ± 10 Nm.

+ 3

4
-- 2

D1240132
F1241073

GB e GB f
Rotate pinion (4) clockwise (+) to determine the required clearance Install safety plate (3) and lock with screw (2).
of 1 mm. Torque wrench setting: 10 ± 11 Nm.
NOTE. A turn of the adjuster produces a clearance of 0.25 mm
(1mm = 4 turns).

1228 BOMAG
26 008 914 20
Axle 20.4

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 planeÂiteÂ 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 seÂcuriteÂ (3), bloquer celle-ci aÁ
F montre (+) pour deÂfinir le jeu prescrit de 1 mm. F l'aide de la vis (2).
REMARQUE. Un tour de reÂgleur donne un jeu de 0,25 Couple de serrage: 10v11 Nm
mm (1mm=4 tours).

008 914 20 BOMAG

27 1229
20.4 MECHANICAL AND MANUAL RELEASE OF THE AXLE - SBLOCCAGGIO MECCANICO MANUALE DELL'ASSALE - Axle
ACHSE MECHANISCH MANUELL ENTSICHERN - DESBLOQUEO MANUAL DE LOS AXAL -
DEBLOCAGE MECANIQUE MANUEL DE L'ESSIEU

11 16

24
25
25

26 24
D1240133
F1241098

GB a GB b
MANUAL EMERGENCY RELEASE Tighten screws (25) so as to fasten them onto the pressure plate
Loosen nuts (24) of screws (25) provided for the mechanical and (16).
manual release of the braking units, then move the nuts backwards
by approx. 8 mm.

25 26
24
25

F1241099 F1241100

GB c GB d
Using a wrench, tighten the screws (25) in an alternate sequence ADJUSTMENT AFTER MANUAL RELEASE
by 1/4 turn at a time so as to compress the Belleville washers (11) Remove screws (25) complete with nuts (24) and seals (26).
and disengage the braking disks. Replace seals (26), apply silicone-based Tecno Lupe /101 grease
IMPORTANT. Tighten max. by one turn. to the screws (25) and install all parts into the arm.

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.

1230 BOMAG
28 008 914 20
Axle 20.4

SBLOCCAGGIO MANUALE D'EMERGENZA Avvitare le viti (25) fino a mandarle in battuta sullo
ITA Allentare i dadi (24) delle viti (25) per lo sblocco ITA spingidisco (16).
meccanico manuale dei gruppi di frenatura e far
arretrare i dadi di circa 8 mm.

MANUELLE NOT-ENTSICHERUNG Schrauben (25) bis zum Anschlag an die Druckplatte

D Die Muttern (24) der Schrauben (25) zur mechani- D (16) zudrehen.
schen manuellen Entsicherung der Bremsaggregate
lockern und die Muttern um 8 mm zuruÈck drehen.
a b
DESBLOQUEO MANUAL DE EMERGENCIA Atornillar los tornillos (25) hasta llegar al tope sobre el
ESP Aflojar las tuercas (24) de los tornillos (25) para el ESP empuja-disco (16).
desbloqueo mecanico manual de los grupos de
frenadura y hacer pasar las tuercas de 8 mm approx.

DEBLOCAGE MANUEL D'EMERGENCE Visser les vis (25) puis les envoyer en buteÂe sur le
F Desserrer les eÂcrous (24) des vis (25) pour le F plateau de pression (16).
deÂblocage meÂcanique manuel des groupes de frei-
nage en faisant reculer les eÂcrous d'environ 8 mm.

Utilizzando una chiave, avvitare le viti (25) in modo REGOLAZIONE DOPO LO SBLOCCAGGIO MANUALE
ITA alternato di 1/4 di giro alla volta, per comprimere le ITA Rimuovere le viti (25) complete dei dadi (24) e delle
molle a tazza (11) e liberare i dischi di frenatura. guarnizioni (26).
IMPORTANTE. Avvitare per max. un giro. Sostituire le guarnizioni (26), lubrificare le viti (25) con grasso al
silicone Tecno Lupe /101 e montare il tutto nel braccio.

Mit einem SchluÈssel, die Schrauben (25) abwechselnd EINSTELLUNG NACH DER MANUELLEN ENTSICHERUNG
D jeweils um 1/4 Umdrehung zudrehen, um die Tellerfe- D Die Schrauben (25) mit den Muttern (24) und den
dern (11) einzudruÈcken und die Bremsscheiben frei- Dichtungen (26) abnehmen.
zusetzen. Die Dichtungen (26) auswechseln, die Schrauben (25) mit Silikon-
c WICHTIG. Maximal um eine Umdrehung zuschrauben. d fett Tecno Lupe/101 schmieren und das ganze Teil in den Arm
montieren.

Utilizando una llave, atornillar los tornillos (25) de REGULACION DESPUES DEL DESBLOQUEO MANUAL
ESP manera alternada de 1/4 de giro a la vez, para ESP Remover los tornillos (25) completas de guarniciones
comprimir los muelles a taza (11) y librar los discos (26).
de frenadura. Sobstituir las guarniciones (26), lubrificar los tornillos (25) con
IMPORTANTE. Atornillar por max. un giro. grasa al silicone Tecno Lupe/101 y montar todo en el eje.

A l'aide d'une cleÂ, visser les vis (25) alternativement 1/ REGLAGE FAISANT SUITE AU DEBLOCAGE MANUEL
F 4 de tour aÁ la fois, pour contraindre le ressort belleville F Enlever les vis (25) compleÁtes d'eÂcrous (24) et de
(11) et deÂgager les disques de freinage. garnitures (26).
IMPORTANT. Visser pour max. un tour. Substituer les garnitures (26), lubrifier les vis (25) avec de la graisse
au silicone Tecno Lupe/101, monter le tout dans le bras.

Regolare le viti (25) fino ad avere una sporgenza Bloccare la posizione con i dadi (24).
ITA rispetto al braccio di 34+0,5
0 mm
ITA
ATTENZIONE! Mantenere la posizione delle viti (25)
quando si bloccano i dadi (24); dopo il bloccaggio,
ricontrollare la sporgenza delle viti (25).

È berstand zum Arm

Schrauben (25) einstellen, bis der U Die Position mit den Muttern (24) blockieren.
D 34+0.5
0 mm betraÈgt. D
ACHTUNG! Die Position der Schrauben (25) darf sich
beim Festziehen der Muttern (24) nicht aÈndern; nach
der Blockierung den U È berstand der Schrauben (25) nochmals
e f kontrollieren.

Regular los tornillos (25) hasta obtener una parte Bloquear la colocacioÁn con las tuercas (24).
ESP saliente respecto al eje de 34+0,5
0 mm
ESP
ATENCION! Mantener la posicion de los tornillos (25)
cuando se bloquean las tuercas (24); despues del
bloqueo, recontrolar la parte saliente de los tornillos (25).

ReÂgler les vis (25) jusqu'aÁ avoir une saillie de 34+0.5

0 mm Bloquer dans la position aÁ l'aide des eÂcrous (24).
F par rapport au bras. F
ATTENTION! Tenir les vis (25) en place quand on
bloque les eÂcrous (24); apreÁs avoir fixeÂ, controÃler la
saillie des vis (25).

008 914 20 BOMAG

29 1231
20.4DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

4
12
9 11
10
3

8 13

14
7
16
15

2
1 D1240131

1
3

2
F1241103 F1241104

GB a GB b
Remove the locking screws (1) of planetary cover (2). Using two screwdrivers or two levers inserted in the slots provided,
pry the planetary cover (2) away from the wheel hub (3).

1232 BOMAG
30 008 914 20
Axle 20.4

SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE

NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR

GB The axle shafts can only be removed once the 2 - Achse zuerst von der Maschine abmontieren und auf eine
extraction of the planetary cover has been performed. Werkbank legen.
Different procedures need to be followed depending on
the kind of repair work required: Nachstehende Beschreibung bezieht sich auf das Zerlegen an der
Werkbank, doch ist die Vorgehensweise in beiden FaÈllen dieselbe.
1 - Disassembly with axle connected to the machine with machine
resting on safety stands.
2 - Disassembly with the axle disconnected from the machine and
supported by the appropriate equipment (at the bench).
The explanations given herein refer to the removal operation as is La remocioÁn de los semi-ejes puede ser efectuada solo
carried out on the bench, but the stages apply to all versions. ESP despues de la remocioÁn de las tapas lleva-satelites y de
manera deversificada, en funcion del tipo de repara-
cion de efectuar:
1 - Desmontaje con axal montado sobre la maquina colocada sobre
caballetes de seguridad;
2 - Desmontaje con axial desmontado desde la maquina y susten-
tado de apositas herramientas (al banco).
Las explicaciones reportadas se refieren a la remocioÁn efectuada al
La rimozione dei semiassi puoÁ essere eseguita solo banco, ma las fases son comunes.
ITA dopo la rimozione del coperchio portasatelliti ed in
modo diversificato, in funzione del tipo di riparazione
da eseguire:
1 - Smontaggio con assale montato sulla macchina appoggiata su
cavalletti di sicurezza.
2 - Smontaggio con assale smontato dalla macchina e sostenuto da
apposita attrezzatura (al banco).
Le spiegazioni riportate si riferiscono alla rimozione eseguita al Le deÂgagement des demi-essieux ne peut se faire
banco, ma le fasi sono comuni. F qu'apreÁs avoir enleveÂ le couvercle porte-satellites
d'une facËon diversifieÂe, en fonction du type de
reÂparations aÁ effectuer:
1 - DeÂmontage essieu monteÂ sur machine deÂposeÂe sur des baÃtis de
seÂcuriteÂ.
1 - DeÂmontage essieu deÂmonteÂ de la machine et soutenu par un
outil speÂcial (sur banc).
Les explications reporteÂes se reÂfeÁrent au deÂgagement effectueÂ au
Die Halbachse kann erst abmontiert werden, wenn der banc, mais les phases sont communes.
D Deckel des Planetenradhalters abgenommen worden
ist; auûerdem wird sie je nach Reparatur unterschied-
lich abmontiert:
1 - Mit Achse abmontieren, die an der Maschine montiert und durch
SicherheitsbloÈcke gestuÈtzt ist.

Rimuovere le viti (1) di fissaggio del coperchio Utilizzando due cacciaviti o due leve inserite nelle
ITA portasatelliti (2). ITA cave predisposte, staccare il coperchio portasatelliti
(2) dal mozzo portaruota (3).

Schrauben (1) abschrauben, die den Deckel des Zwei Schraubenzieher oder zwei Hebel in die vorge-
D Planetenradhalters (2) befestigen. D sehenen Nuten stecken und den Deckel (2) des
Planetenradhalters von den Radhalternaben (3) ab-
heben.
a b
Remover los tornillos (1) de fisaje de la tapa porta- Utilizando dos destornilladores o dos palancas inser-
ESP satelites (2). ESP tadas en las ranuras predispuestas, destacar la tapa
lleva-satelites (2) del cubo lleva-rueda (3).

Enlever les vis (1) de fixation du couvercle porte- A l'aide de deux tournevis ou de deux leviers dans les
F satellites (2). F creux preÂdisposeÂs, deÂgager le couvercle porte-satel-
lites (2) du moyeu porte-roue (3).

008 914 20 BOMAG

31 1233
20.4DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

2 3
5

F1241105 F1241106

GB a GB b
Rotate the wheel hub (3) until one of the screw holes (1) appears at Only in case of replacement of component parts not requiring
the top. the disassembly of the crown wheel (5).
Apply a "U" piece to the screw hole; connect to a hoist and remove Countermark the position between one of the teeth of the axle shaft
the cover (2). (4) and the crown wheel (5).

F1241107 F1241108

GB c GB d
Remove the axle shaft (4). Loosen the screws (6) and remove them.
NOTE. The removal of the axle shaft allows for the substitution of
the snap ring as described in the following paragraphs.

3 5

7
F1241109 F1241110

GB e GB f
Remove the safety flange (7). Partially tighten five of the ten screws (6) in an alternate and
proportional manner.
Using an extractor and applying a counter pressure to the screws
(6), disengage the crown wheel (5) from the hub (3).

1234 BOMAG
32 008 914 20
Axle 20.4

Ruotare il mozzo portaruota (3) fino a portare un foro Solo se si devono sostituire dei componenti che
ITA per le viti (1) in posizione alta. ITA non richiedono lo smontaggio della corona (5).
Applicare un grillo ad "U" nel foro vite; collegare un Contrassegnare la posizione tra un dente del semias-
mezzo di sollevamento e rimuovere il coperchio (2). se (4) e la corona (5).

Nur wenn Bestandteile ausgewechselt werden

D Die Radhalternabe (3) drehen bis ein Loch fuÈr die D muÈssen, fuÈr die der Kranz (5) nicht abmontiert
Schrauben (1) in der oberen Position liegt. werden muû.
Einen U-foÈrmigen BuÈgel in das Schraubenloch stecken; ein Die Position zwischen einem Zahn der Halbachse (4) und dem
a Hebezeug anschlieûen und den Deckel (2) abnehmen. b Kranz (5) markieren.

Girar el cubo lleva-rueda (3) hasta hacer un agujero Solo si se deben de sobstituir algunos componentes
ESP para los tornillos (1) en posicioÁn alta. ESP que no comportan el desmontaje de la corona (5).
Aplicar un grillo a "U" en el agujero tornillos; conectar Senalar la colocacioÁn entre un diente del semi-eje (4) y
un medio de levantamiento y remover la tapa (2). la corona (5).

Tourner le moyeu porte-roue (3) jusqu'aÁ aÁ amener un Uniquement si on doit substituer des composants qui
F des trous pour les vis (1) en haut. F ne veulent pas le deÂmontage de la couronne (5).
Appliquer une manille en "U" dans le trou de vis; Marquer la position entre une dent du demi-essieu (4)
appliquer un moyen de relevage et enlever le couvercle (2). et la couronne (5).

Asportare il semiasse (4). Allentare le viti (6) ed asportarle.

ITA ITA
NOTA. L'asportazione del semiasse permette la
sostituzione dell'anello di tenuta come descritto di
seguito.

Die Halbachse (4) abnehmen. Schrauben (6) abschrauben.

D D
BEMERKUNG. Bei abgenommener Halbachse kann
der Dichtring, wie nachstehend beschrieben, ausge-
wechselt werden.
c d
Sacar el semi-eje (4). Aflojar los tornillos (6) y sacarlos.
ESP ESP
NOTA. Sacar el semi-eje permite la sobstitucioÁn del
anillo de tenida como descrito a seguir.

Enlever le demi-essieu (4). Desserrer les vis (6) puis les enlever.
F F
REMARQUE. Le deÂgagement du demi-essieu consent
la substitution de l'anneau d'eÂtancheÂiteÂ comme deÂcrit
par la suite.

Asportare la flangia di sicurezza (7). Avvitare parzialmente, in modo alternato ed in uguale

ITA ITA misura, cinque delle dieci viti (6).
Utilizzando un estrattore e facendo reazione sulle viti
(6) disimpegnare la corona (5) dal mozzo (3).

Sicherheitsflansch (7) abnehmen. Abwechselnd und im gleichen Maû fuÈnf von den zehn
D D Schrauben (6) zuschrauben.
Mit einem Abzieher den Kranz (5) aus der Nabe (3)
ziehen und dabei auf die Schrauben (6) wirken.
e f
Sacar la arandela de seguridad (7). Atornillar parcialmente, de manera alternada y en
ESP ESP igual mesera, cinco de las diez tornillos (6).
Utilizando un extractor y haciendo reacioÁn sobre los
tornillos (6) desempenar la corona (5) del cubo (3).

Enlever la flasque de seÂcuriteÂ (7). Visser partiellement, en alternance et de la meÃme

F F facËon cinq des dix vis (6).
A l'aide d'un extracteur, tout en faisant reÂagir les vis
(6), deÂgager la couronne (5) du moyeu (3).

008 914 20 BOMAG

33 1235
20.4DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

3
F1241111 F1241112

GB a GB b
Remove screws (6) and crown wheel (5). Sling the hub (3) and connect it to a hoist; partially tighten a screw
(6) and with the help of a hammer, shift the hub (3) and the external
bearing (8).

3
9

8
10
3
F1241113 F1241114

GB c GB d
Remove the bearing (8) and the hub (3). Extract the hub (3) complete with snap ring (9) and internal bearing
(10).

14
13

11 12
F1241115 F1241116

GB e GB f
Using an extractor, remove at the same time the snap ring (11) and Remove the safety spring rings (13) of the planetary gears (14).
the centring ring (12).
NOTE. Note down the direction of assembly of snap and centring
rings.

1236 BOMAG
34 008 914 20
Axle 20.4

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'eÂtancheÂiteÂ (11) et l'anneau centreur (12). F satellites (14).
REMARQUE. Prendre note du sens de montage des
anneaux d'eÂtancheÂiteÂ et de centrage.

008 914 20 BOMAG

35 1237
20.4DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

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.

1238 BOMAG
36 008 914 20
Axle 20.4

Asportare gli ingranaggi satelliti (14). Solo se necessario.

ITA ITA Utilizzando un estrattore, rimuovere dal portasatelliti la
NOTA. Annotare il senso di montaggio dei satelliti.
rondella di rasamento (15).

Planetengetriebe (14) abnehmen. Nur wenn notwendig.

D D Mit einem Abzieher vom Planetenradhalter die Zwi-
BEMERKUNG. Montagerichtung notieren.
schenlegscheibe (15) abnehmen.

a b
Sacar los engranajes satelites (14). Solo si necesario.
ESP ESP Utilizando un extractor, remover del lleva-satelites la
NOTA. Anotar el sentido de desmontaje de los
satelites. arandela de rasamiento (15).

Enlever les engrenages satellites (14). Uniquement si besoin.

F F A l'aide d'un extracteur, enlever du porte-satellite la
REMARQUE. Prendre note du sens de montage.
rondelle de rasage (15).

Rimuovere dal mozzo (3) l'anello di tenuta (9). Rimuovere il cuscinetto interno (10).
ITA ITA
NOTA. Annotare il senso di montaggio.
ATTENZIONE! L'anello di tenuta non puoÁ essere
riutilizzato.

Von der Nabe (3) den Dichtring (9) abnehmen. Das innere Lager (10) abnehmen.
D D
BEMERKUNG. Montagerichtung notieren.
ACHTUNG! Der Dichtring darf nicht wieder verwendet
werden.
c d
Remover del cubo (3) los anillos de retencioÁn (9). Remover el cojinete interior (10).
ESP ESP
NOTA. Anotar el sentido de montaje.
ATENCION! El anillo de retencioÁn no puede ser
reutilizado.

Oter du moyeu (3) l'anneau d'eÂtancheÂiteÂ (9). Enlever le palier interne (10).
F F
REMARQUE. Prendre note du sens de montage.
ATTENTION! L'anneau d'eÂtancheÂiteÂ ne peut pas eÃtre
reÂutiliseÂ.

Rimuovere le ralle esterne dei cuscinetti (8) e (10)

ITA utilizzando un cacciaspine. ITA
NOTA. Battere in modo alternato per evitare impunta-
menti e deformazioni delle ralle.

Die aÈuûeren Scheiben (8) und (10) mit einem DuÈbel

D abnehmen. D
BEMERKUNG. Abwechselnd schlagen, um ein Durch-
schlagen und Verformungen der Scheiben zu vermeiden.
e f
Remover las ranguas externas de los cojinetes (8) y
ESP (10) utilizando un extractor de clavijas. ESP
NOTA. Pegar de manera alternada para evitar
empuntamientos y deformacioÁnes de las ranguas.

Enlever les crapaudines externes des paliers (8) et

F (10) aÁ l'aide d'un chasse-clou. F
REMARQUE. Donner des coups alterneÂs pour eÂviter
talonnages et deÂformations des crapaudines.

008 914 20 BOMAG

37 1239
20.4ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

T3 10 9

3
10

F1241122 F1241123

GB a GB b
Position the wheel hub (3) under a press; lubricate the seat of the Install the bearing (10).
external bearing and, using tool T3, install the thrust block of the Apply an appropriate sealant to the outer surface of the snap ring
bearing (10). (9).
Position the snap ring (9) into the hub (3).
NOTE. Check orientation of the ring.

T4 T3
9 3

8
F1241124 F1241125

GB c GB d
Position tool T4 and press the snap ring (9) down into its seat. Turn the hub (3) upside down, lubricate the seat of the bearing and,
using tool T3, install the thrust block of the bearing (8).

15
2 14

F1241126 F1241117

GB e GB f
Only if shim washer has previously been removed. Fit the planetary gear (14) onto the planetary gear cover (2).
Apply a sealant for removable seals to the outer surface of the shim CAUTION! The jointed portion of the internal ring of the bearings
washer (15) and, using a driver, fit it into the planetary gear cover must face the bottom of the pin.
(2).

1240 BOMAG
38 008 914 20
Axle 20.4

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'eÂtancheÂiteÂ (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'eÂtancheÂiteÂ (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 eÂteÂ enleveÂe. Monter sur les pivots du couvercle porte-satellites (2)
F Enduire la superficie externe de la rondelle de rasage F les engrenages planeÂtaires (14).
(15) avec de la colle pour garnitures amovibles, aÁ ATTENTION! La partie raccordeÂe de l'anneau aÁ
l'aide d'un poussoir monter celle-ci dans le couvercle porte- l'inteÂrieur du palier doit eÃtre tourneÂe vers la partie basse du pivot.
satellites (2).

008 914 20 BOMAG

39 1241
20.4ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

T5
13

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.

1242 BOMAG
40 008 914 20
Axle 20.4

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'eÂtancheÂiteÂ (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'eÂtancheÂiteÂ (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 seÂcuriteÂ (7) au contact de
moyeu du bras. la couronne.

008 914 20 BOMAG

41 1243
20.4ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

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

1244 BOMAG
42 008 914 20
Axle 20.4

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'eÂtancheÂiteÂ (11), les dents, la
F Serrer les vis (6) en deux temps avec la meÂthode du F superficie eÂtanche des demi-essieux.
serrage croiseÂ. Monter le demi-essieu (4) en veillant aÁ ce qu'il
Couple de serrage initial: 120Nm s'enclenche bien dans les disques freins et dans le diffeÂrentiel.
Couple de serrage final: 219v242 Nm.

Montare il coperchio portasatelliti (2) sul mozzo Bloccare il coperchio portasatelliti (2) sul mozzo
ITA portaruota (3). ITA portaruota (3) con le viti (1).
ATTENZIONE! 1 - Controllare lo stato e la posizione Coppia di serraggio viti: 40v50 Nm
della guarnizione OR (16).
2 - Allineare gli scarichi di riferimento.

Den Deckel des Planetenradhalters (2) auf die Nabe Den Deckel des Planetenradhalters (2) an der Rad-
D des Radhalters (3) montieren. D halternabe (3) mit den Schrauben (1) blockieren.
ACHTUNG! 1 - Zustand und Position der O-Ringe (16) Anzugsmoment der Schrauben: 40v50 Nm
kontrollieren.
c 2 - Die Bezugsstellen bzw. AblaûoÈffnung fluchten. d
Montar la tapa lleva-satelites (2) sobre el cubo lleva- Bloquear la tapa lleva-satelietes (2) sobre el cubo
ESP rueda (3). ESP lleva-rueda (3) con los tornillos (1).
ATENCION! 1 - Controlar el estado y la posicioÁn de la Par de torsion tornillos: 40v50 Nm
guarnicioÁn OR (16).
2 - Alinear los descarges de referencia.

Monter le couvercle porte-satellite (2) sur le moyeu Bloquer le couvercle porte-satellite (2) sur le moyeu
F porte-roue (3). F porte-roue (3) aÁ l'aide des vis (1).
ATTENTION! 1 - ControÃler l'eÂtat et la position des Couple de serrage des vis: 40v50 Nm.
garnitures O'Ring (16).
2 - Aligner les points de deÂcharge de reÂfeÂrence.

ITA ITA

D D

e f

ESP ESP

F F

008 914 20 BOMAG

43 1245
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

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).

1246 BOMAG
44 008 914 20
Axle 20.4

RIMOZIONE DIFFERENZIALE Applicare l'attrezzo T6 di centraggio dal lato corona

ITA Rimuovere i bracci completi, i cilindri freni ed il ITA con i relativi distanziali e fissarlo con due dadi.
riduttore completo. Applicare anche l'attrezzo T7A di centratura.
Per i dettagli, vedere «CONTROLLO USURA E SOSTITUZIONE
DISCHI FRENO» e «RIMOZIONE RIDUTTORE».

DIFFERENTIAL ABNEHMEN Das Werkzeug T6 zur Zentrierung an der Kranzseite

D Die kompletten Arme, die Bremszylinder und den D mit den entsprechenden DistanzstuÈcken anbringen
kompletten Reduzierer abnehmen. und das Werkzeug mit zwei Muttern befestigen.
Siehe «VERSCHLEISS KONTROLLIEREN UND BREMSSCHEI- Das Werkzeug T7A zur Zentrierung anbringen.
a BEN AUSWECHSELN» und «REDUZIERER ABNEHMEN». b
REMOCION DIFERENCIAL Aplicar la herramienta T6 de centraje del lado corona
ESP Remover los ejes completos, los cilindros frenos y el ESP con los relativos distanciales y fijarla con dos tuercas.
reductor completo. Aplicar tambien la herramienta T7A de centradura.
Para los detalles, vease «CONTROL DESGASTE Y SOBSTITU-
CION DISCOS FRENOS» y «REMOCION REDUCTOR».

DEGAGEMENT DU DIFFERENTIEL Appliquer l'outil T6 de centrage du coÃteÂ couronne

F Enlever les bras entieÁrement, les cylindres freins et le F avec les entretoises correspondantes et fixer l'outil
reÂducteur tout entier. avec deux eÂcrous.
Pour de plus amples deÂtails, voir "CONTROLE DE L'USURE ET Appliquer eÂgalement l'outil de centrage T7A.
SUBSTITUTION DU DISQUE FREIN" et "DEGAGEMENT DU
REDUCTEUR".

Rimuovere le viti prigioniere e rimuovere il coperchio Montare l'attrezzo T7B di centraggio sul lato opposto
ITA intermedio (1) dal lato opposto corona. ITA corona.

Die Stiftschrauben und den Zwischendeckel (1) von Das Werkzeug T7B zur Zentrierung an der dem Kranz
D der dem Kranz entgegengesetzte Seite abnehmen. D entgegengesetzte Seite montieren.

c d
Remover los tornillos prigioneros y remover la tapa Montar la herramienta T7B de centraje sobre el lado
ESP intermedia (1) del lado opuesto corona. ESP opuesto corona.

Enlever les vis prisonnieÁres et enlever le couvercle Monter l'outil de centrage T7B du coÃteÂ opposeÂ aÁ la
F intermeÂdiaire (1) du coÃteÂ opposeÂ 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 coÃteÂ 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 coÃteÂ couronne. (aluminium etc.) de contraste.
En maintenant la couronne (4) sur le petit bloc "A", deÂvisser et
enlever les vis (5), et ensuite les rondelles eÂlastiques (6).

008 914 20 BOMAG

45 1247
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

7
7

F1241147 F1241148

GB a GB b
Using a driver, push the differential unit (7) or (8) towards the Extract the whole differential unit (7) or (8).
opposite side of the crown so as to disengage it from the crown (4).

T7B 3 3

4
4

F1241223 F1241174

GB c GB d
Remove tool T7B from the crown opposite side. Extract the crown (4).

B
9
9

F1241149 F1241150

GB e GB f
DISASSEMBLY OF THE DIFFERENTIAL UNIT DISASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT
Using an extractor, remove bearings (9) from the differential unit. Insert stay "B" provided for holding into position the no-spin unit
(14) and screw tight the wing nut.

1248 BOMAG
46 008 914 20
Axle 20.4

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 coÃteÂ opposeÂ aÁ la couronne jusqu'aÁ le deÂgager de la F
couronne (4).

Rimuovere l'attrezzo T7B montato sul lato opposto Estrarre la corona (4).
ITA corona. ITA

Das Werkzeug T7B abnehmen, das an der dem Kranz Kranz (4) abziehen.
D entgegengesetzte Seite montiert ist. D

c d
Remover la herramienta T7B montado sobre el lado Extraer la corona (4).
ESP opuesto corona. ESP

DeÂplacer l'outil T7B monteÂ du coÃteÂ opposeÂ aÁ la Extraire la couronne (4).

F couronne. F

SMONTAGGIO DIFFERENZIALE SMONTAGGIO DIFFERENZIALE NO-SPIN

ITA Utilizzando un estrattore, asportare i cuscinetti (9) dal ITA Inserire il tirante "B" di trattenimento del gruppo no-
gruppo differenziale. spin (14) ed avvitare a fondo il dado ad alette.

DIFFERENTIAL ABMONTIEREN DAS NO-SPIN DIFFERENTIAL ABMONTIEREN

D Mit einem Abzieher die Lager (9) vom Differentialag- D Sie Spannstange "B" einsetzen, um das No-Spin
gregat abnehmen. Aggregat (14) festzuhalten und die FluÈgelmutter fest-
ziehen.
e f
DESMONTAJE DIFERENCIAL DESMONTAJE DIFERENCIAL NO-SPIN
ESP Utilizando un extractor, sacar los cojinetes (9) del ESP Introducir el tirante "B" de detencion del grupo no-spin
grupo diferencial. (14) y atornillar hasta el fondo la tuerca a aletas.

DEMONTAGE DU DIFFERENTIEL DEMONTAGE DU DIFFERENTIEL NO-SPIN

F A l'aide d'un extracteur, enlever les paliers (9) du F Introduire la tringle "B" de retenue du groupe no-spin
groupe diffeÂrentiel. (14), puis visser l'eÂcrou aÁ ailettes aÁ fond.

008 914 20 BOMAG

47 1249
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

10 11

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.

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.
1250 BOMAG
48 008 914 20
Axle 20.4

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 moitieÂ du boõÃtier diffeÂrentiel (12). F la moitieÂ du boõÃtier diffeÂrentiel (12).
REMARQUE. Prendre note de la marque d'accou-
plement.

Estrarre il gruppo no-spin (13). Svitare il dado ad alette del tirante "B" e scomporre il
ITA ITA gruppo no-spin per rimuovere il distanziale (14) contro
lo scorrimento assiale dei semiassi.

Das No-Spin Aggregat (13) abziehen. Die FluÈgelmutter der Spannstange "B" abschrauben
D D und das No-Spin Aggregat zerlegen, um das Differen-
tial (14) an der Achsengleitung der Halbachsen
abnehmen zu koÈnnen.
c d
Sacar el grupo no-spin (13). Destornillar la tuerca a aletas del tirante "B" y
ESP ESP decomponer el grupo no-spin para remover el distan-
cial (14) contra el deslizamiento axial de los semi-ejes.

Extraire le groupe no-spin (13). DeÂvisser l'eÂcrou aÁ ailettes de la tringle "B" et

F F deÂcomposer le groupe no-spin pour enlever le
diffeÂrentiel (14) contre le coulisseau axial des demi-
essieux.

SMONTAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Rimuovere il coperchio differenziale (18), gli eventuali
ITA Rimuovere le viti (16) e le rondelle elastiche (17) di ITA spessori (19) e la frizione (20) completa dell'anello (21).
unione del corpo differenziale. ATTENZIONE! 1 - Non scambiare di posizione i dischi
componenti la frizione.
2 - Controllare che lo spessore totale della frizione sia superiore a
17,3 mm; se eÁ inferiore sostituire ambedue le frizioni.

DAS ZU 45% SELBSTHEMMENDE DIFFERENTIAL ABMONTIEREN Differentialdeckel (18) und evtl. Unterlegscheiben (19)
D Schrauben (16) und Federscheiben (17), die den D und die Kupplung (20) mit dem Ring (21) abnehmen.
DifferentialkoÈrper verbinden, abnehmen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
e f 2 - Die GesamtstaÈrke der Kupplung muû mehr als 17,3 mm betragen;
sollte dies nicht der Fall sein, beide Kupplungen auswechseln.

DESMONTAJE DIFERENCIAL AUTOBLOQUEO AL 45% Remover la tapa diferencial (18), los eventuales
ESP Remover los tornillos (16) y las arandelas elasticas ESP espesores (19) y la fricion (20) completa del anillo (21).
(17) de union del cuerpo diferencial. ATENCION! 1 - No cambiar de posicion los discos
componentes la fricion.
2 - Controlar que el espesor total de la fricion sea superior a 17,3
mm; si es inferior sobstituir las dos friciones.

DEMONTAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Enlever le couvercle diffeÂrentiel (18), les eÂventuelles
F Enlever les vis (16), les rondelles eÂlastiques (17) F cales (19) et la friction (20) compleÁte d'anneau (21).
d'union du corps diffeÂrentiel. ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ
17,3 mm; s'il est infeÂrieur substituer les deux frictions.

008 914 20 BOMAG

49 1251
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

22
25 23

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).

1252 BOMAG
50 008 914 20
Axle 20.4

Rimuovere l'ingranaggio planetario (22). Rimuovere il perno porta satelliti lungo (23) ed i due
ITA Segnare su un cacciaspine un contrassegno a 37 mm; ITA perni corti (24).
utilizzando lo stesso cacciaspine, inserire nei perni
(23) e (24) le spine elastiche (25).
NOTA. Le spine elastiche sono centrate nei perni (23) e (24)
quando il contrassegno arriva a filo del corpo differenziale (26).

Das Planetengetriebe (20) abnehmen. An einem DuÈ- Den langen Planetenradhalterstift (23) und die beiden
D bel das Maû von 37 mm markieren; mit diesem DuÈbel D kurzen Planetenradhalterstifte (24) entfernen.
die Federstifte (25) in die Stifte (23) und (24) einsetzen.
BEMERKUNG. Die Federstifte sind in den Stiften (23) und (24)
a zentriert, wenn das markierte Maû auf der HoÈhe des Differential- b
koÈrpers (26) liegt.

Remover el engranaje planetario (22). Senalizar sobre Remover la rotula porta satelites largo (23) y las dos
ESP un extractor de clavijas un contra-segno a 37 mm; ESP rotulas cortas (24).
utilizando el mismo extractor de clavijas, introducir en
los pernos (23) y (24) las clavijas elasticas (25).
NOTA. Las clavijas elasticas son centradas en los pernos (23) y
(24) cuando el contrasegno llega al hilo del cuerpo diferencial (26).

Enlever l'engrenage planeÂtaire (22). Marquer d'une Enlever le pivot porte-satellite long (23) et les deux
F estampille le chasse-clou aÁ 37 mm; a l'aide de ce meÃme F pivots courts (24).
chasse-clou, introduire dans les pivots (23) et (24) les
goupilles eÂlastiques (25).
REMARQUE. Les goupilles eÂlastiques sont centreÂes dans les pivots
(23) et (24) quand l'estampille atteint le bord du corps diffeÂrentiel (26).

Estrarre la crociera (27), i satelliti (28) completi delle Rimuovere la 2ã frizione (20) completa dell'anello (21).
ITA rondelle di rasamento (29) ed il 2ë ingranaggio ITA Rimuovere anche gli eventuali spessori (19).
planetario (22). ATTENZIONE! 1 - Non scambiare di posizione i dischi
componenti la frizione.
2 - Controllare che lo spessore totale della frizione sia superiore a
17,3 mm; se eÁ inferiore sostituire ambedue le frizioni.

Das Kreuz (27), die Planetengetriebe (28) samt Die 2. Kupplung (20) mit Ring (21) abnehmen.
D Zwischenlegscheiben (29) und das 2. Planetengetrie- D Eventuelle Unterlegscheiben (19) auch entfernen.
be (30) abziehen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
c d 2 - Kontrollieren, ob die GesamtstaÈrke der Kupplung mehr als 17,3 mm
betraÈgt; anderenfalls beide Kupplungen auswechseln.

Sacar la cruceta (27), los satelites (28) completos de Remover la 2ë fricion (30) completa del anillo (21).
ESP las arandelas de rasamiento (29) y el 2ë engranaje ESP Remover tambien los eventuales espesores (19).
planetario (22). ATENCION! 1 - No cambiar de posicion los discos
componentes la fricion.
2 - Controlar que el espesor total de la fricion sea superior a 17,3 mm;
si es inferior sobstituir las dos friciones.

Extraire le croisillon (27), les satellites (28) complet de Enlever la 2ë friction (20) compleÁte d'anneau (21).
F rondelles de rasage (29), puis le 2ë engrenage F Enlever eÂgalement les eÂventuelles cales (19).
planeÂtaire (22). ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ
17,3 mm; s'il est infeÂrieur substituer les deux frictions.

Estrarre le spine elastiche (25) dai perni (23) e (24). Solo se si sostituiscono i cuscinetti
ITA ITA Rimuovere le ralle dei cuscinetti (9) dai coperchi
intermedi (1) e (2).

Die Federstifte (25) von den Stiften (23) und (24) Nur falls die Lager ausgewechselt werden.
D abziehen. D Die Scheiben von den Lagern (9) der Zwischendeckel
(1) und (2) abnehmen.

e f
Sacar las clavijas elasticas (25) de las rotulas (23) y Solo si se sobstituiyen los cojinetes
ESP (24). ESP Remover las ranguas de los cojinetes (9) de las tapas
intermedias (1) y (2).

Extraire les goupilles eÂlastiques (25) des pivots (23) et Uniquement en cas de substitution des paliers.
F (24). F Enlever les crapaudines des paliers (9) des couvercles
intermeÂdiaires (1) et (2).

008 914 20 BOMAG

51 1253
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

30
4 33
35 36 3 34
32
7
45 31
1
8

38
44 40
GB a GB b
6 41

39
37

43 47
32
42

GB
33 34
c GB d
31

D1240134

GB e GB f

1254 BOMAG
52 008 914 20
Axle 20.4

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

F F 8

D1240135

ITA ITA

D D

e f

ESP ESP

F F

008 914 20 BOMAG

53 1255
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

12
13

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.

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).

1256 BOMAG
54 008 914 20
Axle 20.4

ASSEMBLAGGIO DIFFERENZIALE NO-SPIN Montare il gruppo no-spin nella semiscatola differen-

ITA Assemblare il gruppo no-spin (13) inserendo il distan- ITA ziale (15).
ziale (14) ed utilizzando il tirante "B". Centrare la semiscatola (12) e mandarla in battuta.
ATTENZIONE! Controllare che le marcature di accoppiamento
coincidano.

NO-SPIN DIFFERENTIAL ZUSAMMENBAUEN Das No-Spin Aggregat in das halbe Differentialge-

D Das No-Spin (13) Aggregat zusammenbauen; dazu D haÈuse (15) montieren.
das DistanzstuÈck (14) mit der Spannstange "B" Das halbe GehaÈuse (12) zentrieren und bis zum
einsetzen. Anschlag einsetzen.
a b ACHTUNG! Kontrollieren, ob die Kupplungsmarkierungen uÈberein-
stimmen.

MONTAJE DIFERENCIAL NO-SPIN Montar el grupo no-spin en la semi-caja diferencial

ESP Asemblaje el grupo no-spin (13) introduciendo el ESP (15).
diferencial (14) y utilizando el tirante "B". Centrar la semi-caja (12) y mandarla a tope.
ATENCION! Controlar que las marcaduras de acoplamiento
coincidan.

ASSEMBLAGE DU DIFFERENTIEL NO-SPIN Monter le groupe no-spin dans la moitieÂ du boõÃtier

F Assembler le groupe no-spin (13) en introduisant F diffeÂrentiel (15).
l'entretoise (14), puis aÁ l'aide de la tringle "B". Centrer la moitieÂ du boõÃtier (12) et l'envoyer en buteÂe.
ATTENTION! ControÃler que les estampilles d'accouplement
correspondent.

Infilare sulle viti (10) le rondelle elastiche (11). Rimuovere il tirante "B".
ITA Spalmare le viti (10) con Loctite 270 ed avvitarle a ITA
fondo per comporre la scatola differenziale.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
86v89 Nm.

Federscheiben (11) in die Schrauben (10) einsetzen. Spannstange "B" abnehmen.

D Die Schrauben (10) mit Loctite 270 schmieren und D
festziehen, um das DifferentialgehaÈuse zusammenzu-
bauen.
c Die Schrauben im Kreuz und mit einem Anzugsmoment von 86v89
Nm festziehen.
d
Insertar sobre tornillos (10) las arandelas elasticas Remover el tirante "B".
ESP (11). ESP
Pasar los tornillos (10) con Loctite 270 y atornillar
hasta el fondo para componer la caja diferencial.
Apretar los tornillos con el metodo cruzado y un par de serraje de
86v89 Nm.

Passer sur les vis (10) les rondelles eÂlastiques (11). Enlever la tringle "B".
F Enduire les vis (10) avec du Loctite 270, puis visser F
celles-ci aÁ fond pour recomposer le boõÃtier diffeÂrentiel.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
86v89 Nm.

ASSEMBLAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Inserire nella corpo differenziale (26) gli eventuali
ITA Controllare con un calibro di profonditaÁ lo spessore ITA spessori (19) e la frizione (20) completa dell'anello
delle frizioni complete degli anelli (21). Se lo spessore (21).
eÁ inferiore a 17,6 mm, aggiungere degli spessori (19). ATTENZIONE! L'anello (21) deve rimanere a contatto dell'ingra-
ATTENZIONE! Gli spessori devono essere posizionati a ridosso del naggio planetario (22).
corpo differenziale (26).

ZU 45% SELBSTHEMMENDE DIFFERENTIAL ZUSAMMENBAUEN In den DifferentialkoÈrper (26) eventuelle Unterleg-

D Mit Hilfe einer Tiefenlehre die StaÈrke der Kupplungen D scheiben (19) und die Kupplung (20) samt Ring (21)
mit den Ringen (21) messen. Sollte das Maû weniger einsetzen.
als 17,6 mm betragen, noch Unterlegscheiben (19) hinzufuÈgen. ACHTUNG! Der Ring (21) muû am Planetengetriebe (22) anliegen.
e ACHTUNG! Die Unterlegscheiben muÈssen am DifferentialkoÈrper f
(26) anliegen.

MONTAJE DIFERENCIAL AUTO-BLOQUEO AL 45% Introducir en el cuerpo diferencial (26) los eventuales
ESP Controlar con un calibro de profundidad el espesor de ESP espesores (19) y la fricion (20) completa del anillo (21).
las friciones completas de los anillos (21). Si el ATENCION! El anillo (33) debe quedar a contacto del
espesor es inferior a 17,6 mm, sumar de los espesorees (19). engranaje planetario (22).
ATENCION! Los espesores deben de ser colocados detraÁs del
cuerpo diferencial (26).

ASSEMBLAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Introduire le corps diffeÂrentiel (26), les eÂventuelles
F ControÃler aÁ l'aide d'un calibre de profondeur l'eÂpais- F cales (19) et la friction (20) compleÁte d'anneau (21.
seur des frictions compleÁtes d'anneaux (21). Si le ATTENTION! L'anneau (21) doit rester au contact de
calage est infeÂrieur aÁ 17,6 mm, ajouter des cales (19). l'engrenage planeÂtaire (22).
ATTENTION! Les cales doivent eÃtre placeÂes aÁ l'abri du corps
diffeÂrentiel (226).

008 914 20 BOMAG

55 1257
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

27
22 28

26
23

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

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.

1258 BOMAG
56 008 914 20
Axle 20.4

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 moitieÂ des pivots quand ATTENTION! L'anneau (21) est aÁ monter aÁ l'abri de l'engrenage
l'estampille atteint le bord du corps diffeÂrentiel (26). planeÂtaire (22) et les eÂventuelles cales (19) aÁ l'abri du couvercle
diffeÂrentiel (18).

Posizionare il coperchio differenziale (18). Infilare sulle viti (16) le rondelle elastiche (17).
ITA ITA Spalmare le viti (16) con Loctite 270 ed avvitarle a
NOTA. Controllare che le marcature di montaggio
coincidano. fondo.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
135v138 Nm.

Den Differentialdeckel (18) positionieren. Auf die Schrauben (16) die Federscheiben (17)
D D montieren.
BEMERKUNG. Kontrollieren, ob die Montagemarkie-
rungen uÈbereinstimmen. Die Schrauben (16) mit Loctite 270 schmieren und
festziehen. Die Schrauben im Kreuz mit einem Anzugsmoment von
e f 135v138 Nm festziehen.

Colocar la tapa diferencial (18). Introducir sobre los tornillos (16) las arandelas
ESP ESP elasticas (17).
NOTA. Colocar que las marcaduras de montaje
coincidan. Pasar los tornillos (16) con Loctite 270 y atornillarlos a
fondo.
Apretar los tornillos con el metodo cruzado a un par de serraje de
135v138 Nm.

Mettre le couvercle diffeÂrentiel (18) en place. Passer sur les vis (16) les rondelles eÂlastiques (17).
F F Enduire les vis (16) avec du Loctite 270 et visser
REMARQUE. ControÃler que les estampilles de mon-
tage coõÈncident. celles-ci aÁ fond.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
135v138 Nm.

008 914 20 BOMAG

57 1259
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

9 9 9 9

7
8
8 7

F1241171 F1241172

GB a GB b
INSTALLATION OF THE DIFFERENTIAL UNIT Turn the unit upside down and install the second bearing (9).
Position the differential unit (7) or (8) under a press and, using a CAUTION! Pay particular attention; position a shim with adequate
driver with an adequate diameter, install the first bearing (9). diameter in order to engage the internal ring of bearing (9) without
engaging the cage.

T8
9

F1241173 F1241174

GB c GB d
Only if bearings are replaced Position the crown wheel (4) in the main body (3).
Using tool T8, insert the thrust blocks of the bearings (9) into the
intermediate covers (1) and (2).

T7B 7 8

F1241175 F1241176

GB e GB f
Fit tool T7B on the crown wheel opposite side, holding it in position Install the differential unit (7) or (8), by fitting it into the hole of tool
with two studs and two nuts. T7B.
NOTE. Engage the crown (4) onto tool T7B. Install the crown (4) onto the differential unit (7) or (8), and fasten it
to the flange.
NOTE. Make sure the holes of the flange match those of the crown.

1260 BOMAG
58 008 914 20
Axle 20.4

INSTALLAZIONE DIFFERENZIALE Capovolgere il gruppo e montare il secondo cuscinetto

ITA Posizionare il differenziale (7) o (8) sotto una pressa ed ITA (9).
utilizzando uno spintore di diametro adatto montare il ATTENZIONE! Prestare molta attenzione e posiziona-
primo cuscinetto (9). re uno spessore di diametro adatto al fine di impegnare l'anello
interno del cuscinetto (9) senza impegnare la gabbia.

DIFFERENTIAL ZUSAMMENBAUEN Das Aggregat wenden und das zweite Lager montie-
D Das Differential (7) oder (8) unter eine Presse legen D ren (9).
und mit einem geeigneten Dynamometer-StoÈûel das ACHTUNG! Den Vorgang mit groûer Sorgfalt durch-
erste Lager (9) montieren. fuÈhren und einen fuÈr die StaÈrke geeigneten Dynamometer
a b verwenden, um den Ring des inneren Lagers (9) einzusetzen,
ohne den KaÈfig einzuklemmen.

INSTALACION DIFERENCIAL Volcar el grupo y montar el segundo cojinete (9).

ESP Colocar el diferencial (7) y (8) bajo una prensa y ESP
ATENCION! Tener mucho cuidado y colocar un
utilizando un empuje de diametro adapto montar el espesor de diametro apto al fin de empegnar el anillo
primer cojinete (9). interno del cojinete (9) si empegnar la jaula.

INSTALLATION DU DIFFERENTIEL Faire basculer le groupe et monter le second palier (9).

F Mettre le diffeÂrentiel (7) ou (8) en place sous la presse, F
ATTENTION! Faire treÁs attention, mettre une cale au
aÁ l'aide d'un poussoir au diameÁtre adeÂquat, monter le diameÁtre adeÂquat afin d'engager l'anneau interne du
premier palier (9). palier (9) sans y engager la cage.

Solo se si sostituiscono i cuscinetti Posizionare la corona (4) dentro il corpo centrale (3).
ITA Utilizzando l'attrezzo T8 inserire le ralle dei cuscinetti ITA
(9) nei coperchi intermedi (1) e (2).

Nur wenn die Lager ausgewechselt werden. Den Kranz (4) in den zentralen KoÈrper (3) einsetzen.
D Mit dem Werkzeug T8 die Scheiben der Lager (9) in D
die Zwischendeckel (1) und (2) einsetzen.

c d
Solo si se sobstituyen los cojinetes Colocar la corona (4) dentro del cuerpo central (3).
ESP Utilizando la herramienta T8 Introducir las ranguas de ESP
los cojinetes (9) en las tapa intermedias (1) y (2).

Uniquement en cas de substitution des paliers Mettre la couronne (4) en place dans le corps central
F A l'aide de l'outil T8, introduire la crapaudine des F (3).
paliers (9) dans les couvercles intermeÂdiaires (1) et (2).

Montare l'attrezzo T7B sul lato opposto corona, Montare il gruppo differenziale (7) o (8) impegnandolo
ITA trattenendolo con due prigionieri e due dadi. ITA nel foro dell'attrezzo T7B.
NOTA. Impegnare la corona (4) sull'attrezzo T7B. Montare la corona (4) sul differenziale (7) o (8)
mandandola in battuta sulla flangia.
NOTA. Far coincidere i fori della flangia con i fori della corona.

Das Werkzeug T7B auf der dem Kranz entgegen- Das Differentialaggregat (7) oder (8) montieren und im
D gesetzten Seite montieren und mit zwei Stiftschrauben D Loch des Werkzeuges T7B einrasten.
und zwei Muttern festhalten. Den Kranz (4) auf das Differential (7) oder (8)
BEMERKUNG. Den Kranz (4) in das Werkzeug T7B einrasten. montieren und bis zum Anschlag am Flansch einsetzen.
e f BEMERKUNG. Die FlanschloÈcher muÈssen mit den KranzloÈchern
uÈbereinstimmen.

Montar la herramienta T7B sobre el lado opuesto Montar el grupo diferencial (7) o (8) empegnandolo en
ESP corona, deteniendo con dos prigionieros y dos ESP el agujero de la herramienta T7B.
tuercas. Montar la corona (4) sobre el diferencial (7) y (8)
NOTA. Empegnar la corona (4) sobre la herramienta T7B. mandandola a tope sobre la brida.
NOTA. Hacer coincidir los agujeros de la brida con los agujeros de
la corona.

Monter l'outil T7B du coÃteÂ opposeÂ aÁ la couronne, en le Monter le groupe diffeÂrentiel (7) ou (8) en l'engageant
F tenant aÁ l'aide de deux prisonniers et de deux eÂcrous. F dans le trou de l'outil T7B.
REMARQUE. Engager la couronne (4) sur l'outil T7B. Monter la couronne (4) sur le diffeÂrentiel (7) ou (8) puis
l'envoyer en buteÂe sur la flasque.
REMARQUE. Faire correspondre les trous de la flasque avec les
trous de la couronne.

008 914 20 BOMAG

59 1261
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

35
5 A

F1241177 F1241145

GB a GB b
Fit spring washers (6) onto the screws (5). Check the condition and position of the O-ring (30); lubricate the
Coat screws with Loctite 270 and screw them tight into the crown. seal and install the intermediate cover (2) on crown wheel side.
Position the stop block "A"; while holding the crown resting on the
block, tighten the screws (5) to a torque of 135 ± 138 Nm.
CAUTION! Tighten screws using the criss-cross method.

2
T6
31
T7A

F1241178 F1241179

GB c GB d
Lock the intermediate cover (2) with the journals (31) tightened to a Install tool T6 on the journals (31) on the crown wheel side, placing
torque of 129 ± 143 Nm. distance pieces and locking with two nuts. Insert differential
centring and support tool T7A into tool T6.
NOTE. Make sure that the differential unit is tightly engaged in the
intermediate cover (2).

T7B 1
30

F1241180 F1241181

GB e GB f
Remove tool T7B on crown opposite side. Check state and position of O-ring (30); lubricate the seal and fit the
intermediate cover (1) on the crown opposite side.
Lock the intermediate cover (1) with journals (31) tightened to a
torque of 129 ± 143 Nm and remove tools T6 and T7A.

1262 BOMAG
60 008 914 20
Axle 20.4

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 coÃteÂ 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) coÃteÂ 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 engageÂ 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 coÃteÂ opposeÂ 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 coÃteÂ opposeÂ aÁ la
couronne.
Fixer le couvercle intermeÂdiaire (1) aÁ l'aide des prisonniers (31)
serreÂs aÁ un couple de 129v143 Nm, enlever les outils T6 et T7A.

008 914 20 BOMAG

61 1263
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

1 32

32 T9

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

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

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.

1264 BOMAG
62 008 914 20
Axle 20.4

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 cleÂ T9, enlever les eÂcrous annulaires (32)
F seÂcuriteÂ (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 coÃteÂ couronne jusqu'aÁ
F celles-ci aÁ fond. F annuler le jeux entre pignon et couronne, puis
Serrer les vis (38) avec la meÂthode croiseÂe aÁ un couple deÂvisser 1/4 de tour.
de serrage de 129v143 Nm.

008 914 20 BOMAG

63 1265
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

F1241187 F1241188

GB a GB b
Allow pinion to turn a few times in both directions to allow bearings Introduce a comparator with rotary key "C" through the rear cap
to set. Pre-load the bearings through the ring nut on crown opposite hole (43).
side to increase pinion torque up to a value of 140 ± 210 Ncm Position comparator on the centre of one of the crown teeth (4), pre-
checked by means of a torque meter. set it to 1 mm and reset it to zero.
CAUTION! If bearings are old, check static torque. If new, check Manually move the crown (4) in both directions to check the
continuous torque. existing clearance between pinion and crown.

RATIO - RAPPORTO CLEARANCE - GIOCO - SPIEL

VERHAÈ LTNIS JUEGO - JEU 32
RAPORTE - RAPPORT MIN. MAX.
T9
6v43 0,18 0,23
Difference between MIN and MAX clearance for whole circumference
should not exceed 0.09 mm.
La differenza tra gioco MIN e MAX rilevata sull'intera circonferenza
non deve superare il valore di 0,09 mm.
Der Unterschied zwischen dem MIN e MAX Spiel der gesamten
Kreislinie darf den Wert von 0,09 mm nicht uÈberschreiten.
La diferencia entre el juego Min y Max determinada sobre la entera
circonferencia no debe de superar el valor de 0,09 mm.
La diffeÂrence de jeu entre MIN et MAX releveÂe sur toute la
circonfeÂrence ne doit pas aller au-delaÁ de la valeur de 0,09 mm.
F1241183

GB c GB d
Mark the position of the ring nuts (32) in relation to the intermediate
covers.
Using wrench T9, adjust clearance between pinion and crown by
loosening one ring nut (32) and tightening the opposite proportion-
ally.
Normal clearance: see table.

36
34

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).

1266 BOMAG
64 008 914 20
Axle 20.4

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 coÃteÂ opposeÂ aÁ la couronne, pour augmenter le couple Positionner celui-ci au centre d'une des dents de la
de rotation du pignon jusqu'aÁ 140v210 Ncm controÃleÂs par un torsiomeÁtre. couronne (4), preÂcharger celui-ci d'environ 1 mm et mettre aÁ zeÂro.
ATTENTION! Avec des paliers usageÂs, controÃler le couple de pointe; avec DeÂplacer manuellement la couronne (4) dans les deux sens pour
des paliers neufs, controÃler le couple de rotation continu. controÃler le jeu existant entre pignon et couronne.

Contrassegnare la posizione delle ghiere (32) rispetto i

ITA ITA coperchi intermedi.
Con la chiave T9, regolare il gioco tra pignone e
corona allentando una ghiera (32) e serrando la ghiera opposta in
egual misura.
Gioco normale: vedere tabella.

Die Position der Nutmuttern (32) im VerhaÈltnis zu den

D D Zwischendeckeln markieren.
Mit dem SchluÈûel T9, das Spiel zwischen Rad und
Kranz einstellen, in dem eine Nutmutter (32) gelockert und die
c d entgegengesetzte festgezogen wird.
Normales Spiel: siehe Tabelle.

Contrasenalr la colocacion de las virolas (32) respecto

ESP ESP a las tapaderas intermedias.
Con la llave T9, regular el juego entre el pignon y la
corona aflojando una virola (32) y apretando la virola opuesta en la
misma mesura.
Juego normal: vease el prospecto.

Marquer la position de l'eÂcrou annulaire (32) par

F F rapport aux couvercles intermeÂdiaires.
A l'aide de la cleÂ T9, reÂgler le jeu entre pignon et
couronne en deÂvissant l'eÂcrou annulaire (32) et en vissant l'eÂcrou
annulaire opposeÂ de la meÃme mesure.
Jeu normal: voir tableau.

Montare le linguette di sicurezza (41) e fissarle con le Con uno spintore, montare il tappo (36) ed assicurarlo
ITA viti (40). ITA in sede con l'anello elastico (35).
Coppia di serraggio viti: 10v11 Nm

Den Sicherheitskeil (41) montieren und mit den Mit einem StoÈûel den Stopfen (36) montieren und in
D Schrauben (40) befestigen. D seinem Sitz mit dem Kolbenring (35) befestigen.
Anzugsmoment der Schrauben: 10v11 Nm

e f
Montar las lenguetas de seguridad (41) y fijarlas con Con un empujador, montar la tapa (36) y asegurarlo en
ESP los tornillos (40). ESP sed con el anillo elastico (36).
Par de serraje tornillos: 10v11 Nm

Monter les languettes de seÂcuriteÂ (41), fixer celles-ci aÁ A l'aide d'un poussoir, monter le bouchon (36), ajuster
F l'aide des vis (40). F celui-ci dans son logement avec l'anneau eÂlastique
Couple de serrage des vis: 10v11 Nm. (35).

008 914 20 BOMAG

65 1267
20.4 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

37
36

40
F1241190 F1241192

GB a GB b
Using a driver and a plastic hammer, install the driving gear (39). Apply Loctite 510 to the surface of the reduction gear body (37) and
install the cover (40).
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.

41 44

40
46

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».

1268 BOMAG
66 008 914 20
Axle 20.4

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'eÂtancheÂiteÂ (45) et les bouchons (47) et (46), serrer
couple de 82v91 Nm. ceux-ci aÁ un couple de 35v50 Nm.

Completare l'assemblaggio dell'assale installando

ITA nell'ordine i cilindri freni ed i bracci completi. ITA
Per i dettagli, vedere «ASSEMBLAGGIO GRUPPI
FRENO».

Die Achse fertig zusammenbauen und der Reihe nach

D die Bremszylinder und die kompletten Arme installie- D
ren.
Siehe «ZUSAMMENBAU DER BREMSAGGREGATE».
e f
Completar el asemblaje del axial instalando en el
ESP orden los cilindros frenos y los ejes completos. ESP
Para los detalles, vease «ASEMBLAJE GRUPOS
FRENOS».

Achever l'assemblage de l'essieu en y installant dans

F l'ordre les cylindres freins et les bras complets. F
Pour de plus amples deÂtails voir "ASSEMBLAGE DU
GROUPE FREIN".

008 914 20 BOMAG

67 1269
20.4DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRADAxle
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

1 7

6 5
F1241141 F1241195

GB a GB b
Remove the whole arms and the differential unit. Loosen and remove screws (1) and (2) and the washers (3) locking
For details, see «CHECKING WEAR AND REPLACING THE the cover (4), the plugs (5) and (6) for oil fill and oil drain, and the
BRAKING DISKS» and «REMOVAL OF DIFFERENTIAL UNIT». bleed union piece (7).
NOTE. Leave two screws (2) in position for safety.

4
13 A

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

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.

1270 BOMAG
68 008 914 20
Axle 20.4

Rimuovere i bracci completi ed il differenziale. Allentare ed asportare le viti (1) e (2) e le rondelle (3) di
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA ritegno coperchio (4), i tappi (5) e (6) di carico e scarico
SOSTITUZIONE DISCHI FRENO» e «RIMOZIONE olio ed il raccordo di sfiato (7).
GRUPPO DIFFERENZIALE». NOTA. Lasciare in posizione per sicurezza due viti (2) contrappo-
ste.

Die kompletten Arme und das Differential abnehmen. Schrauben (1) und (2) abschrauben und die Unter-
D Siehe «VERSCHLEISS KONTROLLIEREN UND D legscheiben (3) zur Halterung des Deckels (4), die
BREMSSCHEIBEN AUSWECHSELN» und «DIFFE- OÈ leinfuÈll- und Ablaûstopfen (5) und (6) sowie das
RENTIALAGGREGAT ABNEHMEN». EndluÈftungsstuÈck (7) abnehmen.
a b BEMERKUNG. Die entgegengesetzten Schrauben (2) zur Sicher-
heit zuruÈck lassen.

Remover los ejes completos y el duferencial. Aflojar y sacar los tornillos (1) y (2) y las arandelas (3)
ESP Para los detalles, vease «CONTROL DESGASTE Y ESP de retencion tapa (4), los tapones (5) y (6) de carga y
SOBSTITUCION DISCOS FRENOS» y «REMOCION descarga aceite y el recorde de escape (7).
GRUPO DIFERENCIAL». NOTA. Dejar en posicion de seguridad dos tornillos (2) contra-
puestas.

Enlever les bras complets et le diffeÂrentiel. Desserrer et enlever les vis (1) et (2), les rondelles (3)
F Pour de plus amples deÂtails, voir "CONTROLE F de fixation du couvercle (4), les bouchons (5) et (6) de
USURE ET SUBSTITUTION DES DISQUES FREIN" remplissage et vidange d'huile et le raccord d'eÂvent (7).
et "DEPOSE DU GROUPE DIFFERENTIEL". REMARQUE. Pour plus de suÃreteÂ, garder deux vis (2) super-
poseÂes.

Utilizzando un mazzuolo in materiale plastico, rimuo- Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)
ITA vere il coperchio (4) ed asportarlo. ITA del pignone un blocchetto "A" di materiale tenero
NOTA. Se si deve intervenire sul gruppo differenziale, (alluminio, ecc.).
rimuovere il gruppo riduttore completo (viti (9) e (10)). Allentare ed asportare il dado (13) di ritegno pignone.

Mit einem Gummihammer den Deckel (4) ausrasten Zwischen dem ReduziererkoÈrper (11) und dem Getrie-
D und abnehmen. D be (12) des Kegelrads einen Block aus weichen
BEMERKUNG. Soll am Differentialaggregat gearbeitet Material einsetzen (Aluminium usw.)
werden, das komplette Reduzieraggregat abnehmen (Schrauben Mutter (13) zur Halterung des Kegelrads abschrauben.
c (9) und (10)). d
Utilizando un martillo en material plastico, remover la Colocar entre el cuerpo reductor (11) y el engranaje
ESP tapa (4) y sacarla. ESP (12) del pinon un bloquete "A" de material tierno
NOTA. Si se debe intervenir sobre el grupo diferen- (aluminio, ect.).
cial, remover el grupo reductor completo (tornillos (9) y (10)). Aflojar y sacar la tuerca (13) de retencion pinon.

A l'aide d'un maillet en matieÁre plastique, deÂplacer le Ajuster, entre le corps reÂducteur (11) et l'engrenage
F couvercle (4) et puis l'enlever. F (12) du pignon, un petit bloc "A" en mateÂriel leÂger
REMARQUE. S'il faut intervenir sur le groupe diffeÂ- (aluminium etc.).
rentiel, enlever le groupe reÂducteur complet (vis (9) et (10)). Desserrer et enlever l'eÂcrou (13) de fixation pignon.

Rimuovere l'ingranaggio del pignone (12) e l'ingra- Scomporre l'ingranaggio conduttore (14) estraendo il
ITA naggio conduttore (14) completo di cuscinetto (15). ITA cuscinetto (15).
NOTA. Per rimuovere l'ingranaggio (14), utilizzare una NOTA. Se necessario, usare un estrattore.
leva.

Das Getriebe (12) des Kegelrads und das Getriebe Das Getriebe (14) zerlegen; dazu das Lager (15)
D (14) samt Lager (15) entfernen. D abziehen.
BEMERKUNG. Um das Getriebe (14) abnehmen zu BEMERKUNG. Wenn noÈtig, einen Abzieher verwen-
koÈnnen, einen Hebel verwenden. den.
e f
Remover el engranaje del pinon (12) y el engranaje Descomponer el engranaje conductor (14) sacando el
ESP conductor (14) completo de cojinete (15). ESP cojinete (15).
NOTA. Para remover el engranaje (14), utilizar una NOTA. Si necesario, usar un extractor.
palanca.

DeÂplacer l'engrenage du pignon (12) et l'engrenage DeÂcomposer l'engrenage conducteur (14) en deÂga-
F conducteur (14) complet de palier (15). F geant le palier (15).
REMARQUE. Pour deÂplacer l'engrenage (14), utiliser REMARQUE. Si besoin, utiliser un extracteur.
un levier.

008 914 20 BOMAG

69 1271
20.4DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRADAxle
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

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).

1272 BOMAG
70 008 914 20
Axle 20.4

Allentare tutte le viti (9) e (10) ed asportare le viti (9) Collegare il corpo riduttore completo (11) ad un mezzo
ITA superiori di ritegno del corpo riduttore. ITA di sollevamento ed asportare le viti (10) lasciate in
NOTA. Lasciare in sede le due viti (10) inferiori per sede per sicurezza.
sicurezza. Utilizzando un mazzuolo in materiale plastico, rimuovere il corpo
riduttore (11) completo.

Alle Schrauben (9) und (10) lockern und die oberen Den kompletten ReduziererkoÈrper (11) an ein Hebe-
D Schrauben (9) zur Halterung des ReduziererkoÈrpers D zeug befestigen und die zuvor zur Sicherheit zuruÈck-
abnehmen. gelassenen Schrauben (10) abschrauben.
BEMERKUNG. Die beiden unteren Schrauben (10) zur Sicherheit Mit einem Gummihammer, den kompletten ReduziererkoÈrper (11)
a zuruÈck lassen. b abnehmen.

Aflojar todos los tornillos (9) y (10) y sacar los tornillos Conectar el cuerpo reductor completo (11) a un medio
ESP (9) superiores de retencion del cuerpo reductor. ESP de elevacion y sacar los tornillos (10) dejadas en su
NOTA. Dejar en su lugar los dos tornillos (10) lugar para seguridad.
inferiores para seguridad. Utilizando un martillo en material plastico, remover el cuerpo
reductor (11) completo.

Desserrer toutes les vis (9) et (10), enlever les vis Brancher le corps reÂducteur complet (11) aÁ un moyen
F supeÂrieures (9) de fixation du corps reÂducteur. F de relevage, puis enlever les vis laisseÂe (10) dans leur
REMARQUE. Garder les deux vis infeÂrieures (10) dans sieÁge pour plus de seÂcuriteÂ.
leur sieÁge pour plus de seÂcuriteÂ. A l'aide d'un maillet en matieÁre plastique, enlever le corps
reÂducteur (11) complet.

Posizionare il corpo riduttore (11) sotto una pressa e, Rimuovere dal pignone (16) il distanziale (20) e gli
ITA utilizzando uno spintore, estrarre il pignone (16) ITA spessori (19).
completo di cuscinetto interno (17), spessori (19) ed Posizionare il pignone sotto una pressa e rimuovere il
il distanziale (20). cuscinetto interno (17).

Den ReduziererkoÈrper (11) unter eine Presse legen Vom Kegelrad (16) das DistanzstuÈck (20) und die
D und mit einem StoÈûel das Kegelrad (16) samt dem D Unterlegscheiben (19) abnehmen.
inneren Lager (17), den Unterlegscheiben (19) und Das Kegelrad unter eine Presse legen und das innere
dem DistanzstuÈck (20) abziehen. Lager (17) abnehmen.
c d
Colocar el cuerpo reductor (11) debajo de una prensa Remover del pinon (16) el distancial (20) y los
ESP y, utilizando un empujador (16) completo de cojinete ESP espesores (19).
interno (17), espesores (19) y el distancial (20). Colocar el pinon bajo una prensa y remover el cojinete
interno (17).

Placer le corps reÂducteur (11) sous une presse, aÁ Enlever du pignon (16) l'entretoise (20) et les cales
F l'aide d'un poussoir extraire le pignon (16) complet de F (19).
palier interne (17), cales (19) et entretoise (20). Placer le pignon sous une presse et enlever le palier
interne (17).

Con un estrattore, rimuovere dal corpo riduttore (11) le

ITA ralle dei cuscinetti (17) e (21) e l'anello di tenuta (22). ITA
NOTA. Annotare il senso di montaggio dell'anello di
tenuta (22).

Mit einem Abzieher vom ReduziererkoÈrper (11) die

D Scheiben der Lager (17) und (21) und den Dichtring D
(22) entfernen.
BEMERKUNG. Montagerichtung des Dichtringes (22) notieren.
e f
Con un extractor, remover del cuerpo reductor (11) las
ESP ranguas de los cojinetes (17) y (21) y el anillo de ESP
retencion (22).
NOTA. Anotar el sentido de desmontaje del anillo de retencion
(22).

A l'aide d'un extracteur, enlever le corps reÂducteur

F (11), les crapaudines des paliers (17) et (21) et F
l'anneau d'eÂtancheÂiteÂ (22).
REMARQUE. Prendre note du sens de montage de l'anneau
d'eÂtancheÂiteÂ (22).

008 914 20 BOMAG

71 1273
20.4DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRADAxle
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

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

1274 BOMAG
72 008 914 20
Axle 20.4

CAUTION! 1 - If disassembly has only been carried ATENCION! 1 - Si el desmontaje ha sido efectuado
GB out to replace the snap ring (22), position the new ring ESP solo para la sobstitucion del anillo de retencion (22),
and reassemble the unit, respecting the tightening proceder al alojamiento del nuevo anillo y remontar el
torques specified in the following section and using the specified grupo respectando los pares de serraje indicadas en el paragrafo
locking and sealing products. siguiente y utilizando los productos de bloqueo y tenida prescritos.
2 - If disassembly is performed to replace either crown wheel and 2 - Si el desmontaje viene efectuado para la sobstitucion del par
pinion, bearings, or planetary gears, take the unit to pieces and find conico, de los cojinetes o de los engranajes satelites, proceder a la
shims and clearances as specified in the sections relative to the descomposicion y a la busqueda de los espesores y de los juegos
removal, disassembly, assembly and installation of the differential como indicados en los paragrafos concernientes la remocion, el
unit and bevel pinion. desmontaje, el asemblaje y la instalacion del diferencial y del pinon
conico.

ATTENZIONE! 1 - Se lo smontaggio eÁ stato eseguito ATTENTION! 1 - Si le deÂmontage n'est effectueÂ que

ITA solo per la sostituzione dell'anello di tenuta (22), F pour substituer l'anneau d'eÂtancheÂiteÂ (22), positionner
procedere al posizionamento del nuovo anello e le nouvel anneau et remonter le groupe en respectant
rimontare il gruppo rispettando le coppie di serraggio indicate nel les couples de serrage indiqueÂs dans le paragraphe suivant aÁ l'aide
paragrafo seguente ed utilizzando i prodotti di bloccaggio e tenuta des produits de blocage et d'eÂtancheÂiteÂ prescrits.
prescritti. 2 - Si le montage est effectueÂ pour substituer le couple conique des
2 - Se lo smontaggio viene eseguito per la sostituzione della coppia paliers et des engrenages satellites, passer aÁ la deÂcomposition et aÁ
conica, dei cuscinetti o degli ingranaggi satelliti, procedere alla la recherche des cales et des jeux comme indiqueÂ dans les
scomposizione ed alla ricerca degli spessori e dei giochi come paragraphes concernant la deÂpose, le deÂmontage, l'assemblage et
indicato nei paragrafi riguardanti la rimozione, lo smontaggio, l'installation du diffeÂrentiel et du pignon conique.
l'assemblaggio e l'installazione del differenziale e del pignone
conico.

ACHTUNG! 1 - Falls das Teil zum Auswechseln des

D Dichtringes (22) zerlegt wurde, den neuen Ring
einsetzen und das Aggregat wieder montieren; dabei
die Anzugsmomente einhalten, die im nachstehenden Kapitel
angegeben sind und die vorgeschriebenen Materialien zur Blok-
kierung und Abdichtung verwenden.
2 - Falls das Zerlegen zum Auswechseln des Kegelradpaars, der
Lager oder der Planetengetriebe vorgenommen wird, den An-
weisungen der Paragraphen zum Zerlegen, Abmontieren und
Zusammenbauen sowie zur Installation des Differentials und des
Kegelrads folgen und die StaÈrken und Spiele einhalten.

008 914 20 BOMAG

73 1275
20.4 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UNDAxle
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

MEASURE (42.35)
MISURA (42,35)
MAß (42,35) St
MESURA (42,35)
MESURE (42,35) B

MARK
CONTRASSEGNO
C C
B KENNZEICHEN
CONTRASENALACION
11
MARQUAGE

17
F1241205 F1241206

GB a GB b
Mark the thrust block and the internal bearing (17) on a faceplate, Lay two 20 mm gauged blocks "C" on the face of the reduction gear
allow the bearing to set by rotating them in both directions and by body (11). With depth gauge "B" (set to zero at the previous point),
applying a vertical thrust. With a centesimal, digital depth gauge measure space between the "C" blocks and the striking surface of
"B", check overall thickness of bearing (e.g.: 42.35 mm) and set the internal bearing (17). The size obtained (e.g.: 0.81 mm) is the
gauge to zero again. theoretical shim "St" (18) to be inserted under the thrust block of
bearing (17).

DIFFERENTIAL AXIS
ASSE DIFFERENZIALE
DIFFERENTIALACHSE
EJE DEFERENCIAL S
ESSIEU DIFFERENTIEL

Y
X
+ --
DEVIATION "X"
SCOSTAMENTI "X"
ABWEICHUNG "X" S = St + (± X)
DESPLAZAMIENTOS "X"
ECARTS "X"
D1240137
F1241225

GB c GB d
On the bar-hold of pinion (16), check the value "X" (in brackets) To calculate final thickness "S", add the negative value of "X" to
relative to the deviation from the theoretical centre distance. "St" or, alternatively, subtract the positive value of "X".
NOTE. "Y" is the number of pinion/crown coupling. For ex.: Deviation X=(±0.13 mm): S=St+X=0.81+0.13=0.94 mm
Deviation X=(+0.12 mm): S=St ± X=0.81 ± 0.12=0.69 mm
CAUTION! Round off to as close to 0.05 mm as possible.

T10
21

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.

1276 BOMAG
74 008 914 20
Axle 20.4

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 È
2 - Auûere 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'eÂtancheÂiteÂ (22). F de l'outil T10 introduire la crapaudine du palier
NOTE. 1 - ControÃ ler attentivement le sens de externe (21).
montage. ATTENTION! Introduire la crapaudine du palier non estampilleÂe.
2 - Lubrifier la surface externe de l'anneau d'eÂtancheÂiteÂ.

008 914 20 BOMAG

75 1277
20.4 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UNDAxle
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

17 T11

18
21
20
17

F1241208 F1241209

GB a GB b
Turn the reduction gear body (11) upside down and insert shim "S"; Fit tool T12 onto tool T11. Then, install bearings (17) and (21) so
then, with tool T10, insert the thrust block of the internal bearing that they are opposed to each other and spaced by the distance
(17). piece (20).
CAUTION! Insert the thrust block of the countermarked bearing. Position the depth comparator in one of the four radial holes; pre-
set the comparator to 3 ± 4 mm, then set it to zero.

T11
21

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
1278 BOMAG
76 008 914 20
Axle 20.4

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 estampilleÂ soit REMARQUE. En serrant, effectuer quelques tours de
monteÂ 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 releveÂ est aÁ additionner aÁ la mesure fixe 0,13v0,15 mm
F mis aÁ zeÂro preÂceÂdemment et en faire la lecture. F pour obtenir la cale "S1" (19) aÁ introduire entre le palier interne
L'eÂcart par rapport au zeÂro, indique la valeur nominale (17) et l'entretoise (20) et deÂfinir la preÂcharge eÂtablie pour les paliers.
"H" des cales aÁ introduire. ATTENTION! Effectuer soigneusement les mesurages parce qu'une diffeÂ-
rence de 0,01 mm ameÁne une variation du couple de rotation de 20v40 Ncm.

008 914 20 BOMAG

77 1279
20.4 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UNDAxle
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

16
16 11

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.

1280 BOMAG
78 008 914 20
Axle 20.4

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 estampilleÂ (17) sur le pignon (16). F cales (19), l'entretoise (20) et le palier externe (21),
ATTENTION! Lubrifier le pignon avec de l'huile. assembler le groupe aÁ l'aide de la presse.
ATTENTION! Lubrifier le pignon avec de l'huile.

Montare il corpo riduttore (11) sul corpo centrale (23) Montare l'ingranaggio (12) del pignone; spalmare il
ITA privo di differenziale e fissarlo provvisoriamente con le ITA dado (13) con Loctite 242 ed avvitarlo manualmente.
due viti inferiori (9).
Montare il cuscinetto (15) dell'ingranaggio di entrata del moto e
mandarlo in battuta.

Den ReduziererkoÈrper (11) auf den zentralen KoÈrper Das Getriebe (12) des Kegelrads montieren; Mutter
D (23) ohne Differential montieren und voruÈbergehend D (13) mit Loctite 242 schmieren und von Hand
mit den zwei unteren Schrauben (9) befestigen. zuschrauben.
Das Lager (15) des Einganggetriebes montieren und bis zum
c Anschlag einsetzen. d
Montar el cuerpo reductor (11) sobre el cuerpo central Asemblar el engranaje (12) del pinon, pasar la tuerca
ESP (23) sin el diferencial y fijarlo provisoriamente con los ESP (13) con Loctite 242 y atornillarla manualmente.
dos tornillos inferiores (9).
Asemblar el cojinete (15) del engranaje de entrada del movimiento
y mandarlo a tope.

Monter le corps reÂducteur (11) sur le corps central (23) Monter l'engrenage (12) du pignon; enduire l'eÂcrou
F sans diffeÂrentiel et fixer provisoirement ce dernier F (13) avec du Loctite 242 et visser celui-ci aÁ la main.
avec les deux vis infeÂrieures (9).
Monter le palier (15) de l'engrenage d'acceÁs au mouvement, puis
l'envoyer en buteÂe.

Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)

ITA del pignone il blocchetto "A" usato per lo smontaggio ITA
e serrare il dado (13) alla coppia minima di 500 Nm,
utilizzando una chiave a bussola ed una chiave dinamometrica.

Zwischen dem ReduziererkoÈrper (11) und dem Getrie-

D be (12) des Kegelrads den Block «A» legen, der zum D
Abmontieren verwendet wurde, und Mutter (13) mit
einem Anzugsmoment von mindestens 500 Nm mit einem
e InbuûschluÈssel und einem Dynamometer festziehen. f
Colocar entre el cuerpo reductor (11) y el engranaje
ESP (12) del pinon el bloquete "A" usado para el ESP
desmontaje y apretar la tierca (13) al valor minimo
de 500 Nm, utilizando una llave a manguito y una llave
dinamometrica.

Placer, entre le corps reÂducteur (11) et l'engrenage

F (12) du pignon, le petit bloc "A" utiliseÂ au deÂmontage, F
serrer l'eÂcrou (13) au couple minimum de 500 Nm aÁ
l'aide d'une cleÂ aÁ pipe et d'une cleÂ dynamomeÂtrique.

008 914 20 BOMAG

79 1281
20.4 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UNDAxle
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

T13

F1241217

GB a
Allow the pinion to rotate a few times in both directions to enable
bearings to set.
Apply bar-hold T13 onto pinion (16) and, with a torque meter, check
the torque of the pinion.
Torque: 140 ± 150 Ncm.
CAUTION! If torque exceeds the maximum value, then the shim
"S1" (19) placed between bearing (17) and distance piece (20)
needs to be increased.
If torque does not reach the set value, increase the tightening
torque setting of nut (13), in different stages, until the maximum
admitted value of 700 Nm is obtained.
CAUTION! If torque does not reach the minimum value, then the
shim "S1" (19) needs to be reduced.
CAUTION! In order to be able to calculate the increase or reduction
of shim "S1", it is necessary to bear in mind that a 0.01 mm
variation in the size of shim (19) results in the torque of the pinion
(16) varying by 20 ± 40 Ncm.

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».

1282 BOMAG
80 008 914 20
Axle 20.4

Far compiere al pignone alcuni giri nei due sensi per Das Kegelrad um einige Umdrehungen in beide
ITA assestare i cuscinetti. D Richtungen drehen, um die Lager richtig einzusetzen.
Applicare sul pignone (16) il codolo T13 e con un Am Kegelrad (16) den Schaft T13 anbringen und mit
torsiometro, controllare la coppia di rotazione del pignone. einem Drehungsmesser das Gegenmoment des Ke-
Coppia di rotazione: 140v150 Ncm gelrads kontrollieren.
ATTENZIONE! Se la coppia supera il valore massimo bisogna Gegenmoment: 140v150 Ncm.
aumentare lo spessore "S1" (19) tra cuscinetto (17) e distanziale ACHTUNG! Falls der Wert den Maximalwert uÈberschreitet, braucht
(20). es eine groÈûere Unterlegscheibe "S1" (19) zwischen Lager (17) und
Se la coppia di rotazione non raggiunge il valore stabilito, DistanzstuÈck (20).
aumentare la coppia di serraggio del dado (13) in piuÁ tempi fino a Falls das Gegenmoment den festgelegten Wert nicht erreicht, das
raggiungere il valore massimo ammesso di 700 Nm. Anzugsmoment der Mutter (13) schrittweise erhoÈhen, bis der
ATTENZIONE! Se la coppia di rotazione non raggiunge il valore maximal zulaÈssige Wert von 700 Nm erreicht worden ist.
minimo, eÁ necessario diminuire lo spessore "S1" (19). ACHTUNG! Falls das Gegenmoment den Mindestwert nicht
ATTENZIONE! Al fine di poter calcolare gli incrementi o la erreicht, muû die Unterlegscheibe "S1" (19) kleiner sein.
diminuzione dello spessore "S1", eÁ necessario considerare che la ACHTUNG! Um das hoÈhere oder niedrigere Maû der Unter-
variazione dello spessore (19) di 0,01 mm, fa variare la coppia di legscheibe "S1" ausrechnen zu koÈnnen, darauf achten, daû ein
rotazione del pignone (16) di 20v40 Ncm. Unterschied von 0,01 mm der Unterlegscheibe (19) das Gegen-
moment des Kegelrads (16) um 20v40 Ncm aÈndert.

a
Hacer efectuar al pinon algunos giros en los dos Faire faire quelques tours au pignon dans les deux
ESP sentidos para ordenar los cojinetes. F sens de manieÁre aÁ ajuster les paliers.
Aplicar sobre el pinon (16) el codolo T13 y con un Appliquer sur le pignon (16), la queue T13, puis aÁ
torsiometro, controlar el par de rotacion del pinon. l'aide d'un torsiomeÁtre, controÃler le couple de rotation du pignon.
Par de rotacion: 140v150 Ncm. Couple de rotation: 140v150 Ncm.
ATENCION! Si el par supera el valor maximo hay que augmentar el ATTENTION! Si le couple de rotation deÂpasse la valeur maximum,
espesor "S1" (19) entre cojinete (17) y distancial (20). augmenter la cale "S1" (19) entre le palier (17) et l'entretoise (20).
Si el par de rotacion no llega al valor establecido, augmentar el par Si le couple de rotation n'atteint pas la valeur eÂtablie, augmenter le
de torsion de la tuerca (13) en mas tiempos hasta llegar al valor couple de serrage de l'eÂcrou (13), en plusieurs temps, jusqu'aÁ
maximo admitido de 700 Nm. atteindre la valeur maximum admise de 700 Nm.
ATENCION! Si el par de rotacion no llega al valor minimo, es ATTENTION! Si le couple de rotation n'atteint pas la valeur
necesario disminuir el espesor "S1" (19). minimum, diminuer la cale "S1" (19).
ATENCION! Al fin de poder calcular los encrementos o la ATTENTION! Pour pouvoir calculer les augmentations et les
disminuciones del espesor "S1", es necesario considerar que la diminutions de la cale "S1", tenir compte que la diffeÂrence de
variacion del espesor (19) de 0,01 mm, hacer cambiar el par de 0,01 de la cale (19) fait varier le couple de rotation du pignon (16) de
rotacion del pinon (16) de 20v40 Ncm. 20v40 Ncm.

Rimuovere il corpo riduttore completo (11) e procedere

ITA con il montaggio del differenziale e dei bracci.
Per i dettagli, vedere «ASSEMBLAGGIO ED INSTAL-
LAZIONE GRUPPO DIFFERENZIALE - ASSEMBLAGGIO GRUP-
PO FRENO».

Den kompletten ReduziererkoÈrper (11) abnehmen und

D das Differential und die Arme montieren.
Siehe «ZUSAMMENBAU UND INSTALLATION DES
DIFFERENTIALAGGREGATS - ZUSAMMENBAU DES BREMSAG-
b GREGATS».

Remover el cuerpo reductor completo (11) y proceder

ESP con el montaje del diferencial y de los ejes.
Para los detalles, vease «ASEMBLAJE Y INSTALA-
CION GRUPO DIFERENCIAL - ASEMBLAJE GRUPO FRENO».

Enlever le corps reÂducteur complet (11) et aller de

F l'avant avec le montage du diffeÂrentiel et des bras.
Pour de plus amples deÂtails, voir "ASSEMBLAGE ET
INSTALLATION DU GROUPE DIFFERENTIEL - ASSEMBLAGE
DU GROUPE FREIN".

008 914 20 BOMAG

81 1283
20.4 SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
Axle
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL

4.3 T1 T2

45°

20
25
1

=
32
32

200
=
90
= =

50
160
110

120± 0.1

120± 0.1
32

25
1

840
45°

10 4.5 930

2313 D1240046 2305 D1240043

T3 Ø40
T4
Ø40
32

3 x45°
3 x45°

150
150

190
195

0
R1
10
0
R1

8
17 13
40
25

32
45

32
32
3 x45°
32
Ø153
32

125
Ø154
20°
Ø178 Ø178
Ø189
Ø184
Ø200

1502 D1240120 1742 D1240121

T5
295
136 10 150
65 3 x45°
27.5
20
3 x15°
-- 0.05

-- 0.4
-- 0.6
-- 0.3
-- 0.4

-- 0.1
Ø80

Ø61

Ø35

Ø25
Ø45
Ø63

Ø46

32 32
0

32
32

107.5 ---- 0.2

0.3

1501 D1240122

1284 BOMAG
82 008 914 20
Axle 20.4

75 Ø290
T6
5 Ø271
12
Ø20

Ø16
A Sez. B - B
1° 30'
° 2
32 17

°
17
32

7°
° 30' 17° 30' 1
3x15°
B
Ø150 H 7
Ø150 Hn 67
Ø318
B

43.60
° 17

82.13
113.48
17

134.91
°
17
°
Ø22
Ø16

17
21° 30'
Ø26

Ø22
Ø15

53.14
32
32

12 A
90.26
68 12
119.50
80 82
139.29
Sez. A - A n°2 pezzi
1545 D1240124

119.50 T7
190
53.14
Ø20
Ø16

9
Ø25

32 32
20
0 0 2 x30°
R1 R1 32 1° 30'
° 2
17
°

134.91
17
T7B

82.13
7°
17° 30' 7° 30' 1
Ø161.5 ±0.1

Ø264 ---- 0.15

0.25
Ø185 ---- 0.08
0.12

Ø262 ---- 0.15

0.25
Ø250
Ø172

Ø320

43.60
17°

113.49
32
°
17

17°
R5
'
21° 30
15°
15°
Ø16

5 x15° 90.26
16 20 138.29
110
32

Ø290 ±0.15
143
153
70
T7A 30 30
3 x15° 32
PROFILO HURT 45.5 x 40.5

A
Ø24

R5
Ø150 ---- 0.08
0.12

2
Ø140
Ø30

Ø38

0
R1 0
R1
Ø25 gH 67

Ø24
Ø23,9

40 74
1.2 h 11
200 200
Particolare A 400

1769 D1240125

008 914 20 BOMAG

83 1285
20.4 SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
Axle
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL

T8 T9

5 - +0
.5
-0
Ø9
Ø25

13 ± 0..2
Ø102 +-- 0.2
Ø120
0
3 x45°
160
192

Sez. A-A
0
R1
22 10

0.8 600
Ø40
0.8

Es Ch 22
␣]

15 20
30
Ø]
Ø129

Ø16
] Bearing ref. 32017 DIN720 Acciaio Fe 42
] Ref. cuscinetto 32017 DIN720
] Lager Ref. 32017 DIN720
] Ref. cojinete 32017 DIN720
] ReÂf. palier 32017 DIN720
Acciaio Fe 42

0355 D1240123

Ø85.5

T10

490
Ø40

Ø25
R1
30

0
3 x45°

R2
48

40
10
22
150

A A
188

135

Acciaio 18 Ni Cr Mo 5
Cementazione 0.6÷0.8
Temprato HRC 60÷63
0
R1

35.5

32
1.5

40
8

32
30

3
4.5
32
32

20°
Ø23.9 ±-- 00.05
Ø104
H7
Ø25 g7
Ø109
Ø30
32

-- 0.1
Ø40.5-- 0.15

Ø80
Ø92

1487/B D1240126 1495 D1240128

1286 BOMAG
84 008 914 20
Axle 20.4

T11 Ø49.8
T12
Ø41.5

4 x45°

93
M14 x1

40 300

Ø110 2323 D1240127

Ø65

T13
M14 x1
Ch
22
Ø20

20
M14 x1

61 –– 0.01
0.02
R5
3/4"
4"

41
1/
30
25 25

Ø20

Ø9
Ø41.2 +-- 0.03
0 14
195
95

45
35
Ø11

60
10
Ø80
10

Ø6.5 25
Ø35
2312 D1240075 0870 D1240129

008 914 20 BOMAG

85 1287
20.4 Axle

1288 BOMAG 008 914 20

21 Circuit diagrams

008 914 20 BOMAG 1289

1290 BOMAG 008 914 20
21.1 Hydraulic diagram 581 202 08
2

008 914 20 BOMAG 1291

21.1 Hydraulic diagram 581 202 08

1292 BOMAG 008 914 20

Hydraulic diagram 581 202 08 21.1

008 914 20 BOMAG 1293

21.1 Hydraulic diagram 581 202 08

1294 BOMAG 008 914 20

21.2 Wiring diagram 582 702 07

008 914 20 BOMAG 1295

21.2 Wiring diagram 582 702 07

S/N Wiring diagram 582 702 07

S/N 101 582 121 001  101 582 121 001 Variocontrol
S/N 101 582 641 001  101 582 641 059 BW 216 DH-4
S/N 101 582 651 001  101 582 651 004 BW 216 PDH-4
S/N 101 582 771 001  101 582 771 170 BW 219 DH-4
S/N 101 582 781 001  101 582 781 018 BW 219 PDH-4
S/N 101 582 861 001  101 582 861 025 BW 226 DH-4 BVC
S/N 101 582 881 001  101 582 881 002 BW 226 DH-4
S/N 101 582 891 001  101 582 891 003 BW 226 PDH-4
S/N 101 583 141 001  101 583 141 075 BW 213 DH-4
S/N 101 583 151 001  101 583 151 004 BW 213 PDH-4
S/N 101 583 161 001  101 583 161 026 BW 213 DH-4 BVC
S/N 101 583 191 001  101 583 141 004 BW 214 DH-4
S/N 101 583 061 001  101 583 061 013 BW 213 DH-4 BVC with attachment plate

1296 BOMAG 008 914 20

Inhaltsverzeichnis: BW 177..226 DH−4

008 914 20
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 582 702 07 Stromlaufplan Circuit Diagram
002 582 702 07 Versorgung, Starten, Hupe supply, starting unit, signal horn
003 582 702 07 Motor Deutz EMR II engine Deutz EMR II
004 582 702 07 Motor Deutz EMR III engine Deutz EMR III
005 582 702 07 Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch
Wiring diagram 582 702 07

006 582 702 07 Datensammler, LC−Display data−collector, LC−display

007 582 702 07 Lenkung, Vibration steering, vibration
008 582 702 07 Fahrhebel, Vibrationsplatten joystick, vibration−plates
009 582 702 07 Variocontrol, Messtechnik Variocontrol, measurement equipm.
010 582 702 07 Bomag Compaction Management BCM Bomag Compaction Management BCM
011 582 702 07 Diebstahlschutz System anti − theft system
012 582 702 07 Beleuchtung und StvZO illumination and StvZO
013 582 702 07 Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph
014 582 702 07 Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater
101 582 702 07 Bauteilliste component listing

BOMAG
19.10.2005
Vogt 001 001 582 702 07
Stromlaufplan
19.10.2005
21.2

1297
circuit diagram 001
Seis
1298
30
21.2

K11
2:12
87
K30 13:1
30 4:1 K11:87 6:1

X1:15E X1:16E X1:27E X1:28E X1:30E

X1:9
F13 1 F05 1 F95 1 F23 1 F39 1

X1:10
30A 10A 10A 15A 15A
2 2 2 2 2
X1:15A X1:16A X1:27A X1:28A
X1:30A
X37:A X1:151

7:17
5:9
30 21 11 31 41 51 61

X36:B

X36:A
nur bei EMR III S00 S01 X3:3
only EMR III
22 12 32 42 52 62
Startschalter NOT−Aus
K32:86
starting swwitch 15 54 58 19 17 50a Emerg.−Stop 13:1

2 x 10qmm
X1:152 X1:155
X1:79
S01:22 3:1
X37:B
F05:2
V01 X1:3 X1:4 6:8
K05 30
2 1 8:3
5

125mA
5 87 87a

X34:P
K14 86 1 30

nicht bei EMR III, bei BW177DH−4 Option

not at EMR III, at BW177DH−4 option
K14.2 K61 K61

Sicherung Heizflansch/Glühstiftkerzen
heating−flange/glow plugs
Hauptsicherung
main fuse
13 23
4:20 3:19 3 R10 2:7 S03
3 2 2 82 OHM
F48 F00
125A 125A 85 2 87 87a X1:7 X1:8 Taster Hupe
push button, horn 14 24

BOMAG
1 1 D+ 6:2
B+ 2:13 2:8 B+
D+ MESX 9:2
G03 G01 X38:A X1:97 X1:98
+ +
− −
X1:1 X1:101 X1:102
1 1 1
X1:109

nur bei Klimaanlage

only acc.to air conditioning
Anzugsw.:50A / Haltew.:10A

30 50

R81
R83
R85
167A
2 2 2 1 B+ D+ 86 86 B11 B11
1 1 1 1 K09 K11 1 2 2 1
G02 M01 V02 XS +
R19 S30 M
12V

R86

R82
R84
2 2 2 2 2 1 V03 1 2 −

Option
option
85 85 −
2
31 EMR 3:3 B− W
X1:110 X1:168 X1:123 X1:103 X1:104

31 31 3:1

Glühstiftkerzen Trennschalter Batter 2:10 14:7 2:16 Starter Signalhörer Steckdose

glow plugs break switch battery starter warning horns socket

Batterie Batterie Generator Nur bei Geländer/ROPS/SD

battery battery generator only at hand−rail/ROPS/sun−roof
Heizflansch
heating−flange

19.10.2005
1 1
Wiring diagram 582 702 07

008 914 20
Vogt Versorgung, Starten, Hupe 582 702 07
19.10.2005
Seis supply, starting unit, signal horn 002
2:17 S01:22 S01:22 4:1

X1:95
1
K14

008 914 20
Relais Heizflansch
relay heating−flange 2

X1:96
X1:179
X1:185
Steckerschnittstelle Deutz
connector interface Deutz
X33:7
X33:2
X33:3
X33:5
X33:6
X33:1
X33:4
X33:8

EPC−Stecker

max 7A
Wiring diagram 582 702 07

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− 4:15
CAN2+ 4:15

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
3 2 1 1 2 1 2 7 2 6 1 1 4 3 2 1 2

RF MESS
EMR Stellglied
EMR commander

B88 B114 B130 Y137 5 B115 B113

X32:L
X32:K
X32:B

X32:H
X32:G

X32:A
X1:186
X34:N
X1:182
Diagnosestecker EMR
diagnosis interface EMR
2:6 4:18
31 31 EMR 31 EMR
2:20 31 4:1
2:4
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

19.10.2005
1 1 582 702 07
Vogt Motor Deutz EMR II
19.10.2005
21.2

1299
Seis engine Deutz EMR II 003
1300
2:15 30 30 5:1
3:20 S01:22 S01:22 7:1
Diagnosestecker EMR 3:4 CAN2+ CAN2+ 5:11
X1:14E Wasserabscheider
21.2

water−seperator diagnosis interface EMR 3:4 CAN2− CAN2− 5:11

1
F93
25A
2

X32:A
X32:K
X32:M
X32:F
X32:H
X32:G
X32:B
X1:14A
B124
86
K41 K41 30

4:2

Nur bei EMRIII

only EMRIII
X1:107 X1:108
87 87a
85
X1:179

X1:191

X1:193
X1:192

X1:194

X1:184
X1:185 X1:183 X1:198 X1:199 max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 3.5m
2.5 qmm in der hier dargestellten Installation (Querschnitt 2,5qmm)

max 7A
K−Line
CAN 1 High
CAN 1 Low
CAN 2 High
CAN 2 Low
max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 10m
bei einer Kabelbaumumgebungstemperatur von 85 Grad C. (Querschnitt 4x2,5qmm)

A48
Motorsteuerung EMR3 (EDC 16)
engine−controller EMR3 (EDC16)

X30:1
X30:5
X30:3
X30:61

X30:63
X30:60

X30:72
X30:25
X30:62

X30:28
X30:82

X30:64

X31:47
X31:46
X31:33
X31:31
X31:48
X31:32
X31:50
X31:12
X31:19
X31:40
X31:14
X31:53
X31:43
X31:8
X31:58
X31:56
X31:13
X31:13
X31:40
X31:24
X31:34

X31:16
X31:1
X31:10
X31:20
X31:27
X31:7
X31:49
X31:23
X31:26
X31:41
X31:51
X31:23
X30:2
X30:4
X30:6

Sign.
Sign.

AGND
AGND
AGND
GND
GND
GND

Signal
AGND
AGND
AGND
AGND
AGND

Signal
Signal
Signal

Signal Druck
Signal Druck

BOMAG
Signal Temperatur

X57:34
X57:35
X57:39
X57:36
X57:40
X57:42
X57:37
X57:41
X57:14
X57:13
X57:9
X57:21
X57:15
X57:1
X57:19
X57:20
X57:28
X57:23
X57:22
X57:29
X57:32
X57:25
X57:31
X57:30
X57:24
X57:27
X57:26
X57:33
X57:28
X57:23
X57:29
X1:180
X1:181
X1:182
X1:186

X66:3

X66:2

1 1 1
Y147 Y148 Y149
Y15.1 Y15.5 Y15.3 85
2 2 2 K14.2
1 2 3 2 1 3 1 4 3 2 3 2 1 1 2 3 2 1 1 2 3 4
1 1 1 1 86
Y166 Y170 Y169 Y137
Y15.6 Y15.2 Y15.4 Y19
2
2 2 2 B114 B130 B93 B113 B88 B145
B40.1 B40.2 B48 B49 B43 B6 B51
X1:90
X1:91
X1:92

3x2.5

3:5
31 31 EMR
3:20 31 5:1
4:3 2:2
EMR Stellglied EMR Kühlmitteltemperatur
EMR commander EMR coolant temperature

Injektor A1 Injektor A2 Injektor A3 Motordrehzahlsensor Ladeluftdruck + Temp EMR Motoröldruck

jet pump A1 jet pump A2 jet pump A3 sender engine rpm 1 charging air pressure + temperature EMR engine oil pressure

Injektor A4 Injektor A5 Injektor A6 Motordrehzahlsensor EMR Kraftstoffdruck EMR Niederdruck Kraftstoff

jet pump A4 jet pump A5 jet pump A6 sender engine rpm 2 rail pressure sensor EMR fuel low pressure sensor

19.10.2005
1 1
Wiring diagram 582 702 07

008 914 20
Vogt Motor Deutz EMR III 582 702 07
19.10.2005
Seis engine Deutz EMR III 004
4:20 30 30 6:1
F24:2 6:3 X1:2 4:20 CAN2+ CAN2+ 8:6
EMR Deutz Fahrhebel
4:20 CAN2− CAN2− 8:6
X1:145
CAN1+ 6:8
31 LC−Display, OPUS 21
CAN1− 6:8
X1:119 X1:120

008 914 20
S01
2:16
120 OHM 120 OHM
X1:146 32 1 2 1 2

X52:1
X52:2
R22 R20
rt sw X1:17E X1:34E
Diagnosestecker Fahrzeug
F67 1 F84 1 X34:G X34:H X34:C X34:D X34:A X34:B diagnosis interface equipment
B112
15A 10A
2 2
Drucksensor Fahrpumpe X1:17A X1:34A
pressure sensor drive pump
X1:34A

X1:51
X1:52
X1:53
X1:54
X1:47
X1:48
X1:49
X1:50
9:2
120 OHM 120 OHM
1 2 1 2
Wiring diagram 582 702 07

R23 R21

Drucksensor
Leistung
Elektronik
TxD
RxD
CAN2+
CAN2−
CAN1+
CAN1−

Pot. 15
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

speed
speed

BOMAG
Neigung

Richtung
Richtung
Gehäuse
housing

Achsmotor

Sitzkontakt
X1:45 X1:44
Bandagenmotor

Fahrpumpe vorw.
Fahrpumpe rückw.

Rückfahrwarnsum.
FM3 7:5 +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

br
ws
br
ws
bl
+ +
dir. dir.

0,46A
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA

B60 B59 2,5V X14:B X9:1

speed
9:2 speed
DIR MESX S06 + + X16:1 1 X15:1 1 1 1
− X1:172 −
Y17 Y16
13:6 4V H14 Y30 Y31

sw
sw
SPEED TAC − b a
− 2 2 2 2
X1:174 9:2 X1:178 − S X1:46 X14:A X9:2 X16:2 X15:2
SPEED MESX
X1:82
X1:124
X1:142
X1:142
X1:143
X1:143

X1:55 7:4 9:2 X1:149 X1:117 X1:123 X1:123 X1:144 X1:124

31 PITCH MESX
4:20 31 6:1

Sensor Achse Sensor Bandage Neigungssensor Sitzkontaktschalter Prop.−Pumpe Vorw. Prop.−Ventil Bandagenmotor
sender axle sender drum slope sensor switch, seat contact prop.−pump forwards prop.−Valve drum motor

Rückfahrwarnsummer Prop.−Pumpe Rückw. Prop.−Ventil Achsmotor

back up alarm buzzer prop−pump backwards prop.−Valve axle motor

19.10.2005
1 1 582 702 07
Vogt Fahrantrieb, Neigungssensor, Sitzkontakt
19.10.2005
21.2

1301
Seis driving system, slope sensor, seat contakt switch 1 005
30

1302
5:20 30 9:1
2:20 K11:87 K11:87 8:14
5:3 F24:2 F24:2 7:15
21.2

X1:29E 2:17 F05:2

1 5:17 CAN1+ CAN1+ 8:14
F24 ESX Fahrsteuerung DIOS Platten
10A 5:17 CAN1− CAN1− 8:14
2
X1:29A

X1:87 X1:88 X1:80 X1:86

X1:41

X1:39
X1:40
11:1

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
X27:2
X27:4
X27:9
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
DIN9
DIN6
DIN3
DIN5
DIN6

DIN8
DIN2
DIN2

AIN2

DIN4
DIN4

DIN11

DIN10
Sepa1
Sepa2
GND/UIN3

BOMAG
X1:106 X1:111 X1:112 X1:105 X1:107 X1:108
BL 12:17 ECO
Low High
BR 12:17 23 13
BEL S127
12:4

24 14

Hydraulikölfilter
hydraulic oil filter
Luftfilter
air cleaner
Kühlmittelvorrat
coolant stock level
Füllstand Diesel
fuel−level
Wasserabscheider
water−seperator
X21:1 X10:2 X8:1
B21 1 B03 1 B55 B124
D+ R03
2:8 P P Q
Schalter Motordrehzahl
2 2 switch engine−rpm mode
X21:2 X10:3 X8:2

0 .. 67 OHM
Nur bei EMRII
only EMRII
X1:117 X1:94 X1:94 X1:117 X1:164 X1:149 X1:82
31
5:20 31 7:1

19.10.2005
1 1
Wiring diagram 582 702 07

008 914 20
Vogt Datensammler, LC−Display 582 702 07
19.10.2005
Seis data−collector, LC−display 006
4:20 S01:22 S01:22
6:20 F24:2
X1:148 Lenkwinkelsensor
X23:1 steering angle sensor
8:1
X1:41
X1:201
X51:1 Lenkeinheit X1:187

008 914 20
B65 + A45 steering unit br
Aufnehmer Vibrationsmotor
S 5:4 FM3 X22:1 sensor vibration motor
br +
X1:161 X41:1 X39:1 VCC X39:2 bl
S1 B − X22:2
−
X1:160 X41:3 X40:1 VCC X40:2 bei BW177 sw / bei BW213 bl
B B16
bei BW177 bl / bei BW213 sw
X1:159 X41:4 X40:4 S2 X40:3

X1:203
B132 2 2 2 2 0V A ws X22:3
VIB
X1:162 X41:2 X39:4 0V X39:3 X22:4 13:6
S1 A gg sw

X1:55 X1:202
Lenkwink.
1 1 1 1

−
BTS BREMSE 8:2

X41:5
X41:7
X41:8
X41:6

Sig.
AGND

X34:J
X1:60 FM5 X1:61
X1:56 FM1 X1:57

X1:62 FM3 X1:63

X1:58 FM2 X1:59
X1:189
X1:188

armrest−switch
X1:55

Schalter Armlehne
Wiring diagram 582 702 07

Vib.− Richtung
Vib.− Frequenz
BTS Bremse

5:6

X1:205
X1:207
X1:206

X1:208
8,5V
X1:42

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

X35:16
X35:20
X35:21
X35:43
X35:22
X35:2
X35:48
X35:3
X35:61

30
Bremse

Armlehne
Prop. out

30 K48 8:2
Warnsummer

BOMAG
X51:3

X51:2
X1:89 87 87a

Umsch. Amplitude
K43 7:12

Pumpe Vib.−Platten
X1:154 X1:196 X1:195 87 87a

Schnellverschl.−Platten
KA MESX
9:2 X1:147
X1:38
X35:22 GA MESX 11
8:13 9:2
X1:37 S01
X35:43
8:13 X1:116 X1:115 2:16
12
X1:150

400 ... 1.200mA

400 ... 1.200mA
150mA

X6:1 X7:1 9:2

400 ... 1.200mA

1 1 K43 86 Y08 1 Y07 1 H07

X1:113 BRAKE MESX
+ Y04 1
Y93 Y92
b d
2 2 85 2 2 − a1 2
X6:2 X7:2
max.1.8A

X1:149 X1:197 X1:197 X1:82 X1:117 X1:190

X1:118
6:20 8:1
31
31 Anbau 177DH: h.r. a Anbau 177DH: h.l. b
7:14 Anbau 213DH: unten Anbau 213DH: oben

Prop.−Ventil Vibration klein Magnetventil Bremse

prop. valve vibration small solenoid valve brake

Prop. Ventil lenken links Prop−Ventil Vibration groß

prop. valve steering left prop. valve vibration big

Prop. Ventil lenken rechts Warnsummer Störung

prop. valve steering right warning buzzer, failure

19.10.2005
1 1 582 702 07
Vogt Lenkung, Vibration
19.10.2005
21.2

1303
Seis steering, vibration 007
1304
7:2 X23:1 5:17 CAN2+ 6:14 CAN1+ CAN1+ 9:16
ESX Fahrst. LC−Display BTM
5:17 CAN2− 6:14 CAN1− CAN1− 9:16
K11:87
21.2

6:20 K11:87 9:1

Taster 1 = Platten rechts
push button 1 = plates right X1:31E
Taster 2 = Platten heben
push button 2 = lift plates 1 F145
Taster 3 = Vibration EIN/AUS Näherungssch. Platten oben
push button 3 = vibration ON/OFF 20A
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
X1:213
X1:214

Taster 8 = Infotaste 2

X1:156
push button 8 = Info button 2

X1:157
BTS BREMSE
7:18

br
br
3 2 + +

X63:1
X63:1
7
B135 B134
1 Fahrstufenschalter
4 − −
5 8 speed range selector
bl bl

S S

X63:2
X63:2
sw
ws

S42

quick connecting clutch

+ − S

X35:43 X1:215
Ub in CAN− 7:11

X25:2
X25:4
X25:3
Bremse zu = 0V 1 7

Schnellverschluss − Kupplung
Bremse auf = Ub BTS Bremse CAN+
3 S55 6 X35:22
BTS zus. Fahrhebel +5V out
7:11
X1:153 4 5
travel lever
0V in 0V (Ref PIN5) X62:12
2 8 A54
Add1 AK Ext1 Platten Steuerung
X62:1

X62:3
X62:9
X62:2

9 11
X62:4
X62:10

Add2 AK Ext2
plate−controller
10 12
Stecker X23

BOMAG
Stecker X24
1 2 3 4 5 6 7 8
X62:5
X62:6
X62:7
X62:8

X62:11
X62:13
X62:15
X62:14

Ub out
OV out

DK Ext1
DK Ext3
DK Ext5
DK Ext6

DK Ext2
DK Ext4
X50:2
X50:3
X50:1

S − + Y123 1 Y143 1 Y144.2 1

X1:210
S35 K0G S09 13 S64 13 S36 13 S139
13 23 2 2 2
400 .. 1.200 mA

86 86 1 Y122 1 Y142 1 Y144.1 1 Y145 1

K48 K05 Y98
14 14 14 14
24
2 2 2 2 2
85 85

X1:149 X1:211 X1:212

7:20 31
9:1
7:17 2:13 31

nicht bei BVC Nur bei BVC Schalter Schwimmstellung Platten MV Platten heben MV Platten rechts
not at BVC Only at BVC sw. swimming pos. plates plates up plates right
Frequenzverstellung Platten
freq. adjust plates MV Platten senken MV Platten Schwimmst
Schalter Amplitude Schalter Vibration Ein/Aus Schalter Betriebsart Platten Prop−Pumpe Platten plates down plates float−pos.
switch amplitudes switch vibration on/off modesw. plates prop.−valve plates MV Platten links MV Platten Priorität
plates left plates priority

19.10.2005
1 1
Wiring diagram 582 702 07

008 914 20
Vogt Fahrhebel, Vibrationsplatten 582 702 07
19.10.2005
Seis joystick, vibration−plates 008
Beschleunigungssensoren Beschleunigungssensoren Aufnehmer Verstellmotor Drucker Bedieneinheit BEM Display Messtechnik BOP
acc. sensor front acc. sensor rear sens. adjust. motor printer control−unit BEM display measurem. BOP
X1:34A
5:9
6:20 30 30 12:1
Pot 30
8:20 K11:87 K11:87 12:1
Pot 15

008 914 20
X2:47 X2:48 X2:49
+ −
X2:66
X2:70 X42:1 X42:2 X42:3

X46:B X46:A X46:E

X1:32E X1:35E
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+
F148:2 B62 B62 X2:67 X2:68 CAN−
10:15

X4:C
X4:E
X4:D

+/sw
+/sw
−/gg −/gg X47:A X47:B
Wiring diagram 582 702 07

X46:D X46:F
nur bei BTM+/BTM prof
only at BTM+/BTM prof

X42:4 X42:5
15g/bl 15g/bl

−/sw
X74:3
X74:5
X74:4
8:20
X2:57 B61 P11 CAN1−

20g/br
20g/br
+/rt 8:20
DIOS Platten

X48:3 X48:4 X49:3 X49:4 S/ws

CAN1+

nur bei BTM prof

X74:1 X74:2

only at BTM prof

X2:54 X2:55 X2:58 X2:59 X47:C
X4:A X4:B
X2:50 X2:51
R24
X2:69 X2:64 X2:65 1 2

Pot. 15
Leistung
Elektronik
8.5V
AGND MESX

Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
Erregerpos.
RxD TxD CAN1+ 60 OHM CAN1−

BOMAG
X44:1

X44:7
X44:9
X44:5
X44:27
X44:26

X44:4

X44:31

X44:56
X44:57
X44:59
X44:60
X44:30

X44:58
X44:29
X44:23

X44:28
X44:54
A83
Messtechnik−Rechner
measurement calc. unit

X44:15
X44:38
X44:35
X44:14
X44:32
X44:36
X44:37
X44:41
X44:47
X44:46
X44:53
X44:33

X44:3

X44:55
X44:65
X44:66
X44:67
X44:68

CAN3+ CAN3−
7:15 KA MESX
EVIB

GA MESX

Prop.
Prop.
GND
0..6VDC

7:15
SPEED MESX X1:85 10:15
5:3 CAN3−

400 .. 1.200mA
400 .. 1.200mA

DIR MESX X2:75 X2:73 X2:52 +

5:3
PITCH MESX Y140 1 Y141 1 P07 E 10:15
5:8 VIB CAN3+
BRAKE MESX

v.l.
v.r.

7:17 −
D+ MESX BEL MESX 2 2
2:8 12:4 X2:49 X2:76 X2:74 X2:63 X2:66 X1:82
31 31 10:1
8:20

Prop−Ventil Erreger auf EVIB−Meter

solenoid−valve exciter up EVIB−meter
Prop−Ventil Erreger ab nur bei BEM
solenoid valve exciter down only at BEM

19.10.2005
1 1 582 702 07
Vogt Variocontrol, Messtechnik
19.10.2005
21.2

1305
Seis Variocontrol, measurement equipm. 009
1306
21.2

F148:2
9:4

CAN3−
9:18

9:18 CAN3+

CAN3+ CAN3−
1 R25 2
60 OHM
X2:61 X2:62

X4:N X4:M

X75:7 X75:2

A87
USB−CAN Schnittst.
USB−CAN Interface BCM

BOMAG
X2:70

X76:1 X4:G

P15 X76:2

X4:F

X2:63

BCM 05
BCM 05
nur bei BCM
only at BCM

9:20 31 31 11:1

19.10.2005
1 1
Wiring diagram 582 702 07

008 914 20
Vogt Bomag Compaction Management BCM 582 702 07
19.10.2005
Seis Bomag Compaction Management BCM 010
9:3 K11:87 K11:87
9:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
F11 F18 F07 F08
15A 10A 15A 15A

008 914 20
30
X1:18A K06 X1:19A X1:25A
X1:26A
12:4 X1:305
X1:83

X1:301
Schalter StvZO 87 87a
switch, StvZO
13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:306
X1:307

X3:4 X3:5 with cabin 30 49L 49R

Wiring diagram 582 702 07

STV1

X1:302
13:17 A02
STV2
13:17
X1:23E X1:24E
K16 30 31 82 L R
12:9 F09 F10
10A 10A
87 87a X1:23A X1:24A
BEL 6:9 BL
6:9
13 BR
6:9

S16 14

switch, working head lights

BOMAG
X1:304

13 23

Schalter Arbeitsbele
01

X1:311

X1:310
X1:319
X1:313

X1:312
X1:321
X1:314

X1:309
X1:303

X1:320
X1:322

S14

lights without StvZO

Anschluß Arbeitsschein−
werfer ohne StvZO
connection working head
X1:84
Warnblinkschalter 14 24
BEL MESX
X61:1

X61:3
X60:1

X59:5
X60:3
X59:3

X58:5
X58:3
X59:2

X58:2

switch, hazard light

Arbeitsscheinwerfer hinten links

working head lights, rear lh.
Arbeitsscheinwerfer hinten rechts
working head lights, rear rh.
Arbeitsscheinwerfer vorne links
working head lights, front lh.
Arbeitsscheinwerfer vorne rechts
working head lights, front rh.

9:7
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
11:12 13:1
31 12:10 Schlußleuchte links 12:2 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

19.10.2005
1 1 582 702 07
Vogt Beleuchtung und StvZO
19.10.2005
21.2

1307
Seis illumination and StvZO 012
1308
X3:6
2:15 K30 K32:87 14:2
X3:7
21.2

K32 30 STV2
X3:8 12:13
13:1 12:13 STV1
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
F42 14:8
F130 13:9 F130 F130 14:7
13:14

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 13:16 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
5:3 P09 +

indicator
X55:1
X56:1

X55:3
X56:3
2 1 XS

X55:4
X56:4
night illumination
SPEED TAC A16 1 B3 E27 1 E28 1 E23 1 E25
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
7:18
A5+A6

BOMAG
S45 TK −

Heizung Heckscheibe
heating rear screen
3,8A
3,8A

Schalter Innenleuche
switches interior lights
3
5A

86 S86 + + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
− − M07 − M06 4 −
85

2,9A
3 min

ZA
4,7A

X55:2 X56:2 option

Abfallverzögert

14:18
KABINE 31
Relais Kabine Türkontaktschalter Tachograph Schalter Nachtleuchte
relais cabin door switch tachograph switch, night illumination

X3:1
X3:2
Schalterbel.
switch illum.

12:20 31 31 14:1

3:6 Wascher hinten Wascher vorn 13:2 Arbeitsscheinwerfer vorn

washer rear washer front working head lights, front

Wischer hinten Wischer vorne Arbeitsscheinwerfer hinten Rundumkennleuchte

windscreen wiper, rear windscreen wiper, rear working head lights, rear rotary beacon

19.10.2005
1 1
Wiring diagram 582 702 07

008 914 20
Vogt Kabinenausrüstung, Beleuchtung, Radio, Tachograph 582 702 07
19.10.2005
Seis cabin−equipment, headlights, radio, tachograph 013
13:19 K32:87
Potential 15 aus Kabine
13:17 F130
F42 Potential 15 aus Kabine
13:9
D Potential 30 aus Kabine H A
F31 F40 F15
20A 20A 5A
4 8 1

008 914 20
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
Wiring diagram 582 702 07

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
2:10
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 _t
2 2

BOMAG
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 13:19

X20:4
X20:3
V06 Y14 KABINE 31

monitoring coolant pressure

M09 M M09 M
2 2 2

Überwachung Kühlmitt
Stromaufnahme Lüfter / current blower br br
Stufe 1: 3.0A pro Lüfter
X20:2 V04
Stufe 2: 4.5A pro Lüfter 1
Stufe 3: 11.5A pro Lüfter
Y15 1
X17:4 X1:168
2

3,5A
X1:164

X1:190
13:20 31 31

Kabinenlüfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit
Kabinenlüfter
cab ventilator

19.10.2005
1 1 582 702 07
Vogt Kabinenheizung, Klimaanlage, Zusatzheizung
19.10.2005
21.2

1309
Seis cabin−heater, air conditioning, add. heater 014
21.2 Wiring diagram 582 702 07
Name Bl. Pf. Benennung title TYP
004 12

A02 012 17 Blinkrelais indicator relay

A12 013 5 Radio Radio
A16 013 6 Elektronik Tachograph Electronic system, tachograph
A34 005 6 Prozessorplatine Prozessing circuit board
A34 007 6 Prozessorplatine Prozessing circuit board
A45 007 9 Lenkrad Steering wheel
A48 003 3 Elektronische Motorsteuerung Electronic engine management
A48 004 9 Elektronische Motorsteuerung Electronic engine management
A54 008 17 Modul Pumpenansteuerung Modul pump control
A66 011 9 Elektronik Steuereinheit Electronic control unit
A67 011 15 Eingabeeinheit Keyboard
A72 014 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
Seis
19.10.2005
Vogt
19.10.2005

A80 006 3 Modul Datensammler modul data−collector

A81 006 18 Anzeigeeinheit Display−Unit
A83 009 6 Elektronik Messtechnik electronic measurement−equipment
A87 010 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM

B03 006 3 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B11 002 16 Signalhorn Warning horn
B11 002 18 Signalhorn Warning horn
B16 007 16 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 006 2 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B51 013 4 Lautsprecher Radio Speaker radio
B51 013 6 Lautsprecher Radio Speaker radio
B55 006 4 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B57 005 6 Neigungssensor Stufenumschaltung Slope sensor, speed range selection
B59 005 4 Aufnehmer Bandagengeschwindigkeit Sensor, drum speed
B60 005 2 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 009 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 009 8 Beschleunigungsaufnehmer Acceleration sensor
B62 009 10 Beschleunigungsaufnehmer Acceleration sensor
B65 007 4 Sensor, Lenkwinkel vorn Sensor, angularity steering, front
B88 003 6 Druckgeber Motoroel Sender, engine oil pressure
B88 004 15 Druckgeber Motoroel Sender, engine oil pressure
B93 004 13 Leistungskraftstoffdruck Sensor RPS Rail pressure sensor
B103 014 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 014 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B112 005 3 Druckgeber Fahrpumpe pressure sender, driving pump
B113 003 13 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B113 004 14 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 003 7 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
component listing

B114 004 7 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1

B115 003 11 Geber Ladeluftdruck Sender, charging air pressure
Bauteilliste

B124 004 5 Geber Wasserstandsabscheider Diesel Sender, water separator fuel

B124 006 6 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 003 14 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B130 003 8 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
B130 004 8 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
B131 014 10 Temperaturschalter Heizung Temperature switch, heating
B132 007 2 Inititator Armlehne links proximity switch left arm rest
B134 008 17 Näherungsschalter Platten oben proximity switch, plate up
B135 008 16 Näherungsschalter Platten mitte proximity switch, plate middle
B145 004 17 Sensor Niederdruck Kraftstoff fuel low pressure sensor

E08 012 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 012 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 012 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 012 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 012 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 012 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 012 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 012 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 012 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 012 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E23 012 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 013 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 012 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 013 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 012 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 013 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 012 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 013 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 013 3 Innenleuchte Kabine Inside light, cabin 1,75A
E30 014 13 Heizgeraet Heating unit
E32 013 19 Kennleuchte Warning light 5A
E70 013 15 Nachtleuchte Night lamp 0,83A
E71 013 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 013 16 Beleuchtung Bedienschalter illum. Switches

F00 002 6 Hauptsicherung Batterie Fuse, main, battery 125A

F05 002 14 Sicherung Steckdose Fuse, socket 10A

F07 012 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 012 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 012 6 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 012 8 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
11

F11 012 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 11 Sicherung Startschalter Fuse, starter switch 30A
F15 014 18 Sicherung Heizgeraet Fuse, heating unit 5A
F18 012 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
582 702 07

F19 012 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 15A
F22 012 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 15A
F23 002 18 Sicherung Signalhorn Fuse, warning horn 15A
F24 006 2 Sicherung Ueberwachungsmodul Fuse, monitoring module 10A
F31 014 3 Sicherung Kabinenluefter Fuse, cabin ventilator 20A
101

F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A

F40 014 13 Sicherung Kabinenheizung Fuse, heating unit cab 20A
F41 013 19 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A

1310 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
Name Bl. Pf. Benennung title TYP
F42 013 3 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
F43 013 10 Sicherung Wischermotor hinten Fuse, wipermotor rear 15A
F44 013 13 Sicherung Wischermotor vorn Fuse, wipermotor front 15A
F48 002 5 Sicherung Gluehanlage Fuse, glow plug system 125A
F67 005 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 15A
F68 002 8 Sicherung Potential 30 Fuse, potential 30 5A
F84 005 9 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F93 004 3 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 25A
F95 002 16 Sicherung Motormanagement intern Fuse, engine controller (internal) 10A
FM1 007 6 Platinensicherung Multifuse MULTIFUSE
FM2 007 6 Platinensicherung Multifuse MULTIFUSE
FM3 007 5 Platinensicherung Multifuse MULTIFUSE
FM4 009 11 Platinensicherung Multifuse MULTIFUSE
FM5 007 6 Platinensicherung Multifuse MULTIFUSE
Seis
19.10.2005
Vogt
19.10.2005

F130 013 15 Sicherung Nachtleuchte Fuse, night lamp 10A

F143 013 2 Sicherung Heckscheibenheizung fuse rear screen heating unit 15A
F144 013 20 Sicherung Kabinensteckdose Fuse cabin−socket 15A
F145 008 18 Sicherung Anhängeplatten fuse vibration plates 20A
F146 009 5 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30) 15A
F148 009 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15) 10A

G01 002 6 Batterie Battery 103A

G02 002 7 Generator Generator
G03 002 5 Batterie Battery 103A

H06 012 15 Meldeleuchte Warnblinker Indicator light, hazard light LED ROT
H07 007 16 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0.15A
H14 005 11 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX O,46A

K05 008 3 Relais Startstrom Relay, starting current BOSCHW

K06 012 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 10 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 12 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K14 003 19 Relais Vorgluehen Relay, glow plug system TYCOX
K16 012 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K32 013 1 Relais Kabine Relay, cabin BOSCHW
K41 004 2 Trennrelais Relay, separation BOSCHW
K43 007 12 Relais Vibration Relay, vibration BOSCHW
K48 008 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K61 002 7 Relais Ladekontrolle Relay, charge control BOSCHW
K14.2 004 20 TYCOX
K141 013 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
component listing

M01 002 13 Starter Starter 2.3 KW

M04 013 12 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
Bauteilliste

M05 013 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A

M06 013 13 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 013 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 014 3 Kabinenluefter Cabin ventilator
M09 014 4 Kabinenluefter Cabin ventilator

P07 009 15 Omegameter Omegameter

P09 013 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 009 14 Drucker Printer
P15 010 16 BCM 03 Bildschirm BCM 03 terminal
P16 009 16 Diagnose, Variomatic Diagnostics, varimatic
P33 009 18 Opus 21 Opus 21

R03 006 5 Geber Tankanzeige Sender, level gauge 0 .. 67 OHM

R10 002 8 Parallelwiderstand Parallel resistor 82 OHM
R19 002 4 Heizflansch heater flange 167A
R20 005 15 Widerstand Resistor 120 OHM
R21 005 15 Widerstand Resistor 120 OHM
R22 005 12 Widerstand Resistor 120 OHM
R23 005 12 Widerstand Resistor 120 OHM
R24 009 17 Widerstand Resistor 60 OHM
R25 010 15 Widerstand Resistor 60 OHM
R80 013 2 Heizung Heckscheibe heating rear screen MAX. 13A
R81 002 1 Gluehstiftkerze 1 glow plug 1
R82 002 1 Gluehstiftkerze 2 glow plug 2
R83 002 2 Gluehstiftkerze 3 glow plug 3
R84 002 2 Gluehstiftkerze 4 glow plug 4
R85 002 2 Gluehstiftkerze 5 glow plug 5
R86 002 3 Gluehstiftkerze 6 glow plug 6

S00 002 11 Startschalter Starter switch

S01 002 16 Schalter NOT AUS Switch, emergency off NOTAUSH
S03 002 18 Taster Signalhorn Push button, warning horn
S06 005 10 Sitzkontaktschalter links Switch, seat contact, lh.
S09 008 8 Vibrationsschalter vorne Switch, vibration, front
S14 012 15 Warnblinkschalter Switch, hazard light
S15 012 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
2

S16 012 4 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 013 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 013 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 014 18 Schalter Kabinenheizung Switch, cabin heating
S30 002 5 Batterietrennschalter Switch, battery disconnect
11

S35 008 7 Vibrationsschalter klein/gross Switch, vibration low/high

S36 008 11 Vibrationsschalter Switch, vibration
S37 012 18 Schalter Blinker Switch, indicator
S38 013 19 Schalter Kennleuchte Switch, warning light
582 702 07

S42 008 11 Stufenumschalter schnell−langsam Speed range selector, fast−slow

S44 014 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 013 3 Schalter Kabineninnenleuchte Switch, cabin inside light
S55 008 6 Schalter Fahrhebel Switch, travel control lever
S64 008 10 Schalter Schwimmstellung Switch, float position
102

S86 013 3 Schalter Tuer, links Switch door, lh.

S127 006 17 Schalter Motordrehzahl Switch, engine rpm
S139 008 13 Schalter Frequenzverstellung Switch, frequency control

008 914 20 BOMAG 1311

21.2 Wiring diagram 582 702 07
Name Bl. Pf. Benennung title TYP
S158 013 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 013 16 Schalter Heckscheibenheizung switch rear screen heating unit

V01 002 9 Diode Diode FE5B

V02 002 17 Diode Diode FE5B
V03 002 18 Diode Diode FE5B
V04 014 8 Diode Diode FE5B
V06 014 9 Diode Diode

X1:1 002 7 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:2 005 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:2 012 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:3 002 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:4 002 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
Seis
19.10.2005
Vogt
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X1:7 002 13 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:8 002 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:9 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:10 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:37 007 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:38 007 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:39 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:40 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:41 006 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:41 007 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:42 007 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:43 012 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:44 005 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:45 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:46 005 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:47 005 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:48 005 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:49 005 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:50 005 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:51 005 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:52 005 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:53 005 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:54 005 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:55 007 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:56 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:57 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:58 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:59 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:60 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

X1:61 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:62 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:63 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:79 002 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:80 006 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 005 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 006 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 007 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 009 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:83 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:84 012 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:85 009 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:86 006 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:87 006 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:88 006 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:89 007 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:90 004 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:91 004 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:92 004 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:94 006 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:94 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:95 003 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:96 003 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:97 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:98 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:101 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:102 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:103 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:104 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:105 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:106 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:107 004 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:107 006 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:108 004 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:108 006 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:109 002 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:110 002 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:111 006 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:112 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
3

X1:113 007 17 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:114 005 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:115 007 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:116 007 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:117 005 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
11

X1:117 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:117 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:117 007 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:118 007 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
582 702 07

X1:119 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:120 005 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:121 005 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:122 005 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:123 002 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
103

X1:123 005 12 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:123 005 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:124 005 16 WAGO ZENTRALELEKTRIK WAGO E−BOX

1312 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
Name Bl. Pf. Benennung title TYP
X1:124 005 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:141 005 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:142 005 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:142 005 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:143 005 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:143 005 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:143 005 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:144 005 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:145 005 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:146 005 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:147 007 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:148 007 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:149 005 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:149 006 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
Seis
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Vogt
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X1:149 007 2 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:149 008 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:14A 004 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:14E 004 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:150 007 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:151 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:152 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:153 008 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:154 007 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:155 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:156 008 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:157 008 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:158 005 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:159 007 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:15A 002 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:15E 002 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:160 007 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:161 007 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:162 007 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:163 014 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:164 006 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:164 014 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:165 014 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:166 014 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:167 014 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:168 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:168 014 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:169 014 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:16A 002 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

X1:16E 002 14 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:170 014 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:171 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:172 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:173 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:174 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:175 005 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:176 005 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:177 005 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:178 005 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:179 003 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:179 004 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:17A 005 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:17E 005 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:180 003 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:180 004 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:181 003 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:181 004 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:182 003 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:182 004 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:183 003 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:183 004 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:184 003 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:184 004 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:185 003 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:185 004 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:186 003 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:186 004 20 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:187 007 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:188 007 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:189 007 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:18A 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:18E 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:190 007 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:190 014 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:191 004 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:192 004 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:193 004 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:194 004 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
4

X1:195 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:196 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:197 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:197 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:198 004 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
11

X1:199 004 5 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:19A 012 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:19E 012 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:201 007 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
582 702 07

X1:202 007 4 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:203 007 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:205 007 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:206 007 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:207 007 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
104

X1:208 007 11 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:209 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:20A 002 8 WAGO ZENTRALELEKTRIK WAGO E−BOX

008 914 20 BOMAG 1313

21.2 Wiring diagram 582 702 07
Name Bl. Pf. Benennung title TYP
X1:20E 002 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:210 008 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:211 008 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:212 008 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:213 008 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:214 008 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:215 008 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:21A 012 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:21E 012 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:22A 012 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:22E 012 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:23A 012 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:23E 012 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:24A 012 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
Seis
19.10.2005
Vogt
19.10.2005

X1:24E 012 8 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:25A 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:25E 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:26A 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:26E 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:27A 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:27E 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:28A 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:28E 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:29A 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:29E 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:301 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:302 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:303 012 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:304 012 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:305 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:306 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:307 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:309 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:30A 002 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:30E 002 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:310 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:311 012 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:312 012 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:313 012 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:314 012 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:315 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:315 012 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:315 012 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

X1:316 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:316 012 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:316 012 19 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:319 012 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:31A 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:31E 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:320 012 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:321 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:322 012 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:323 012 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:323 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:324 012 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:324 012 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:32A 009 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:32E 009 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:34A 005 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:34E 005 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:35A 009 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:35E 009 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X2:47 009 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:48 009 19 WAGO−MESSTECHNIK Wago−measurement equip.
X2:49 009 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:49 009 19 WAGO−MESSTECHNIK Wago−measurement equip.
X2:50 009 17 WAGO−MESSTECHNIK Wago−measurement equip.
X2:51 009 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:52 009 13 WAGO−MESSTECHNIK Wago−measurement equip.
X2:53 009 8 WAGO−MESSTECHNIK Wago−measurement equip.
X2:54 009 7 WAGO−MESSTECHNIK Wago−measurement equip.
X2:55 009 8 WAGO−MESSTECHNIK Wago−measurement equip.
X2:56 009 7 WAGO−MESSTECHNIK Wago−measurement equip.
X2:57 009 2 WAGO−MESSTECHNIK Wago−measurement equip.
X2:57 009 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:58 009 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:59 009 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:60 009 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:61 010 15 WAGO−MESSTECHNIK Wago−measurement equip.
X2:62 010 16 WAGO−MESSTECHNIK Wago−measurement equip.
X2:63 009 13 WAGO−MESSTECHNIK Wago−measurement equip.
X2:63 010 18 WAGO−MESSTECHNIK Wago−measurement equip.
5

X2:64 009 14 WAGO−MESSTECHNIK Wago−measurement equip.

X2:65 009 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:66 009 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:66 009 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:67 009 11 WAGO−MESSTECHNIK Wago−measurement equip.
11

X2:68 009 12 WAGO−MESSTECHNIK Wago−measurement equip.

X2:69 009 12 WAGO−MESSTECHNIK Wago−measurement equip.
X2:70 009 15 WAGO−MESSTECHNIK Wago−measurement equip.
X2:70 010 18 WAGO−MESSTECHNIK Wago−measurement equip.
582 702 07

X2:71 009 13 WAGO−MESSTECHNIK Wago−measurement equip.

X2:73 009 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:74 009 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:75 009 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:76 009 10 WAGO−MESSTECHNIK Wago−measurement equip.
105

X2:77 009 11 WAGO−MESSTECHNIK Wago−measurement equip.

X2:78 009 11 WAGO−MESSTECHNIK Wago−measurement equip.
X3:1 012 11 STECKER ROPS/SD conn. ROPS/SR

1314 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
Name Bl. Pf. Benennung title TYP
X3:1 013 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:2 013 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:3 002 19 SETCKER KABINE/ROPS Con cabin/ROPS
X3:4 012 10 STECKER ROPS/SD conn. ROPS/SR
X3:5 012 12 STECKER ROPS/SD conn. ROPS/SR
X3:6 013 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:7 013 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:8 013 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:9 014 3 STECKER KABINE/ROPS conn. cabin/ROPS
X3:10 014 3 STECKER KABINE/ROPS conn. cabin/ROPS
X3:11 014 4 STECKER KABINE/ROPS conn. cabin/ROPS
X3:12 014 4 STECKER KABINE/ROPS conn. cabin/ROPS
X3:13 014 7 STECKER KABINE/ROPS conn. cabin/ROPS
X3:14 014 10 STECKER KABINE/ROPS conn. cabin/ROPS
Seis
19.10.2005
Vogt
19.10.2005

X3:17 013 6 STECKER KABINE/ROPS conn. cabin/ROPS

X3:18 013 6 STECKER KABINE/ROPS conn. cabin/ROPS
X4:A 009 14 KABINENST. MESST. con. measurem.equipm.
X4:B 009 14 KABINENST. MESST. con. measurem.equipm.
X4:C 009 14 KABINENST. MESST. con. measurem.equipm.
X4:D 009 14 KABINENST. MESST. con. measurem.equipm.
X4:E 009 15 KABINENST. MESST. con. measurem.equipm.
X4:F 010 18 KABINENST. MESST. con. measurem.equipm.
X4:G 010 18 KABINENST. MESST. con. measurem.equipm.
X4:M 010 16 KABINENST. MESST. con. measurem.equipm.
X4:N 010 15 KABINENST. MESST. con. measurem.equipm.
X6:1 007 13 STECKER VIBRATION GRO conn. vibration big
X6:2 007 14 STECKER VIBRATION GRO conn. vibration big
X7:1 007 15 STECKER VIBRATION KLE conn. vibration small
X7:2 007 14 STECKER VIBRATION KLE conn. vibration small
X8:1 006 6 STECKER WASSERABSCHEI connector water separator
X8:2 006 6 STECKER WASSERABSCHEI connector water separator
X9:1 005 11 STECKER RÜCKFAHRALARM conn. backupalarm
X9:2 005 11 STECKER RÜCKFAHRALARM conn. backupalarm
XS 002 19 Steckdose Socket
XS 013 20 Steckdose Socket
X10:2 006 5 STECKER TAUCHROHRGEBE connector fuel level sensor
X10:3 006 5 STECKER TAUCHROHRGEBE connector fuel level sensor
X14:A 005 10 STECKER SITZKONTAKT connector seat contact switch
X14:B 005 10 STECKER SITZKONTAKT connector seat contact switch
X15:1 005 13 STECKER FAHRPUMPE RÜC connectoe driving pump back
X15:2 005 13 STECKER FAHRPUMPE RÜC connectoe driving pump back
X16:1 005 12 STECKER FAHRPUMPE VOR connector driving pump front
X16:2 005 12 STECKER FAHRPUMPE VOR connector driving pump front
component listing

X17:1 014 3 STECKER LÜFTER HKL conn. blower

X17:2 014 3 STECKER LÜFTER HKL conn. blower
Bauteilliste

X17:3 014 4 STECKER LÜFTER HKL conn. blower

X17:4 014 5 STECKER LÜFTER HKL conn. blower
X18:1 014 10 STECKER THERMOFÜHLER conn. sender temp.
X18:2 014 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 014 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X19:2 014 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X20:1 014 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:2 014 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:3 014 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:4 014 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X21:1 006 4 STECKER KÜHLMITTEL connector coolant sensor
X21:2 006 4 STECKER KÜHLMITTEL connector coolant sensor
X22:1 007 16 ST. VIBRATIONSAUFNEHM connector vibration sensor
X22:2 007 17 ST. VIBRATIONSAUFNEHM connector vibration sensor
X22:3 007 17 ST. VIBRATIONSAUFNEHM connector vibration sensor
X22:4 007 16 ST. VIBRATIONSAUFNEHM connector vibration sensor
X25:2 008 10 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X25:3 008 11 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X25:4 008 11 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X26:1 006 8 STECKER DATENSAMMLER connector data collector
X26:2 006 8 STECKER DATENSAMMLER connector data collector
X26:3 006 2 STECKER DATENSAMMLER connector data collector
X26:4 006 9 STECKER DATENSAMMLER connector data collector
X26:5 006 2 STECKER DATENSAMMLER connector data collector
X26:6 006 9 STECKER DATENSAMMLER connector data collector
X26:8 006 3 STECKER DATENSAMMLER connector data collector
X26:9 006 7 STECKER DATENSAMMLER connector data collector
X26:10 006 4 STECKER DATENSAMMLER connector data collector
X26:11 006 9 STECKER DATENSAMMLER connector data collector
X26:12 006 12 STECKER DATENSAMMLER connector data collector
X27:1 006 11 STECKER DATENSAMMLER connector data collector
X27:2 006 5 STECKER DATENSAMMLER connector data collector
X27:3 006 10 STECKER DATENSAMMLER connector data collector
X27:4 006 6 STECKER DATENSAMMLER connector data collector
X27:5 006 11 STECKER DATENSAMMLER connector data collector
X27:6 006 9 STECKER DATENSAMMLER connector data collector
X27:7 006 10 STECKER DATENSAMMLER connector data collector
6

X27:8 006 2 STECKER DATENSAMMLER connector data collector

X27:9 006 7 STECKER DATENSAMMLER connector data collector
X27:10 006 10 STECKER DATENSAMMLER connector data collector
X27:11 006 10 STECKER DATENSAMMLER connector data collector
X27:12 006 10 STECKER DATENSAMMLER connector data collector
11

X28:1 006 16 STECKER LC−DISPLAY 1 connector LC−display 1

X28:2 006 13 STECKER LC−DISPLAY 1 connector LC−display 1
X28:3 006 13 STECKER LC−DISPLAY 1 connector LC−display 1
X28:4 006 14 STECKER LC−DISPLAY 1 connector LC−display 1
582 702 07

X28:5 006 16 STECKER LC−DISPLAY 1 connector LC−display 1

X28:6 006 17 STECKER LC−DISPLAY 1 connector LC−display 1
X29:1 006 14 STECKER LC−DISPLAY 2 connector LC−display 2
X29:2 006 14 STECKER LC−DISPLAY 2 connector LC−display 2
X29:3 006 15 STECKER LC−DISPLAY 2 connector LC−display 2
106

X29:4 006 15 STECKER LC−DISPLAY 2 connector LC−display 2

X29:5 006 17 STECKER LC−DISPLAY 2 connector LC−display 2
X29:6 006 17 STECKER LC−DISPLAY 2 connector LC−display 2

008 914 20 BOMAG 1315

21.2 Wiring diagram 582 702 07
Name Bl. Pf. Benennung title TYP
X29:7 006 18 STECKER LC−DISPLAY 2 connector LC−display 2
X29:8 006 17 STECKER LC−DISPLAY 2 connector LC−display 2
X30:1 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:1 004 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:2 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:2 004 18 EMR−Stecker Fahrzeug EMR−connector compactor
X30:3 003 8 EMR−Stecker Fahrzeug EMR−connector compactor
X30:3 004 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:4 003 7 EMR−Stecker Fahrzeug EMR−connector compactor
X30:4 004 18 EMR−Stecker Fahrzeug EMR−connector compactor
X30:5 003 7 EMR−Stecker Fahrzeug EMR−connector compactor
X30:5 004 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:6 004 19 EMR−Stecker Fahrzeug EMR−connector compactor
X30:10 003 2 EMR−Stecker Fahrzeug EMR−connector compactor
Seis
19.10.2005
Vogt
19.10.2005

X30:11 003 2 EMR−Stecker Fahrzeug EMR−connector compactor

X30:12 003 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:13 003 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:14 003 2 EMR−Stecker Fahrzeug EMR−connector compactor
X30:15 003 7 EMR−Stecker Fahrzeug EMR−connector compactor
X30:17 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X30:22 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:23 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X30:24 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X30:25 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X30:25 004 13 EMR−Stecker Fahrzeug EMR−connector compactor
X30:28 004 9 EMR−Stecker Fahrzeug EMR−connector compactor
X30:60 004 13 EMR−Stecker Fahrzeug EMR−connector compactor
X30:61 004 14 EMR−Stecker Fahrzeug EMR−connector compactor
X30:62 004 14 EMR−Stecker Fahrzeug EMR−connector compactor
X30:63 004 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:64 004 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:72 004 2 EMR−Stecker Fahrzeug EMR−connector compactor
X30:82 004 13 EMR−Stecker Fahrzeug EMR−connector compactor
X31:1 003 16 EMR−Stecker Motor EMR−connector engine
X31:1 004 5 EMR−Stecker Motor EMR−connector engine
X31:2 003 17 EMR−Stecker Motor EMR−connector engine
X31:3 003 17 EMR−Stecker Motor EMR−connector engine
X31:4 003 12 EMR−Stecker Motor EMR−connector engine
X31:5 003 14 EMR−Stecker Motor EMR−connector engine
X31:6 003 15 EMR−Stecker Motor EMR−connector engine
X31:7 003 17 EMR−Stecker Motor EMR−connector engine
X31:7 004 9 EMR−Stecker Motor EMR−connector engine
X31:8 003 13 EMR−Stecker Motor EMR−connector engine
component listing

X31:8 004 14 EMR−Stecker Motor EMR−connector engine

X31:9 003 13 EMR−Stecker Motor EMR−connector engine
Bauteilliste

X31:10 003 8 EMR−Stecker Motor EMR−connector engine

X31:10 004 7 EMR−Stecker Motor EMR−connector engine
X31:11 003 8 EMR−Stecker Motor EMR−connector engine
X31:12 003 7 EMR−Stecker Motor EMR−connector engine
X31:12 004 8 EMR−Stecker Motor EMR−connector engine
X31:13 003 7 EMR−Stecker Motor EMR−connector engine
X31:13 004 16 EMR−Stecker Motor EMR−connector engine
X31:13 004 17 EMR−Stecker Motor EMR−connector engine
X31:14 003 9 EMR−Stecker Motor EMR−connector engine
X31:14 004 12 EMR−Stecker Motor EMR−connector engine
X31:15 003 9 EMR−Stecker Motor EMR−connector engine
X31:16 003 11 EMR−Stecker Motor EMR−connector engine
X31:16 004 1 EMR−Stecker Motor EMR−connector engine
X31:17 003 10 EMR−Stecker Motor EMR−connector engine
X31:18 003 10 EMR−Stecker Motor EMR−connector engine
X31:19 003 10 EMR−Stecker Motor EMR−connector engine
X31:19 004 10 EMR−Stecker Motor EMR−connector engine
X31:20 003 6 EMR−Stecker Motor EMR−connector engine
X31:20 004 8 EMR−Stecker Motor EMR−connector engine
X31:21 003 6 EMR−Stecker Motor EMR−connector engine
X31:22 003 6 EMR−Stecker Motor EMR−connector engine
X31:23 003 11 EMR−Stecker Motor EMR−connector engine
X31:23 004 11 EMR−Stecker Motor EMR−connector engine
X31:23 004 18 EMR−Stecker Motor EMR−connector engine
X31:24 003 11 EMR−Stecker Motor EMR−connector engine
X31:24 004 19 EMR−Stecker Motor EMR−connector engine
X31:25 003 12 EMR−Stecker Motor EMR−connector engine
X31:26 004 13 EMR−Stecker Motor EMR−connector engine
X31:27 004 9 EMR−Stecker Motor EMR−connector engine
X31:31 004 4 EMR−Stecker Motor EMR−connector engine
X31:32 004 6 EMR−Stecker Motor EMR−connector engine
X31:33 004 3 EMR−Stecker Motor EMR−connector engine
X31:34 004 20 EMR−Stecker Motor EMR−connector engine
X31:40 004 12 EMR−Stecker Motor EMR−connector engine
X31:40 004 17 EMR−Stecker Motor EMR−connector engine
X31:41 004 15 EMR−Stecker Motor EMR−connector engine
X31:43 004 13 EMR−Stecker Motor EMR−connector engine
7

X31:46 004 2 EMR−Stecker Motor EMR−connector engine

X31:47 004 1 EMR−Stecker Motor EMR−connector engine
X31:48 004 5 EMR−Stecker Motor EMR−connector engine
X31:49 004 11 EMR−Stecker Motor EMR−connector engine
X31:50 004 7 EMR−Stecker Motor EMR−connector engine
11

X31:51 004 15 EMR−Stecker Motor EMR−connector engine

X31:53 004 13 EMR−Stecker Motor EMR−connector engine
X31:56 004 16 EMR−Stecker Motor EMR−connector engine
X31:58 004 14 EMR−Stecker Motor EMR−connector engine
582 702 07

X32:A 003 2 EMR − Diagnose EMR−diagnosis

X32:A 004 12 EMR − Diagnose EMR−diagnosis
X32:B 003 3 EMR − Diagnose EMR−diagnosis
X32:B 004 14 EMR − Diagnose EMR−diagnosis
X32:F 004 13 EMR − Diagnose EMR−diagnosis
107

X32:G 003 3 EMR − Diagnose EMR−diagnosis

X32:G 004 14 EMR − Diagnose EMR−diagnosis
X32:H 003 3 EMR − Diagnose EMR−diagnosis

1316 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
Name Bl. Pf. Benennung title TYP
X32:H 004 14 EMR − Diagnose EMR−diagnosis
X32:K 003 2 EMR − Diagnose EMR−diagnosis
X32:K 004 13 EMR − Diagnose EMR−diagnosis
X32:L 003 2 EMR − Diagnose EMR−diagnosis
X32:M 004 13 EMR − Diagnose EMR−diagnosis
X33:1 003 19 Trennstelle EMR II conector EMR II
X33:2 003 18 Trennstelle EMR II conector EMR II
X33:3 003 18 Trennstelle EMR II conector EMR II
X33:4 003 19 Trennstelle EMR II conector EMR II
X33:5 003 18 Trennstelle EMR II conector EMR II
X33:6 003 19 Trennstelle EMR II conector EMR II
X33:7 003 17 Trennstelle EMR II conector EMR II
X33:8 003 20 Trennstelle EMR II conector EMR II
X34:A 005 14 DIAGNOSESTECKER ESX connector diagnosis ESX
Seis
19.10.2005
Vogt
19.10.2005

X34:B 005 16 DIAGNOSESTECKER ESX connector diagnosis ESX

X34:C 005 12 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:D 005 13 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:G 005 10 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:H 005 11 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:J 007 3 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:N 003 4 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:P 002 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:R 006 2 DIAGNOSESTECKER ESX connector diagnosis ESX
X35:1 007 4 ESX STECKER esx connector
X35:2 007 12 ESX STECKER esx connector
X35:3 007 16 ESX STECKER esx connector
X35:4 005 11 ESX STECKER esx connector
X35:5 005 10 ESX STECKER esx connector
X35:12 005 3 ESX STECKER esx connector
X35:15 005 10 ESX STECKER esx connector
X35:16 007 4 ESX STECKER esx connector
X35:17 007 18 ESX STECKER esx connector
X35:18 007 11 ESX STECKER esx connector
X35:19 007 11 ESX STECKER esx connector
X35:20 007 5 ESX STECKER esx connector
X35:21 007 6 ESX STECKER esx connector
X35:22 007 11 ESX STECKER esx connector
X35:23 007 5 ESX STECKER esx connector
X35:24 005 11 ESX STECKER esx connector
X35:26 005 16 ESX STECKER esx connector
X35:27 005 15 ESX STECKER esx connector
X35:28 005 2 ESX STECKER esx connector
X35:29 007 4 ESX STECKER esx connector
component listing

X35:30 005 9 ESX STECKER esx connector

X35:31 005 5 ESX STECKER esx connector
Bauteilliste

X35:33 005 13 ESX STECKER esx connector

X35:34 005 6 ESX STECKER esx connector
X35:35 007 17 ESX STECKER esx connector
X35:37 005 5 ESX STECKER esx connector
X35:38 005 2 ESX STECKER esx connector
X35:40 007 11 ESX STECKER esx connector
X35:41 007 11 ESX STECKER esx connector
X35:43 007 10 ESX STECKER esx connector
X35:46 005 15 ESX STECKER esx connector
X35:47 005 16 ESX STECKER esx connector
X35:48 007 14 ESX STECKER esx connector
X35:49 005 12 ESX STECKER esx connector
X35:53 005 12 ESX STECKER esx connector
X35:54 005 9 ESX STECKER esx connector
X35:55 005 18 ESX STECKER esx connector
X35:56 005 7 ESX STECKER esx connector
X35:57 005 7 ESX STECKER esx connector
X35:58 005 8 ESX STECKER esx connector
X35:59 005 8 ESX STECKER esx connector
X35:60 005 8 ESX STECKER esx connector
X35:61 007 17 ESX STECKER esx connector
X35:64 005 13 ESX STECKER esx connector
X35:65 005 18 ESX STECKER esx connector
X35:66 005 19 ESX STECKER esx connector
X35:67 005 19 ESX STECKER esx connector
X35:68 005 19 ESX STECKER esx connector
X36:A 002 5 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 6 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 11 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X37:B 002 13 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 13 STECKER STARTER E−KAS connector starter, e−Box
X39:1 007 9 STECKER 1 LENKRAD connector 1 steering unit
X39:2 007 10 STECKER 1 LENKRAD connector 1 steering unit
X39:3 007 10 STECKER 1 LENKRAD connector 1 steering unit
X39:4 007 9 STECKER 1 LENKRAD connector 1 steering unit
X40:1 007 9 STECKER 2 LENKRAD connector 2 steering unit
X40:2 007 10 STECKER 2 LENKRAD connector 2 steering unit
8

X40:3 007 10 STECKER 2 LENKRAD connector 2 steering unit

X40:4 007 9 STECKER 2 LENKRAD connector 2 steering unit
X41:1 007 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:2 007 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:3 007 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
11

X41:4 007 8 ST. LENKRADKABELBAUM conn. steer. wire harn.

X41:5 007 11 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:6 007 11 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:7 007 11 ST. LENKRADKABELBAUM conn. steer. wire harn.
582 702 07

X41:8 007 11 ST. LENKRADKABELBAUM conn. steer. wire harn.

X42:1 009 18 STECKER ADAPTER BOP conector adapter BOP
X42:2 009 19 STECKER ADAPTER BOP conector adapter BOP
X42:3 009 19 STECKER ADAPTER BOP conector adapter BOP
X42:4 009 18 STECKER ADAPTER BOP conector adapter BOP
108

X42:5 009 18 STECKER ADAPTER BOP conector adapter BOP

X43:1 007 2 STECKER SCHALTER ARML connector switch arm rest
X43:2 007 1 STECKER SCHALTER ARML connector switch arm rest

008 914 20 BOMAG 1317

21.2 Wiring diagram 582 702 07
Name Bl. Pf. Benennung title TYP
X44:1 009 13 MESX STECKER MESX Stecker
X44:3 009 15 MESX STECKER MESX Stecker
X44:4 009 14 MESX STECKER MESX Stecker
X44:5 009 14 MESX STECKER MESX Stecker
X44:7 009 10 MESX STECKER MESX Stecker
X44:9 009 12 MESX STECKER MESX Stecker
X44:14 009 5 MESX STECKER MESX Stecker
X44:15 009 4 MESX STECKER MESX Stecker
X44:23 009 11 MESX STECKER MESX Stecker
X44:26 009 18 MESX STECKER MESX Stecker
X44:27 009 17 MESX STECKER MESX Stecker
X44:28 009 2 MESX STECKER MESX Stecker
X44:29 009 7 MESX STECKER MESX Stecker
X44:30 009 9 MESX STECKER MESX Stecker
Seis
19.10.2005
Vogt
19.10.2005

X44:31 009 8 MESX STECKER MESX Stecker

X44:32 009 5 MESX STECKER MESX Stecker
X44:33 009 18 MESX STECKER MESX Stecker
X44:35 009 5 MESX STECKER MESX Stecker
X44:36 009 6 MESX STECKER MESX Stecker
X44:37 009 6 MESX STECKER MESX Stecker
X44:38 009 4 MESX STECKER MESX Stecker
X44:41 009 7 MESX STECKER MESX Stecker
X44:46 009 11 MESX STECKER MESX Stecker
X44:47 009 10 MESX STECKER MESX Stecker
X44:53 009 17 MESX STECKER MESX Stecker
X44:54 009 6 MESX STECKER MESX Stecker
X44:55 009 13 MESX STECKER MESX Stecker
X44:56 009 4 MESX STECKER MESX Stecker
X44:57 009 5 MESX STECKER MESX Stecker
X44:58 009 5 MESX STECKER MESX Stecker
X44:59 009 5 MESX STECKER MESX Stecker
X44:60 009 6 MESX STECKER MESX Stecker
X44:65 009 13 MESX STECKER MESX Stecker
X44:66 009 13 MESX STECKER MESX Stecker
X44:67 009 14 MESX STECKER MESX Stecker
X44:68 009 14 MESX STECKER MESX Stecker
X46:A 009 19 STECKER BOP Connector BOP
X46:B 009 18 STECKER BOP Connector BOP
X46:D 009 18 STECKER BOP Connector BOP
X46:E 009 19 STECKER BOP Connector BOP
X46:F 009 18 STECKER BOP Connector BOP
X47:A 009 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 009 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
component listing

X47:C 009 12 STECKER AUFN. PLEIGER conn. sender PLEIGER

X48:1 009 8 STECKER AUFN. VORNE conn. sender front
Bauteilliste

X48:2 009 7 STECKER AUFN. VORNE conn. sender front

X48:3 009 7 STECKER AUFN. VORNE conn. sender front
X48:4 009 8 STECKER AUFN. VORNE conn. sender front
X49:1 009 10 STECKER AUFN. HINTEN conn. sender rear
X49:2 009 9 STECKER AUFN. HINTEN conn. sender rear
X49:3 009 9 STECKER AUFN. HINTEN conn. sender rear
X49:4 009 10 STECKER AUFN. HINTEN conn. sender rear
X50:1 008 13 ST. PLATTENFREQ. conn. plate−freq.
X50:2 008 13 ST. PLATTENFREQ. conn. plate−freq.
X50:3 008 13 ST. PLATTENFREQ. conn. plate−freq.
X51:1 007 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X51:2 007 1 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X51:3 007 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X52:1 005 3 STECKER DRUCKSENSOR connector pressure sensor
X52:2 005 3 STECKER DRUCKSENSOR connector pressure sensor
X53:B 014 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 014 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 014 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:L 014 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 014 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 014 11 STECKER HEIZSTEUERUNG conn. heating controller
X54:2 014 11 STECKER HEIZSTEUERUNG conn. heating controller
X54:3 014 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:4 014 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:6 014 7 STECKER HEIZSTEUERUNG conn. heating controller
X54:11 014 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:12 014 11 STECKER HEIZSTEUERUNG conn. heating controller
X55:1 013 11 STECKER WISCHER HINTE connector wiper rear
X55:2 013 10 STECKER WISCHER HINTE connector wiper rear
X55:3 013 10 STECKER WISCHER HINTE connector wiper rear
X55:4 013 10 STECKER WISCHER HINTE connector wiper rear
X56:1 013 14 STECKER WISCHER VORNE conn. wiper front
X56:2 013 13 STECKER WISCHER VORNE conn. wiper front
X56:3 013 13 STECKER WISCHER VORNE conn. wiper front
X56:4 013 12 STECKER WISCHER VORNE conn. wiper front
X57:1 003 15 Stecker Motor connector engine
X57:1 004 9 Stecker Motor connector engine
9

X57:2 003 13 Stecker Motor connector engine

X57:3 003 14 Stecker Motor connector engine
X57:4 003 12 Stecker Motor connector engine
X57:5 003 14 Stecker Motor connector engine
X57:6 003 15 Stecker Motor connector engine
11

X57:8 003 13 Stecker Motor connector engine

X57:9 003 13 Stecker Motor connector engine
X57:9 004 8 Stecker Motor connector engine
X57:10 003 8 Stecker Motor connector engine
582 702 07

X57:11 003 8 Stecker Motor connector engine

X57:12 003 7 Stecker Motor connector engine
X57:13 003 7 Stecker Motor connector engine
X57:13 004 7 Stecker Motor connector engine
X57:14 003 9 Stecker Motor connector engine
109

X57:14 004 7 Stecker Motor connector engine

X57:15 003 9 Stecker Motor connector engine
X57:15 004 9 Stecker Motor connector engine

1318 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
Name Bl. Pf. Benennung title TYP
X57:16 003 11 Stecker Motor connector engine
X57:17 003 10 Stecker Motor connector engine
X57:18 003 10 Stecker Motor connector engine
X57:19 003 10 Stecker Motor connector engine
X57:19 004 10 Stecker Motor connector engine
X57:20 003 6 Stecker Motor connector engine
X57:20 004 11 Stecker Motor connector engine
X57:21 003 6 Stecker Motor connector engine
X57:21 004 8 Stecker Motor connector engine
X57:22 003 6 Stecker Motor connector engine
X57:22 004 12 Stecker Motor connector engine
X57:23 003 11 Stecker Motor connector engine
X57:23 004 12 Stecker Motor connector engine
X57:23 004 17 Stecker Motor connector engine
Seis
19.10.2005
Vogt
19.10.2005

X57:24 003 11 Stecker Motor connector engine

X57:24 004 15 Stecker Motor connector engine
X57:25 003 12 Stecker Motor connector engine
X57:25 004 13 Stecker Motor connector engine
X57:26 004 16 Stecker Motor connector engine
X57:27 004 15 Stecker Motor connector engine
X57:28 004 11 Stecker Motor connector engine
X57:28 004 17 Stecker Motor connector engine
X57:29 004 13 Stecker Motor connector engine
X57:29 004 18 Stecker Motor connector engine
X57:30 004 14 Stecker Motor connector engine
X57:31 004 14 Stecker Motor connector engine
X57:32 004 13 Stecker Motor connector engine
X57:33 004 16 Stecker Motor connector engine
X57:34 004 1 Stecker Motor connector engine
X57:35 004 1 Stecker Motor connector engine
X57:36 004 3 Stecker Motor connector engine
X57:37 004 5 Stecker Motor connector engine
X57:39 004 2 Stecker Motor connector engine
X57:40 004 4 Stecker Motor connector engine
X57:41 004 6 Stecker Motor connector engine
X57:42 004 5 Stecker Motor connector engine
X58:2 012 17 STECKER STVZO VL Con. STVZO FL
X58:3 012 7 STECKER STVZO VL Con. STVZO FL
X58:5 012 2 STECKER STVZO VL Con. STVZO FL
X58:6 012 2 STECKER STVZO VL Con. STVZO FL
X58:6 012 7 STECKER STVZO VL Con. STVZO FL
X58:6 012 17 STECKER STVZO VL Con. STVZO FL
X59:2 012 19 STECKER STVZO VR Con. STVZO FR
component listing

X59:3 012 7 STECKER STVZO VR Con. STVZO FR

X59:5 012 2 STECKER STVZO VR Con. STVZO FR
Bauteilliste

X59:6 012 2 STECKER STVZO VR Con. STVZO FR

X59:6 012 7 STECKER STVZO VR Con. STVZO FR
X59:6 012 19 STECKER STVZO VR Con. STVZO FR
X60:1 012 18 STECKER STVZO HL Con. STVZO BL
X60:2 012 18 STECKER STVZO HL Con. STVZO BL
X60:3 012 6 STECKER STVZO HL Con. STVZO BL
X60:4 012 6 STECKER STVZO HL Con. STVZO BL
X61:1 012 19 STECKER STVZO HR Con. STVZO BR
X61:2 012 19 STECKER STVZO HR Con. STVZO BR
X61:3 012 8 STECKER STVZO HR Con. STVZO BR
X61:4 012 8 STECKER STVZO HR Con. STVZO BR
X62:1 008 19 STECKER DIOS PLATTEN con. DIOS−plates
X62:2 008 19 STECKER DIOS PLATTEN con. DIOS−plates
X62:3 008 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:4 008 16 STECKER DIOS PLATTEN con. DIOS−plates
X62:5 008 16 STECKER DIOS PLATTEN con. DIOS−plates
X62:6 008 17 STECKER DIOS PLATTEN con. DIOS−plates
X62:7 008 17 STECKER DIOS PLATTEN con. DIOS−plates
X62:8 008 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:9 008 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:10 008 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:11 008 15 STECKER DIOS PLATTEN con. DIOS−plates
X62:12 008 17 STECKER DIOS PLATTEN con. DIOS−plates
X62:13 008 19 STECKER DIOS PLATTEN con. DIOS−plates
X62:14 008 20 STECKER DIOS PLATTEN con. DIOS−plates
X62:15 008 19 STECKER DIOS PLATTEN con. DIOS−plates
X63:1 008 13 SCHNELLVERSCHLUSSKUPP quick connecting clutch
X63:1 008 14 SCHNELLVERSCHLUSSKUPP quick connecting clutch
X63:2 008 13 SCHNELLVERSCHLUSSKUPP quick connecting clutch
X63:2 008 14 SCHNELLVERSCHLUSSKUPP quick connecting clutch
X65:1 011 5 KEYBOARD Keyboard
X65:2 011 5 KEYBOARD Keyboard
X65:3 011 5 KEYBOARD Keyboard
X65:4 011 5 KEYBOARD Keyboard
X65:5 011 5 KEYBOARD Keyboard
X65:7 011 5 KEYBOARD Keyboard
X65:8 011 12 KEYBOARD Keyboard
10

X65:9 011 5 KEYBOARD Keyboard

X65:10 011 5 KEYBOARD Keyboard
X65:11 011 5 KEYBOARD Keyboard
X65:12 011 5 KEYBOARD Keyboard
X66:2 004 19 ANSCHLUß EMR3 VORGLÜH connector EMR3 preglow
11

X66:3 004 20 ANSCHLUß EMR3 VORGLÜH connector EMR3 preglow

X74:1 009 14 STECKER DRUCKER con. printer
X74:2 009 14 STECKER DRUCKER con. printer
X74:3 009 14 STECKER DRUCKER con. printer
582 702 07

X74:4 009 15 STECKER DRUCKER con. printer

X74:5 009 14 STECKER DRUCKER con. printer
X75:2 010 16 SUB−D STECKER BCM INT con. SUB−D BCM
X75:7 010 15 SUB−D STECKER BCM INT con. SUB−D BCM
X76:1 010 17 STECKER VERS. BCM con. Power−sup. BCM
110

X76:2 010 17 STECKER VERS. BCM con. Power−sup. BCM

Y04 007 17 Magnetventil Bremse Solenoid valve, brake MAX. 1.8A

008 914 20 BOMAG 1319

21.2 Wiring diagram 582 702 07
Name Bl. Pf. Benennung title TYP
Y07 007 15 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high 0.4 .. 1.2A
Y08 007 13 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low 0.4 .. 1.2A
Y14 014 14 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 014 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y16 005 13 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 0.4 .. 1.2A
Y17 005 12 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 0.4 .. 1.2A
Y30 005 15 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 0.4 .. 1.2A
Y31 005 16 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear 0.4 .. 1.2A
Y92 007 6 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. 0.4 .. 1.2A
Y93 007 5 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. 0.4 .. 1.2A
Y98 008 14 Magnetventil Vibrationsfrequenz, hinten Solenoid valve, vibrat.freq.,rear 0.4 .. 1.2A
Y122 008 16 Magnetventil Platten heben Solenoid valve, lift plates MAX. 1.8A
Y123 008 17 Magnetventil Platten senken Solenoid valve, let down plates MAX. 1.8A
Y137 003 10 EMR Verstellung EMR adjustment
Seis
19.10.2005
Vogt
19.10.2005

Y137 004 10 EMR Verstellung EMR adjustment

Y138 014 10 Magnetveentil Heizung Solenoid valve, heating unit 1A
Y140 009 10 Magnetventil Erreger auf solenoid valve exciter up 0.4 .. 1.2A
Y141 009 11 Magnetventil Erreger ab solenoid valve exciter down 0.4 .. 1.2A
Y142 008 17 Magnetventil Plattenverschieben Links solenoid valve, plate displace left MAX. 1.8A
Y143 008 18 Magnetventil Plattenverschieben rechts solenoid−valve, plate displace right MAX. 1.8A
Y144.1 008 19 MAX. 1.8A
Y144.2 008 19 MAX. 1.8A
Y145 008 20 Magnetventil Platten (Priorität) solenoid−valve, plate (priority) MAX. 1.8A
Y147 004 1 Injektor A1 jet pump A1
Y148 004 3 Injektor A2 jet pump A2
Y149 004 5 Injektor A3 jet pump A3
Y166 004 2 Injektor A4 jet pump A4
Y169 004 6 Injektor A6 jet pump A6
Y170 004 4 Injektor A5 jet pump A5
component listing
Bauteilliste
11
11
582 702 07
111

1320 BOMAG 008 914 20

X38
X36 X37

008 914 20
A80
Wiring diagram 582 702 07

Nur bei StvzO

only acc. To StvZO illumination

BOMAG
A02 R10 K05

K11 K16 K06

Nur bei Klimaanlage

K09 K43
only acc. to aircond.

K48

K61
B57
K41

X32:1-12 X34:1-19

Gez.: 19.10.2005 Seite: 1 von: 2

Name: Vogt Übersicht Schaltkasten BW 177...226 DH/BVC-4 page: 1 from: 2
582 702 07
21.2

1321
Gepr.: 19.10.2005 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box BW 177...226 DH/BVC-4 Replaces: Sheet No.: 201
Nur bei VM8
only acc. To VM8

1322
F1 F2

CAN 1
21.2

LCD+
CAN 1
Datensammler

A34
Fahrsteuerung

CAN 2 EMR + Fahrhebel

BOMAG
CAN 1 OPUS 21

A83
Messtechnik Steuerung

CAN 3 BCM
Wiring diagram 582 702 07

008 914 20
Gez.: 19.10.2005 Seite: 2 von: 2
Name: Vogt
Übersicht Schaltkasten-Tür BW 177...226 DH-4 page: 2 from: 2
582 702 07
Gepr.: 19.10.2005 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box door BW 177...226 DH-4 Replaces: Sheet No.: 201
Wiring diagram 582 702 07 21.2
WAGO smart DESIGNER 4.1

1 057 564 17

2 280-315
3 2 x 057 564 25 "L" + 793-501

5 2 x 057 564 25 "L" + 057 564 20 + 793-501

008 914 20 BOMAG 1323

21.2 Wiring diagram 582 702 07
WAGO smart DESIGNER 4.1

30 3 x 057 564 36 "R" + 793-501 30 F148 Flachsicherung DIN 72581-C10 / 057

510 97 (Nur bei VM8-11 Messtechnik)

31 F84 Flachsicherung DIN 72581-C10 / 057

510 97 (Nur bei VM8-11 Messtechnik)

32 F146 Flachsicherung DIN 72581-C15 / 057

510 98 (Nur bei VM8-11 Messtechnik)

33 057 564 35
34 2 x 057 564 17

36 057 564 21
37 2 x 057 564 25 "L" + 793-501

39 3 x 057 564 25 "L" + 057 564 20 + 793-501

42 5 x 057 564 25 "L" + 793-501

47 8 x 057 564 25 "L" + 057 564 20 + 793-501

55 057 564 25 "L" + 793-501

56 4 x 057 564 38 "L" + 793-501 56 Nur bei BVC

57 Nur bei BVC

60 057 564 17

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

30.11.2005 08:36:29 Seite 2

1324 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

30.11.2005 08:36:59 Seite 3

008 914 20 BOMAG 1325

21.2 Wiring diagram 582 702 07
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

30.11.2005 08:36:59 Seite 4

1326 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
WAGO smart DESIGNER 4.1

1 05756417

2 3 x 05756540 "R" + 793-501

5 05756535 "R" + 793-501

6 05756537
7 3 x 05756540 "R" + 793-501

10 05756537
11 05756540 "R" + 793-501
12 05756535 "R" + 793-501

13 05756537
14 2 x 05756538 "R" + 793-501

16 2 x 05756539 "R" + 793-501

18 05756537
19 4 x 05756540 "R" + 793-501

23 05756537
24 4 x 05756540 "R" + 793-501

28 2 x 05756539 "R" + 793-501

30 05756537
31 05756540 "R" + 793-501
32 05756539 "R" + 793-501

33 05756537
34 4 x 05756540 "R" + 793-501

38 05756535 "R" + 793-501

39 05756537
40 4 x 05756540 "R" + 793-501

44 05756537
45 05756540 "R" + 793-501
46 05756535 "R" + 793-501

47 05756537
48 05756540 "R" + 793-501
49 05756535 "R" + 793-501

50 05756537

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : DH-4 Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Kabelbäume DH-4 komplett Lieferadresse :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Optional7 : Größe der Bohrung : 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

08.11.2005 11:25:37 Seite 1

008 914 20 BOMAG 1327

21.2 Wiring diagram 582 702 07
WAGO smart DESIGNER 4.1

51 05756538 "R" + 793-501

52 2 x 05756540 "R" + 793-501

54 05756538 "R" + 793-501

55 05756537
56 3 x 05756540 "R" + 793-501

59 05756538 "R" + 793-501

60 05756537
61 3 x 05756540 "R" + 793-501

64 05756535 "R" + 793-501

65 05756537
66 2 x 05756540 "R" + 793-501 66 Bei DH-4 TierIII und BVC
67 Bei DH-4 TierIII und BVC

68 05756535 "R" + 793-501

69 05756537 69 Bei DH-4 TierIII und BVC

70 3 x 05756540 "R" + 793-501 70 Nur bei Variocontrol
71 Nur bei Variocontrol

72 Nur bei Variocontrol

73 05756535 "R" + 793-501 73 Nur bei Variocontrol

74 05756537 74 Nur bei Variocontrol

75 2 x 05756540 "R" + 793-501 75 Nur bei AG28 Anbau-Vibrationsplatten
76 Nur bei AG28 Anbau-Vibrationsplatten

77 2 x 05756535 "R" + 793-501 77 Nur bei AG28 Anbau-Vibrationsplatten

78 Nur bei AG28 Anbau-Vibrationsplatten

79 05756537 79 Nur bei AG28 Anbau-Vibrationsplatten

80 05756417

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

08.11.2005 11:25:37 Seite 2

1328 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

08.11.2005 11:26:35 Seite 3

008 914 20 BOMAG 1329

21.2 Wiring diagram 582 702 07
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

08.11.2005 11:26:35 Seite 4

1330 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
WAGO smart DESIGNER 4.1

1 05756417

2 2 x 05756540 "R" + 793-501

4 05756539 "R" + 793-501

5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501

9 05756538 "R" + 793-501

10 05756537
11 2 x 05756540 "R" + 793-501

13 05756539 "R" + 793-501

14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501

17 05756540 "R" + 793-501

18 05756537

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Messtechnik / BVC* Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Klemmenleiste X2 Lieferadresse :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Optional7 : Größe der Bohrung : 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

08.11.2005 12:45:24 Seite 1

008 914 20 BOMAG 1331

21.2 Wiring diagram 582 702 07
WAGO smart DESIGNER 4.1

19 05756540 "R" + 793-501 19 Nur bei BVC

20 05756539 "R" + 793-501 20 Nur bei BVC

21 05756537 21 Nur bei BVC

22 2 x 05756438 "R" + 793-501 22 Nur bei BVC
23 Nur bei BVC

24 05756421 24 Nur bei BVC

25 05756417

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

08.11.2005 12:45:24 Seite 2

1332 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

08.11.2005 12:45:47 Seite 3

008 914 20 BOMAG 1333

21.2 Wiring diagram 582 702 07
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

08.11.2005 12:45:47 Seite 4

1334 BOMAG 008 914 20

Wiring diagram 582 702 07 21.2
WAGO smart DESIGNER 4.1

1 05756417 1 Nur bei ZA E2 StvZO Beleuchtung

2 4 x 05756540 "R" + 793-501 2 Nur bei ZA E2 StvZO Beleuchtung

3 Nur bei ZA E2 StvZO Beleuchtung

4 Nur bei ZA E2 StvZO Beleuchtung

5 Nur bei ZA E2 StvZO Beleuchtung

6 05756537 6 Nur bei ZA E2 StvZO Beleuchtung

7 2 x 05756540 "R" + 793-501 7 Nur bei ZA E2 StvZO Beleuchtung
8 Nur bei ZA E2 StvZO Beleuchtung

9 4 x 05756538 "R" + 793-501 9 Nur bei ZA E2 StvZO Beleuchtung

10 Nur bei ZA E2 StvZO Beleuchtung

11 Nur bei ZA E2 StvZO Beleuchtung

12 Nur bei ZA E2 StvZO Beleuchtung

13 2 x 05756539 "R" + 793-501 13 Nur bei ZA E2 StvZO Beleuchtung

14 Nur bei ZA E2 StvZO Beleuchtung

15 05756537 15 Nur bei ZA E2 StvZO Beleuchtung

16 05756417 16 Nur bei ZA E2 StvZO Beleuchtung

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : E2 Beleuchtung Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Option E2 StvZO Beleuchtung Lieferadresse :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Optional7 : Größe der Bohrung : 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

08.11.2005 14:30:09 Seite 1

008 914 20 BOMAG 1335

21.2 Wiring diagram 582 702 07
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

08.11.2005 14:30:27 Seite 2

1336 BOMAG 008 914 20

X74 X75
X55
X56 X76 X53 X54

008 914 20
X29
X28 X21
X39 X23 X24 X50
X59 X40 X25 X41
X13
X58 X42 X51 X43 X57
X20
X46 X14

X18 X30 X77

X17 X33 X6 X7
X52
X47 X22 X19 X31 X4 X3 X15 X16
X8
X48 X49
Wiring diagram 582 702 07

X48 X49 X10

(BVC) (BVC) X36 X26 X60
X37 X1 X27 X61 X62
X38 X2
X9
X44
X35
X32 X34

BOMAG
X61
X77 X9
X21
X74 X75
X59 X62
X76
X42 X23 X24 X50 X8
X57
X10
X46 X25 X41 X51
X56
X53
X20
X29 X18
X17 X14
X28 X19 X55 X6 X7
X54 X15 X16
X39
X43
X40

X30
X58 X52 X33
X31 X4 X3
X36 X35 X1 X26
X37 X44 X2 X27
X38 X32 X34 X60
X47
X48 X49
(BVC) (BVC) X48 X49
X22

Gez.: 19.10.2005 Seite: 1 von: 1

Name: Vogt
Übersicht Schaltkasten-Tür BW 177...226 DH-4 page: 1 from: 1
582 702 07
21.2

1337
Gepr.: 19.10.2005 Ers. f.: Blatt Nr.: 301
Name: Seis overview e-box door BW 177...226 DH-4 Replaces: Sheet No.: 301
21.2 Wiring diagram 582 702 07

1338 BOMAG 008 914 20

21.3 Wiring diagram 582 702 32

008 914 20 BOMAG 1339

21.3 Wiring diagram 582 702 32

S/N Wiring diagram 582 702 32

S/N 101 582 121 002  101 582 121 006 Variocontrol
S/N 101 582 131 001  101 582 131 001 Variocontrol +
S/N 101 582 641 060  101 582 641 096 BW 216 DH-4
S/N 101 582 651 005  101 582 651 005 BW 216 PDH-4
S/N 101 582 771 171  101 582 771 229 BW 219 DH-4
S/N 101 582 781 019  101 582 781 020 BW 219 PDH-4
S/N 101 582 861 026  101 582 861 042 BW 226 DH-4 BVC
S/N 101 582 881 003  101 582 881 014 BW 226 DH-4
S/N 101 582 891 004  101 582 891 006 BW 226 PDH-4
S/N 101 583 141 076  101 583 141 137 BW 213 DH-4
S/N 101 583 151 005  101 583 141 011 BW 213 PDH-4
S/N 101 583 161 027  101 583 161 073 BW 213 DH-4 BVC
S/N 101 583 191 005  101 583 141 010 BW 214 DH-4
S/N 101 583 201 001  101 583 201 001 BW 214 PDH-4
S/N 101 583 371 001  101 583 371 005 BW 213 DH-4 with attachment plate
S/N 101 583 061 014  101 583 061 030 BW 213 DH-4 BVC with attachment plate

1340 BOMAG 008 914 20

Inhaltsverzeichnis: BW 177..226 DH−4

008 914 20
table of contents: BW 177..226 DH−4
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 582 702 32 Stromlaufplan Circuit Diagram
002 582 702 32 Versorgung, Starten, Kraftstoffvorwärmung, Hupe supply, starting unit, fuel pre−heater, signal horn
003 582 702 32 Motor Deutz EMR II engine Deutz EMR II
004 582 702 32 Motor Deutz EMR III engine Deutz EMR III
005 582 702 32 Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch
Wiring diagram 582 702 32

006 582 702 32 Datensammler, LC−Display data−collector, LC−display

007 582 702 32 Lenkung, Vibration steering, vibration
008 582 702 32 Fahrhebel, Vibrationsplatten joystick, vibration−plates
009 582 702 32 Variocontrol, Messtechnik Variocontrol, measurement equipm.
010 582 702 32 Bomag Compaction Management BCM, GPS Bomag Compaction Management BCM, GPS
011 582 702 32 Diebstahlschutz System DH−4 anti − theft system
012 582 702 32 Beleuchtung und StvZO illumination and StvZO
013 582 702 32 Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph
014 582 702 32 Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater
101 582 702 32 Bauteilliste component listing

BOMAG
08.03.2007
001 001
Vogt Stromlaufplan 582 702 32
08.03.2007
21.3

1341
circuit diagram 001
Seis
1342
30
21.3

K11
2:11
87
K30 13:1
30 4:1 K11:87 6:1

X1:15E X1:16E X1:27E X1:33E X1:28E X1:30E

X1:9
F13 1 F05 1 F95 1 F124 1 F23 1 F39 1

X1:10
30A 10A 10A 25A 15A 15A
2 2 2 2 2 2
X1:15A X1:16A X1:27A X1:33A X1:28A
X1:30A
X37:A X1:151

7:17
5:9

X36:B
30 21 11 31 41 51 61

X36:A
nur bei EMR III S00 S01 X3:3
only EMR III
22 12 32 42 52 62
Startschalter NOT−Aus
K32:86
15
starting swwitch 54 58 19 17 50a Emerg.−Stop 13:1

2 x 10qmm
X1:152 X1:155
X1:79
S01:22 3:1
X37:B
F05:2
V01 X1:3 X1:4 6:8
K05 30

2 1 8:3
5

125mA
5 87 87a

X34:P
K14 86 1 30

nicht bei EMR III, bei BW177DH−4 Option

not at EMR III, at BW177DH−4 option
K14.2 K61 K61

BOMAG
1 1 D+ X1:217
6:2
B+ 2:12 2:8 B+
D+ MESX 9:2
G03 G01 X38:A X1:97 X1:98
+ +
X67:1
− −
X1:1 X1:101 X1:102
1
1 1 1 R79
X1:109

nur bei Klimaanlage

only acc.to air conditioning
Anzugsw.:50A / Haltew.:10A

30 50

R81
R83
R85
167A
2 2 2 B+ D+ 2
1 86 86 B11 B11
1 1 1 1 K09 K11 X67:2 1 2 2 1
G02 M01 V02 XS +
R19 S30 M
12V

R86

R82
R84
2 2 2 2 2 1 V03 1 2 −

Option
option
85 85 −
2
31 EMR 3:3 B− W
Option Winterpaket
option winter package

X1:110 X1:168 X1:123 X1:218 X1:103 X1:104

31 31 3:1

Glühstiftkerzen Trennschalter Batter 2:10 14:7 2:15 Starter Signalhörer Steckdose

glow plugs break switch battery starter warning horns socket

Batterie Batterie Generator Kraftstoffvorwärmung Nur bei Geländer/ROPS/SD

battery battery generator fuel pre−heater only at hand−rail/ROPS/sun−roof

Heizflansch
heating−flange

08.03.2007
1 1
Wiring diagram 582 702 32

008 914 20
Vogt Versorgung, Starten, Kraftstoffvorwärmung, Hupe 582 702 32
08.03.2007
Seis supply, starting unit, fuel pre−heater, signal horn 002
2:16 S01:22 S01:22 4:1

008 914 20
X1:95
1
Relais Heizflansch K14
relay heating−flange
X1:96 2

X1:185
Steckerschnittstelle Deutz
X1:179 connector interface Deutz
X33:7
X33:2
X33:3
X33:5
X33:6
X33:1
X33:4
X33:8

EPC−Stecker

max 7A
Wiring diagram 582 702 32

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− 4:15
CAN2+ 4:15

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
3 2 1 1 2 1 2 7 2 6 1 1 4 3 2 1 2

RF MESS
EMR Stellglied
EMR commander
B88 B114 B130 Y137 5 B115 B113

X32:L
X32:K
X32:B

X32:H
X32:G

X32:A
X1:186
X34:N
X1:182
Diagnosestecker EMR
diagnosis interface EMR
2:6 4:18
31 31 EMR 31 EMR
2:20 31 4:1
2:4
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

08.03.2007
1 1 582 702 32
Vogt Motor Deutz EMR II
08.03.2007
21.3

1343
Seis engine Deutz EMR II 003
30

1344
2:14 30 5:1
3:20 S01:22 S01:22 7:1
Diagnosestecker EMR 3:4 CAN2+ CAN2+ 5:11
X1:14E Wasserabscheider
21.3

water−seperator diagnosis interface EMR 3:4 CAN2− CAN2− 5:11

1
F93
25A
2

X32:A
X32:K
X32:M
X32:F
X32:H
X32:G
X32:B
X1:14A
B124
86
K41 K41 30

4:2

Nur bei EMRIII

only EMRIII
X1:107 X1:108
87 87a
85
X1:179

X1:191

X1:193
X1:192

X1:194

X1:184
X1:185 X1:183 X1:198 X1:199 max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 3.5m
2.5 qmm in der hier dargestellten Installation (Querschnitt 2,5qmm)

A48
Motorsteuerung EMR3 (EDC 16)
engine−controller EMR3 (EDC16)

X30:1
X30:5
X30:3
X30:61

X30:63
X30:60

X30:72
X30:25
X30:62

X30:28
X30:82

X30:64

X31:47
X31:46
X31:33
X31:31
X31:48
X31:32
X31:50
X31:12
X31:19
X31:40
X31:14
X31:53
X31:43
X31:8
X31:58
X31:56
X31:13
X31:11
X31:57
X31:24
X31:34

X31:16
X31:1
X31:10
X31:20
X31:27
X31:7
X31:49
X31:23
X31:26
X31:41
X31:51
X31:54
X30:2
X30:4
X30:6

Sign.
Sign.

AGND
AGND
AGND
GND
GND
GND

Signal
AGND
AGND
AGND
AGND
AGND

Signal
Signal
Signal

Signal Druck
Signal Druck

BOMAG
Signal Temperatur

X66:3

X66:2

1 1 1
Y147 Y148 Y149
Y15.1 Y15.5 Y15.3 86
2 2 2 K14.2
1 2 3 2 1 3 1 4 3 2 3 2 1 1 2 3 2 1 1 2 3 4
1 1 1 1 85
Y166 Y170 Y169 Y137
Y15.6 Y15.2 Y15.4 Y19
2
2 2 2 B114 B130 B133 B93 B113 B88 B145
B40.1 B40.2 B48 B49 B43 B6 B51
X1:90
X1:91
X1:92

3x2.5

3:5
31 31 EMR
3:20 31 5:1
4:3 2:2
EMR Stellglied EMR Kühlmitteltemperatur
EMR commander EMR coolant temperature

Injektor A1 Injektor A2 Injektor A3 Motordrehzahlsensor Ladeluftdruck + Temp EMR Motoröldruck

jet pump A1 jet pump A2 jet pump A3 sender engine rpm 1 charging air pressure + temperature EMR engine oil pressure
Injektor A4 Injektor A5 Injektor A6 Motordrehzahlsensor EMR Kraftstoffdruck EMR Niederdruck Kraftstoff
jet pump A4 jet pump A5 jet pump A6 sender engine rpm 2 rail pressure sensor EMR fuel low pressure sensor

08.03.2007
1 1
Wiring diagram 582 702 32

008 914 20
Vogt Motor Deutz EMR III 582 702 32
08.03.2007
Seis engine Deutz EMR III 004
4:20 30 30 6:1
F24:2 6:3 X1:2 4:20 CAN2+ CAN2+ 8:6
EMR Deutz Fahrhebel
4:20 CAN2− CAN2− 8:6
X1:145
CAN1+ 6:8
31 LC−Display, OPUS 21
CAN1− 6:8
X1:119 X1:120

008 914 20
S01
2:15
120 OHM 120 OHM
X1:146 32 1 2 1 2

X1:51
X1:52
X1:53
X1:54
X1:47
X1:48
X1:49
X1:50
9:2
120 OHM 120 OHM
1 2 1 2
Wiring diagram 582 702 32

R23 R21

Drucksensor
Leistung
Elektronik
TxD
RxD
CAN2+
CAN2−
CAN1+
CAN1−

Pot. 15
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

speed
speed

BOMAG
Neigung

Richtung
Richtung
Gehäuse
housing

Achsmotor

Sitzkontakt
X1:45 X1:44
Bandagenmotor

Fahrpumpe vorw.
Fahrpumpe rückw.

Rückfahrwarnsum.
FM3 7:5 +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

br
ws
br
ws
bl
+ +
dir. dir.

0,46A
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA

B60 B59 2,5V X14:B X9:1

speed
9:2 speed
DIR MESX S06 + + X16:1 1 X15:1 1 1 1
− X1:172 −
Y17 Y16
13:6 4V H14 Y30 Y31

sw
sw
SPEED TAC − b a
− 2 2 2 2
X1:174 9:2 X1:178 − S X1:46 X14:A X9:2 X16:2 X15:2
SPEED MESX
X1:82
X1:124
X1:142
X1:142
X1:143
X1:143

X1:55 7:4 9:2 X1:149 X1:117 X1:123 X1:123 X1:144 X1:124

31 PITCH MESX
4:20 31 6:1

Rückfahrwarnsummer Prop.−Pumpe Rückw. Prop.−Ventil Achsmotor

back up alarm buzzer prop−pump backwards prop.−Valve axle motor

08.03.2007
1 1 582 702 32
Vogt Fahrantrieb, Neigungssensor, Sitzkontakt
08.03.2007
21.3

1345
Seis driving system, slope sensor, seat contakt switch 1 005
30

1346
5:20 30 9:1
2:20 K11:87 K11:87 8:14
5:3 F24:2 F24:2 7:13
21.3

X1:29E 2:16 F05:2

5:17 CAN1+ CAN1+ 8:14
F24 1 ESX Fahrsteuerung DIOS Platten
5:17 CAN1− CAN1− 8:14
10A
2
X1:29A

X1:87 X1:88 X1:80 X1:86

X1:41

X1:39
X1:40
11:1

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
X27:2
X27:4
X27:9
X26:9
X26:1
X26:2
X26:6
X26:4
X26:11
X27:10
X27:11
X27:12
X27:1
X27:3
X29:1
X29:2
X29:4
X29:3
X29:5
X29:6

X27:5
X26:12
X28:2

GND
GND
GND

UIN1
DIN1
DIN1

AIN1

UIN3
UIN2

DIN3
DIN5
DIN9
DIN6
DIN3
DIN5
DIN6

DIN8
DIN2
DIN2

AIN2

DIN4
DIN4

DIN11

DIN10
Sepa1
Sepa2
GND/UIN3

BOMAG
X1:106 X1:111 X1:112 X1:105 X1:107 X1:108
BL 12:17 ECO
Low High 13 23 down up
BR 12:17 13 23
S127
BEL S139
12:4

14 24 14 24

D+ R03
2:8 P P Q
Schalter Motordrehzahl Schalter Frequenzverstellung
2 2 switch engine−rpm mode switch frequency−control
X21:2 X10:3 X8:2

0 .. 67 OHM
Nur bei EMRII
only EMRII
X1:117 X1:94 X1:94 X1:117 X1:164 X1:149 X1:82
31
5:20 31 7:1

08.03.2007
1 1
Wiring diagram 582 702 32

008 914 20
Vogt Datensammler, LC−Display 582 702 32
08.03.2007
Seis data−collector, LC−display 006
4:20 S01:22 S01:22
6:20 F24:2
X1:148 Lenkwinkelsensor
X23:1 steering angle sensor
8:1
X1:41
X1:201
X51:1 Lenkeinheit X1:187

008 914 20
B65 + A45 steering unit br
Aufnehmer Vibrationsmotor
S 5:4 FM3 X22:1 sensor vibration motor
br +
X1:161 X41:1 X39:1 VCC B X39:2 X22:2 bl
S1 −
−
X1:160 X41:3 X40:1 X40:2 bei BW177 u. 213 m. Sauer Motor sw / bei BW213−226 m. Rexroth Motor bl
VCC B B16
bei BW177 u. 213 m. Sauer Motor bl / bei BW213−226 m. Rexroth Motor sw
X1:159 X41:4 X40:4 S2 X40:3

X1:203
B132 2 2 2 2 0V A ws X22:3
VIB
X1:162 X41:2 X39:4 0V A X39:3 X22:4 13:6
S1 gg sw

X1:55 X1:202
Lenkwink.
1 1 1 1

−
BTS BREMSE 8:2

X41:5
X41:7
X41:8
X41:6

Sig.
AGND

X34:J
X1:60 FM5 X1:61
X1:56 FM1 X1:57

X1:62 FM3 X1:63

X1:58 FM2 X1:59
X1:189

armrest−switch
X1:55

Schalter Armlehne
Wiring diagram 582 702 32

Vib.− Richtung
Vib.− Frequenz
BTS Bremse

5:6

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

X35:16
X35:20
X35:21
X35:43
X35:22
X35:2
X35:48
X35:3
X35:61

30
Bremse

Armlehne
Prop. out

30 K48 8:2
Warnsummer

BOMAG
X51:3

X51:2
X1:89 87 87a

Umsch. Amplitude
K43 7:12

Pumpe Vib.−Platten
X1:154 X1:196 X1:195 87 87a

Schnellverschl.−Platten
KA MESX
9:2 X1:147
X1:38
X35:22 GA MESX 11
8:13 9:2
X1:37 S01
X35:43
8:13 X1:116 X1:115 2:15
12
X1:150

400 ... 1.200mA

400 ... 1.200mA
150mA

X6:1 X7:1 9:2

X1:113
400 ... 1.200mA

1 1 K43 86 Y08 1 Y07 1 H07 BRAKE MESX

+ Y04 1
Y93 Y92
b d
2 2 85 2 2 − a1 2
X6:2 X7:2
max.1.8A

X1:149 X1:197 X1:197 X1:82 X1:117 X1:190

X1:118
6:20 8:1
31
31 Anbau 177DH: h.r. a Anbau 177DH: h.l. b
7:14 Anbau 213DH: unten Anbau 213DH: oben

Prop.−Ventil Vibration klein Magnetventil Bremse

prop. valve vibration small solenoid valve brake

Prop. Ventil lenken links Prop−Ventil Vibration groß

prop. valve steering left prop. valve vibration big

Prop. Ventil lenken rechts Warnsummer Störung

prop. valve steering right warning buzzer, failure

08.03.2007
1 1 582 702 32
Vogt Lenkung, Vibration
08.03.2007
21.3

1347
Seis steering, vibration 007
1348
7:2 X23:1 5:17 CAN2+ 6:14 CAN1+ CAN1+ 9:16
ESX Fahrst. LC−Display BTM
5:17 CAN2− 6:14 CAN1− CAN1− 9:16
K11:87
21.3

6:20 K11:87 9:1

Taster 8 = Infotaste 2

X1:156
push button 8 = Info button 2

X1:157
BTS BREMSE
7:18

br
br
3 2 + +

X63:1
X63:1
7
B135 B134
1 Fahrstufenschalter
4 − −
5 8 speed range selector
bl bl

S S

X63:2
X63:2
sw
ws

S42

+ −

quick connecting clutch

X35:43 X1:215
Ub in CAN− 7:11

X25:2
X25:4
X25:3
Bremse zu = 0V 1 7

X62:3
X62:9
X62:2

9 11
X62:4
X62:10

Add2 AK Ext2
plate−controller
10 12
Stecker X23

BOMAG
Stecker X24
1 2 3 4 5 6 7 8
X62:5
X62:6
X62:7
X62:8

X62:11
X62:13
X62:15
X62:14

Ub out
OV out

DK Ext1
DK Ext3
DK Ext5
DK Ext6

DK Ext2
DK Ext4
X50:2
X50:3
X50:1

S − + Y123 1 Y143 1 Y144.2 1

X1:210
S35 K0G S09 13 S64 13 S36 13 S139
13 23 2 2 2
400 .. 1.200 mA

86 86 1 Y122 1 Y142 1 Y144.1 1 Y145 1

K48 K05 Y98
14 14 14 14
24
2 2 2 2 2
85 85

X1:149 X1:211 X1:212

7:20 31
9:1
7:17 2:12 31

08.03.2007
1 1
Wiring diagram 582 702 32

008 914 20
Vogt Fahrhebel, Vibrationsplatten 582 702 32
08.03.2007
Seis joystick, vibration−plates 008
Beschleunigungssensoren Beschleunigungssensoren Aufnehmer Verstellmotor Drucker Bedieneinheit BEM Display Messtechnik BOP
acc. sensor front acc. sensor rear sens. adjust. motor printer control−unit BEM display measurem. BOP
X1:34A
5:9
6:20 30 30 12:1
Pot 30

8:20 K11:87 K11:87 12:1

Pot 15

008 914 20
X2:47 X2:48 X2:49
F146:1 10:2 + −
X2:66
X2:70 X42:1 X42:2 X42:3

X46:B X46:A X46:E

X1:32E X1:35E
X2:77 P16 F1 F2
1 1 1
F148 F146
nur bei BEM
only at BEM

10A 15A
X2:56 X2:53 X2:60 X2:57 FM4 X2:71
2 2 2
X1:32A X1:35A X48:2 X48:1 X49:2 X49:1 X2:78 P33

CAN+
CAN−

F148:2 B62 B62 X2:67 X2:68

10:2

X4:C
X4:E

X4:D

+/sw
+/sw
−/gg −/gg X47:A X47:B
Wiring diagram 582 702 32

X46:D X46:F
nur bei BTM+/BTM prof
only at BTM+/BTM prof

X42:4 X42:5
15g/bl 15g/bl

−/sw
X74:3
X74:5
X74:4
8:20
X2:57 B61 P11 CAN1−

20g/br
20g/br
+/rt 8:20
DIOS Platten

X48:3 X48:4 X49:3 X49:4 S/ws

CAN1+

nur bei BTM prof

X74:1 X74:2

only at BTM prof

X2:54 X2:55 X2:58 X2:59 X47:C
X4:A X4:B
X2:50 X2:51
R24
X2:69 X2:64 X2:65 1 2

Pot. 15
Leistung
Elektronik
8.5V
AGND MESX

Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
Erregerpos.
RxD TxD CAN1+ 60 OHM CAN1−

BOMAG
X44:1

X44:7
X44:9
X44:5
X44:27
X44:26

X44:4

X44:31

X44:56
X44:57
X44:59
X44:60
X44:30

X44:58
X44:29
X44:23

X44:28
X44:54
A83
Messtechnik−Rechner
measurement calc. unit

X44:15
X44:38
X44:35
X44:14
X44:32
X44:36
X44:37
X44:41
X44:47
X44:46
X44:25
X44:53
X44:33

X44:3

X44:55
X44:65
X44:66
X44:67
X44:68

CAN3+ CAN3−
7:15 KA MESX
EVIB
GPS

GA MESX

Prop.
Prop.
GND
0..6VDC

7:15
SPEED MESX X1:85 10:2
5:3 CAN3−

400 .. 1.200mA
400 .. 1.200mA

DIR MESX X2:75 X2:73 X2:52 +

5:3
PITCH MESX Y140 1 Y141 1 P07 E X2:79 10:2
5:8 VIB CAN3+
BRAKE MESX

v.l.
v.r.

7:17 − X44:25 10:2

D+ MESX BEL MESX 2 2
2:8 12:4 X2:49 X2:76 X2:74 X2:63 X2:66 X1:82
31 31 10:1
8:20

Prop−Ventil Erreger auf EVIB−Meter

solenoid−valve exciter up EVIB−meter
Prop−Ventil Erreger ab nur bei BEM
solenoid valve exciter down only at BEM

08.03.2007
1 1 582 702 32
Vogt Variocontrol, Messtechnik
08.03.2007
21.3

1349
Seis Variocontrol, measurement equipm. 009
1350
9:18 CAN3−

9:18 CAN3+
21.3

9:4 F148:2

9:17 X44:25

9:5 F146:1

X2 80E
1 CAN3+ R25 CAN3−
F150 1 2
5A
2 60 OHM
X2 80A

X2 X2 X2 X2 X2
43 44 70 61 62

X4 X4 X4 X4 X4
H J G N M

X75:7 X75:2

X78:1
X78:2
X78:3
X78:4
X71:12 X72:A X73:A
A93 30 A87
X71:6 X72:B X73:B USB−CAN Schnittst.
15 USB−CAN Interface BCM
X71:5

BOMAG
TxD2 X76:1
X71:8
RxD2
X71:10 X72:E X70:3
TxD1
X71:3 X72:D X70:2
RxD1
X71:7 X72:C X70:5
GND
GPS Empfänger StarFire P15
X73:C X76:2
GPS Receiver StarFire
BCM 05
nur bei BCM
only at BCM
X4:F

nur bei StarFire GPS X2:63

only at StarFire GPS

9:20 31 31 11:1

08.03.2007
1 1
Wiring diagram 582 702 32

008 914 20
Vogt Bomag Compaction Management BCM, GPS 582 702 32
08.03.2007
Seis Bomag Compaction Management BCM, GPS 010
A67 1 2 3
Keyboard

008 914 20
keyboard
4 5 6

7 8 9

ANN 0 VAL
Wiring diagram 582 702 32

A66
Steuereinheit
control unit

X68:1 X68:2

BOMAG
+
H80
−

ZA
option

08.03.2007
1 1 582 702 32
Vogt Diebstahlschutz System DH−4
08.03.2007
21.3

1351
Seis anti − theft system 011
K11:87 K11:87

1352
9:3
9:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
21.3

F11 F18 F07 F08

15A 10A 15A 15A
30
X1:18A K06 X1:19A X1:25A
X1:26A
12:4 X1:305
X1:83

X3:4 X3:5 with cabin 30 49L 49R

STV1

X1:302
13:17 A02
STV2
13:17
X1:23E X1:24E
K16 30 31 82 L R
12:9 F09 F10
10A 10A
87 87a X1:23A X1:24A

BEL 6:9 BL
6:9
13 BR
6:9

S16 14

BOMAG
switch, working head lights
X1:304

13 23

Schalter Arbeitsbele
01

X1:311

X1:310
X1:319
X1:313

X1:312
X1:321
X1:314

X1:309
X1:303

X1:320
X1:322

S14

lights without StvZO

Anschluß Arbeitsschein−
werfer ohne StvZO
connection working head
X1:84
Warnblinkschalter 14 24
BEL MESX
X61:1

X61:3
X60:1

X59:5
X60:3
X59:3

X58:5
X58:3
X59:2

X58:2

switch, hazard light

Arbeitsscheinwerfer hinten links

9:7
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

08.03.2007
1 1
Wiring diagram 582 702 32

008 914 20
Vogt Beleuchtung und StvZO 582 702 32
08.03.2007
Seis illumination and StvZO 012
F42:H 14:14 F41:5 14:14
K30 X3:6
2:14 K32:87 14:2
X3:7
K32 30 STV2
X3:8 12:13
13:1 STV1

008 914 20
12:13
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
F42 14:8
F130 13:9 F130 F130 14:7
13:14

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 13:16 E29 E70
− − − − 1
Wiring diagram 582 702 32

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
5:3 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
7:18
A5+A6
S45 TK −

Heizung Heckscheibe
heating rear screen

BOMAG
3,8A
3,8A

Schalter Innenleuche
switches interior lights
3
5A

86 S86 + + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
− − M07 − M06 4 −
85

2,9A
3 min

ZA
4,7A

X55:2 X56:2 option

Abfallverzögert

14:11
KABINE 31
Relais Kabine Türkontaktschalter Tachograph Schalter Nachtleuchte
relais cabin door switch tachograph switch, night illumination

X3:1
X3:2
Schalterbel.
switch illum.

12:20 31 31 14:1

13:6 Wascher hinten Wascher vorn 13:2 Arbeitsscheinwerfer vorn

washer rear washer front working head lights, front

Wischer hinten Wischer vorne Arbeitsscheinwerfer hinten Rundumkennleuchte

windscreen wiper, rear windscreen wiper, rear working head lights, rear rotary beacon

08.03.2007
1 1 582 702 32
Vogt Kabinenausrüstung, Beleuchtung, Radio, Tachograph
08.03.2007
21.3

1353
Seis cabin−equipment, headlights, radio, tachograph 013
1354
13:19 K32:87
Potential 15 aus Kabine
13:19 F41:5
13:17 F130 F42:H
13:4
F42 Potential 15 aus Kabine
13:9
21.3

D Potential 30 aus Kabine A B

F31 F40 BOX2 F15 BOX2
20A 20A 5A
4 1 2

2.5qmm
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 5 7 11 3 10 1
S44 A72
Steuergerät
control unit
6 11 12 1 Regel aus = 0,4A
S28
Schalter Kabinenlüfter
E30 Kleine Stufe = 0,67A
switch blower cabin X54:6 X54:11 X54:12 X54:1 Zusatzheizung mittleter Stufe = 1,0A
add. heater große Stufe = 1.9A
heater timer

X3:13 Power Stufe = 2,8A

Schaltuhr Heizung

Anlaufstrom beim Start = 8,3A

30 2 6 8 9 4 12
K09
X3:14

X53:L
X53:H

X53:M
2:10
87 87a X1:167 5 9 10 6 8 7 4 15
2.5qmm

X1:169 X18:1

X3:9
X3:11

X3:10
X3:12
X19:1
B131
B103 1 1 F97 1
_t 3A

BOMAG
_t 2 2
2 inline fuse
X19:2 Inline Sicherung
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 X69:1 X77:1

1A
LP 3

ge rt or ge rt or +
Y138 1 1
X1:170 M17

X20:4
X20:3
V06 Y14

monitoring coolant pressure

M09 M M09 M M
2 2 2

Überwachung Kühlmitt
Stromaufnahme Lüfter / current blower br br −
Stufe 1: 3.0A pro Lüfter
X20:2 V04
X69:2 X77:2
Stufe 2: 4.5A pro Lüfter 1
Option
option

Stufe 3: 11.5A pro Lüfter

Y15 1
X17:4 X1:168
2 13:19

3,5A
X1:164 KABINE 31

X1:190
13:20 31 31

Kabinenlüfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit
Kabinenlüfter
Frischluft Lüfter
cab ventilator blower fresch air

08.03.2007
1 1
Wiring diagram 582 702 32

008 914 20
Vogt Kabinenheizung, Klimaanlage, Zusatzheizung 582 702 32
08.03.2007
Seis cabin−heater, air conditioning, add. heater 014
Name Bl. Pf. Benennung title TYP
A02

A16
012
Wiring diagram 582 702 32
A12 013
013
17
5
6
Blinkgeber
Radio
Elektronik Tachograph
flasher
Radio
Electronic system, tachograph
21.3
A34 005 6 Prozessorplatine Prozessing circuit board
A34 007 6 Prozessorplatine Prozessing circuit board
A45 007 9 Lenkrad Steering wheel
A48 003 3 Elektronische Motorsteuerung Electronic engine management
A48 004 9 Elektronische Motorsteuerung Electronic engine management
A54 008 17 Modul Pumpenansteuerung Modul pump control
A66 011 9 Elektronik Steuereinheit Electronic control unit
A67 011 15 Eingabeeinheit Keyboard
A72 014 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A80 006 3 Modul Datensammler modul data−collector
A81 006 18 Anzeigeeinheit Display−Unit
Seis
08.03.2007
Vogt
08.03.2007

A83 009 6 Elektronik Messtechnik electronic measurement−equipment

A87 010 18 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
A93 010 7 GPS Antenne GPS antenna

B03 006 3 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B11 002 16 Signalhorn Warning horn
B11 002 18 Signalhorn Warning horn
B16 007 14 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 006 2 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B51 013 4 Lautsprecher Radio Speaker radio
B51 013 6 Lautsprecher Radio Speaker radio
B55 006 4 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B57 005 6 Neigungssensor Stufenumschaltung Slope sensor, speed range selection
B59 005 4 Aufnehmer Bandagengeschwindigkeit Sensor, drum speed
B60 005 2 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 009 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 009 8 Beschleunigungsaufnehmer Acceleration sensor
B62 009 10 Beschleunigungsaufnehmer Acceleration sensor
B65 007 4 Sensor, Lenkwinkel vorn Sensor, angularity steering, front
B88 003 6 Druckgeber Motoroel Sender, engine oil pressure
B88 004 15 Druckgeber Motoroel Sender, engine oil pressure
B93 004 13 Leistungskraftstoffdruck Sensor RPS Rail pressure sensor
B103 014 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 014 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B112 005 3 Druckgeber Fahrpumpe pressure sender, driving pump
B113 003 13 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B113 004 14 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 003 7 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B114 004 7 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
component listing

B115 003 11 Geber Ladeluftdruck Sender, charging air pressure

B124 004 5 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
Bauteilliste

B124 006 6 Geber Wasserstandsabscheider Diesel Sender, water separator fuel

B126 003 14 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B130 003 8 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
B130 004 8 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
B131 014 10 Temperaturschalter Heizung Temperature switch, heating
B132 007 2 Inititator Armlehne links proximity switch left arm rest
B133 004 12 Sensor Ladeluftdruck / −temperatur sesnor charging air prssure / temperature
B134 008 17 Näherungsschalter Platten oben proximity switch, plate up
B135 008 16 Näherungsschalter Platten mitte proximity switch, plate middle
B145 004 17 Sensor Niederdruck Kraftstoff fuel low pressure sensor

E08 012 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 012 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 012 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 012 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 012 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 012 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 012 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 012 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 012 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 012 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E23 012 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 013 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 012 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 013 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 012 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 013 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 012 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 013 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 013 3 Innenleuchte Kabine Inside light, cabin 1,75A
E30 014 15 Heizgeraet Heating unit
E32 013 19 Kennleuchte Warning light 5A
E70 013 15 Nachtleuchte Night lamp 0,83A
E71 013 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 013 16 Beleuchtung Bedienschalter illum. Switches

F00 002 6 Hauptsicherung Batterie Fuse, main, battery 125A

F05 002 13 Sicherung Steckdose Fuse, socket 10A

F11 012 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 11 Sicherung Startschalter Fuse, starter switch 30A
F15 014 19 Sicherung Heizgeraet Fuse, heating unit BOX2
F18 012 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
582 702 32

F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A

F40 014 15 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
008 914
F41 20 013 19 Sicherung Rundumkennleuchte BOMAG
Fuse, rotary beacon 10A 1355
Name Bl. Pf. Benennung title TYP

21.3 F42
F43
F44
013
013
013
3
10
13
Sicherung Kabineninnenleuchte
Sicherung Wischermotor hinten
Sicherung Wischermotor vorn
Fuse, inside light cab
Fuse, wipermotor rear
Fuse, wipermotor front
10A
Wiring diagram 582 702 32
15A
15A
F48 002 5 Sicherung Gluehanlage Fuse, glow plug system 125A
F67 005 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 15A
F68 002 8 Sicherung Potential 30 Fuse, potential 30 5A
F84 005 9 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F93 004 3 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 25A
F95 002 15 Sicherung Motormanagement intern Fuse, engine controller (internal) 10A
F97 014 13 Sicherung Frischluftluefter fuse, blower fresh air 3A
FM1 007 6 Platinensicherung Multifuse MULTIFUSE
FM2 007 6 Platinensicherung Multifuse MULTIFUSE
FM3 007 5 Platinensicherung Multifuse MULTIFUSE
FM4 009 11 Platinensicherung Multifuse MULTIFUSE
Seis
08.03.2007
Vogt
08.03.2007

FM5 007 6 Platinensicherung Multifuse MULTIFUSE

F124 002 17 Sicherung Kraftstoffvorwärmung Fuse, fuel pre−heating 25A
F130 013 15 Sicherung Nachtleuchte Fuse, night lamp 10A
F143 013 2 Sicherung Heckscheibenheizung fuse rear screen heating unit 15A
F144 013 20 Sicherung Kabinensteckdose Fuse cabin−socket 15A
F145 008 18 Sicherung Anhängeplatten fuse vibration plates 20A
F146 009 5 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30) 15A
F148 009 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15) 10A
F150 010 14 Sicherung GPS Receiver Fuse, GPS receiver 5A

G01 002 6 Batterie Battery 103A

G02 002 7 Generator Generator
G03 002 5 Batterie Battery 103A

K05 008 3 Relais Startstrom Relay, starting current BOSCHW

K06 012 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 10 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 11 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K14 003 19 Relais Vorgluehen Relay, glow plug system TYCOX
K16 012 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K32 013 1 Relais Kabine Relay, cabin BOSCHW
K41 004 2 Trennrelais Relay, separation BOSCHW
K43 007 12 D*Relais Vibration E*relay, vibration BOSCHW
K48 008 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
component listing

K61 002 7 Relais Ladekontrolle Relay, charge control BOSCHW

K14.2 004 20 TYCOX
Bauteilliste

K141 013 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW

M01 002 12 Starter Starter 2.3 KW

M04 013 12 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 013 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 013 13 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 013 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 014 3 Kabinenluefter Cabin ventilator
M09 014 4 Kabinenluefter Cabin ventilator
M17 014 13 Zusatzluefter Additional blower

P07 009 15 Omegameter Omegameter

P09 013 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 009 14 Drucker Printer
P15 010 18 BCM 03 Bildschirm BCM 03 terminal
P16 009 16 Diagnose, Variomatic Diagnostics, varimatic
P33 009 18 Opus 21 Opus 21

R03 006 5 Geber Tankanzeige Sender, level gauge 0 .. 67 OHM

R10 002 8 Parallelwiderstand Parallel resistor 82 OHM
R19 002 4 Heizflansch heater flange 167A
R20 005 15 Widerstand Resistor 120 OHM
R21 005 15 Widerstand Resistor 120 OHM
R22 005 12 Widerstand Resistor 120 OHM
R23 005 12 Widerstand Resistor 120 OHM
R24 009 17 Widerstand Resistor 60 OHM
R25 010 18 Widerstand Resistor 60 OHM
R79 002 15 Kraftstoffvorwärmung fuel pre−heater 250W
R80 013 2 Heizung Heckscheibe heating rear screen MAX. 13A
R81 002 1 Gluehstiftkerze 1 glow plug 1
R82 002 1 Gluehstiftkerze 2 glow plug 2
R83 002 2 Gluehstiftkerze 3 glow plug 3
R84 002 2 Gluehstiftkerze 4 glow plug 4
R85 002 2 Gluehstiftkerze 5 glow plug 5
R86 002 3 Gluehstiftkerze 6 glow plug 6

S00 002 11 Startschalter Starter switch

S01 002 15 Schalter NOT AUS Switch, emergency off NOTAUSH

S03 002 18 Taster Signalhorn Push button, warning horn
S06 005 10 Sitzkontaktschalter links Switch, seat contact, lh.
S09 008 8 Vibrationsschalter vorne Switch, vibration, front
S14 012 15 Warnblinkschalter Switch, hazard light
11

S15 012 4 Beleuchtungsschalter StVZO Switch, lighting StVZO

S28 014 19 Schalter Kabinenheizung Switch, cabin heating

S30 002 5 Batterietrennschalter Switch, battery disconnect
S35 008 7 Vibrationsschalter klein/gross Switch, vibration low/high
S36 008 11 Vibrationsschalter Switch, vibration
S37 012 18 Schalter Blinker Switch, indicator
102

S38 013 19 Schalter Kennleuchte Switch, warning light

S42 008 11 Stufenumschalter schnell−langsam Speed range selector, fast−slow
1356 S44 014 3 Schalter Kabinenluefter BOMAG
Switch, cabin ventilator 008 914 20
Name Bl. Pf. Benennung title TYP
S45

S64
013
Wiring diagram 582 702 32
S55 008
008
3
6
10
Schalter Kabineninnenleuchte
Schalter Fahrhebel
Schalter Schwimmstellung
Switch, cabin inside light
Switch, travel control lever
Switch, float position
21.3
S86 013 3 Schalter Tuer, links Switch door, lh.
S127 006 17 Schalter Motordrehzahl Switch, engine rpm
S139 006 19 Schalter Frequenzverstellung Switch, frequency control
S139 008 13 Schalter Frequenzverstellung Switch, frequency control
S158 013 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 013 16 Schalter Heckscheibenheizung switch rear screen heating unit

V01 002 9 Diode Diode FE5B

V02 002 17 Diode Diode FE5B
V03 002 18 Diode Diode FE5B
V04 014 8 Diode Diode FE5B
Seis
08.03.2007
Vogt
08.03.2007

V06 014 9 Diode Diode

X1:1 002 7 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:2 005 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:2 012 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:3 002 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:4 002 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:7 002 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:8 002 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:9 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:10 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:37 007 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:38 007 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:39 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:40 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:41 006 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:41 007 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:42 007 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:43 012 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:44 005 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:45 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:46 005 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:47 005 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:48 005 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:49 005 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:50 005 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:51 005 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:52 005 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:53 005 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

X1:54 005 13 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:55 007 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:56 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:57 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:58 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:59 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:60 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:61 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:62 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:63 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:79 002 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:80 006 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 005 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 006 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 007 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:82 009 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:83 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:84 012 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:85 009 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:86 006 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:87 006 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:88 006 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:89 007 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:90 004 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:91 004 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:92 004 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:94 006 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:94 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:95 003 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:96 003 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:97 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:98 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:101 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:102 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:103 002 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:104 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:105 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:106 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:107 004 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
3

X1:107 006 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:108 004 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:108 006 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:109 002 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:110 002 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
11

X1:111 006 3 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:112 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:113 007 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:114 005 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
582 702 32

X1:115 007 15 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:116 007 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:117 005 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:117 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:117 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
103

X1:117 007 17 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:118 007 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
008 914
X1:11920 005 2 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 1357
Name Bl. Pf. Benennung title TYP

21.3 X1:120
X1:121
X1:122
005
005
005
4
12
13
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO E−BOX
WAGO E−BOX
WAGO E−BOX
Wiring diagram 582 702 32
X1:123 002 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:123 005 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:123 005 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:124 005 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:124 005 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:141 005 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:142 005 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:142 005 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:143 005 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:143 005 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:143 005 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
Seis
08.03.2007
Vogt
08.03.2007

X1:144 005 15 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:145 005 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:146 005 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:147 007 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:148 007 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:149 005 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:149 006 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:149 007 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:149 008 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:14A 004 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:14E 004 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:150 007 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:151 002 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:152 002 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:153 008 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:154 007 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:155 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:156 008 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:157 008 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:158 005 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:159 007 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:15A 002 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:15E 002 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:160 007 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:161 007 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:162 007 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:163 014 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:164 006 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:164 014 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

X1:165 014 3 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:166 014 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:167 014 10 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:168 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:168 014 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:169 014 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:16A 002 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:16E 002 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:170 014 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:171 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:172 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:173 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:174 005 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:175 005 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:176 005 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:177 005 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:178 005 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:179 003 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:179 004 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:17A 005 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:17E 005 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:180 003 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:180 004 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:181 003 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:181 004 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:182 003 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:182 004 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:183 003 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:183 004 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:184 003 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:184 004 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:185 003 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:185 004 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:186 003 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:186 004 20 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:187 007 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:188 007 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:189 007 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:18A 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
4

X1:18E 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:190 007 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:190 011 12 WAGO,E−Kasten WAGO,E−BOX
X1:190 014 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:191 004 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
11

X1:192 004 14 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:193 004 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:194 004 13 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:195 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
582 702 32

X1:196 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:197 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:197 007 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:198 004 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:199 004 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
104

X1:19A 012 15 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:19E 012 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
1358 X1:201 007 4 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 008 914 20
Name Bl. Pf. Benennung title TYP
X1:202

X1:205
007
Wiring diagram 582 702 32
X1:203 007
007
4
4
11
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO E−BOX
WAGO E−BOX
WAGO E−BOX
21.3
X1:206 007 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:207 007 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:208 007 11 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:209 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:20A 002 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:20E 002 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:210 008 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:211 008 14 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:212 008 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:213 008 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:214 008 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
Seis
08.03.2007
Vogt
08.03.2007

X1:215 008 13 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:217 002 15 WAGO,E−Kasten WAGO,E−BOX
X1:218 002 15 WAGO,E−Kasten WAGO,E−BOX
X1:21A 012 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:21E 012 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:22A 012 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:22E 012 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:23A 012 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:23E 012 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:24A 012 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:24E 012 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:25A 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:25E 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:26A 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:26E 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:27A 002 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:27E 002 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:28A 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:28E 002 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:29A 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:29E 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:301 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:302 012 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:303 012 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:304 012 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:305 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:306 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:307 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:309 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

X1:30A 002 19 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:30E 002 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:310 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:311 012 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:312 012 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:313 012 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:314 012 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:315 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:315 012 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:315 012 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:316 012 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:316 012 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:316 012 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:319 012 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:31A 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:31E 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:320 012 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:321 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:322 012 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:323 012 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:323 012 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:324 012 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:324 012 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:32A 009 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:32E 009 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:33A 002 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:33E 002 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:34A 005 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:34E 005 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:35A 009 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:35E 009 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X2:43 010 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:44 010 15 WAGO−MESSTECHNIK Wago−measurement equip.
X2:47 009 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:48 009 19 WAGO−MESSTECHNIK Wago−measurement equip.
X2:49 009 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:49 009 19 WAGO−MESSTECHNIK Wago−measurement equip.
X2:50 009 17 WAGO−MESSTECHNIK Wago−measurement equip.
X2:51 009 18 WAGO−MESSTECHNIK Wago−measurement equip.
5

X2:52 009 13 WAGO−MESSTECHNIK Wago−measurement equip.

X2:53 009 8 WAGO−MESSTECHNIK Wago−measurement equip.
X2:54 009 7 WAGO−MESSTECHNIK Wago−measurement equip.
X2:55 009 8 WAGO−MESSTECHNIK Wago−measurement equip.
X2:56 009 7 WAGO−MESSTECHNIK Wago−measurement equip.
11

X2:57 009 2 WAGO−MESSTECHNIK Wago−measurement equip.

X2:57 009 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:58 009 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:59 009 10 WAGO−MESSTECHNIK Wago−measurement equip.
582 702 32

X2:60 009 9 WAGO−MESSTECHNIK Wago−measurement equip.

X2:61 010 17 WAGO−MESSTECHNIK Wago−measurement equip.
X2:62 010 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:63 009 13 WAGO−MESSTECHNIK Wago−measurement equip.
X2:63 010 15 WAGO−MESSTECHNIK Wago−measurement equip.
105

X2:64 009 14 WAGO−MESSTECHNIK Wago−measurement equip.

X2:65 009 14 WAGO−MESSTECHNIK Wago−measurement equip.
008 914
X2:66 20 009 14 WAGO−MESSTECHNIK BOMAG
Wago−measurement equip. 1359
Name Bl. Pf. Benennung title TYP

21.3 X2:66
X2:67
X2:68
009
009
009
14
11
12
WAGO−MESSTECHNIK
WAGO−MESSTECHNIK
WAGO−MESSTECHNIK
Wago−measurement equip.
Wago−measurement equip.
Wago−measurement equip.
Wiring diagram 582 702 32
X2:69 009 12 WAGO−MESSTECHNIK Wago−measurement equip.
X2:70 009 15 WAGO−MESSTECHNIK Wago−measurement equip.
X2:70 010 15 WAGO−MESSTECHNIK Wago−measurement equip.
X2:71 009 13 WAGO−MESSTECHNIK Wago−measurement equip.
X2:73 009 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:74 009 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:75 009 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:76 009 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:77 009 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:78 009 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:79 009 16 WAGO ZENTRALELEKTRIK WAGO E−BOX
Seis
08.03.2007
Vogt
08.03.2007

X2:80A 010 14 WAGO−MESSTECHNIK Wago−measurement equip.

X2:80E 010 14 WAGO−MESSTECHNIK Wago−measurement equip.
X3:1 012 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 013 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:2 013 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:3 002 19 SETCKER KABINE/ROPS Con cabin/ROPS
X3:4 012 10 STECKER ROPS/SD conn. ROPS/SR
X3:5 012 12 STECKER ROPS/SD conn. ROPS/SR
X3:6 013 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:7 013 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:8 013 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:9 014 3 STECKER KABINE/ROPS conn. cabin/ROPS
X3:10 014 3 STECKER KABINE/ROPS conn. cabin/ROPS
X3:11 014 4 STECKER KABINE/ROPS conn. cabin/ROPS
X3:12 014 4 STECKER KABINE/ROPS conn. cabin/ROPS
X3:13 014 7 STECKER KABINE/ROPS conn. cabin/ROPS
X3:14 014 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:17 013 6 STECKER KABINE/ROPS conn. cabin/ROPS
X3:18 013 6 STECKER KABINE/ROPS conn. cabin/ROPS
X4:A 009 14 KABINENST. MESST. con. measurem.equipm.
X4:B 009 14 KABINENST. MESST. con. measurem.equipm.
X4:C 009 14 KABINENST. MESST. con. measurem.equipm.
X4:D 009 14 KABINENST. MESST. con. measurem.equipm.
X4:E 009 15 KABINENST. MESST. con. measurem.equipm.
X4:F 010 15 KABINENST. MESST. con. measurem.equipm.
X4:G 010 15 KABINENST. MESST. con. measurem.equipm.
X4:H 010 14 KABINENST. MESST. con. measurem.equipm.
X4:J 010 15 KABINENST. MESST. con. measurem.equipm.
X4:M 010 18 KABINENST. MESST. con. measurem.equipm.
component listing

X4:N 010 17 KABINENST. MESST. con. measurem.equipm.

X6:1 007 13 STECKER VIBRATION GRO conn. vibration big
Bauteilliste

X6:2 007 14 STECKER VIBRATION GRO conn. vibration big

X7:1 007 15 STECKER VIBRATION KLE conn. vibration small
X7:2 007 14 STECKER VIBRATION KLE conn. vibration small
X8:1 006 6 STECKER WASSERABSCHEI connector water separator
X8:2 006 6 STECKER WASSERABSCHEI connector water separator
X9:1 005 11 STECKER RÜCKFAHRALARM conn. backupalarm
X9:2 005 11 STECKER RÜCKFAHRALARM conn. backupalarm
XS 002 19 Steckdose Socket
XS 013 20 Steckdose Socket
X10:2 006 5 STECKER TAUCHROHRGEBE connector fuel level sensor
X10:3 006 5 STECKER TAUCHROHRGEBE connector fuel level sensor
X14:A 005 10 STECKER SITZKONTAKT connector seat contact switch
X14:B 005 10 STECKER SITZKONTAKT connector seat contact switch
X15:1 005 13 STECKER FAHRPUMPE RÜC connectoe driving pump back
X15:2 005 13 STECKER FAHRPUMPE RÜC connectoe driving pump back
X16:1 005 12 STECKER FAHRPUMPE VOR connector driving pump front
X16:2 005 12 STECKER FAHRPUMPE VOR connector driving pump front
X17:1 014 3 STECKER LÜFTER HKL conn. blower
X17:2 014 3 STECKER LÜFTER HKL conn. blower
X17:3 014 4 STECKER LÜFTER HKL conn. blower
X17:4 014 5 STECKER LÜFTER HKL conn. blower
X18:1 014 10 STECKER THERMOFÜHLER conn. sender temp.
X18:2 014 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 014 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X19:2 014 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X20:1 014 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:2 014 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:3 014 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:4 014 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X21:1 006 4 STECKER KÜHLMITTEL connector coolant sensor
X21:2 006 4 STECKER KÜHLMITTEL connector coolant sensor
X22:1 007 14 ST. VIBRATIONSAUFNEHM connector vibration sensor
X22:2 007 15 ST. VIBRATIONSAUFNEHM connector vibration sensor
X22:3 007 15 ST. VIBRATIONSAUFNEHM connector vibration sensor
X22:4 007 14 ST. VIBRATIONSAUFNEHM connector vibration sensor
X25:2 008 10 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X25:3 008 11 ST. FAHRSTUFENSCHALTE connector switch speed ranges
6

X25:4 008 11 ST. FAHRSTUFENSCHALTE connector switch speed ranges

X26:1 006 8 STECKER DATENSAMMLER connector data collector
X26:2 006 8 STECKER DATENSAMMLER connector data collector
X26:3 006 2 STECKER DATENSAMMLER connector data collector
X26:4 006 9 STECKER DATENSAMMLER connector data collector
11

X26:5 006 2 STECKER DATENSAMMLER connector data collector

X26:6 006 9 STECKER DATENSAMMLER connector data collector
X26:8 006 3 STECKER DATENSAMMLER connector data collector
X26:9 006 7 STECKER DATENSAMMLER connector data collector
582 702 32

X26:10 006 4 STECKER DATENSAMMLER connector data collector

X26:11 006 9 STECKER DATENSAMMLER connector data collector
X26:12 006 12 STECKER DATENSAMMLER connector data collector
X27:1 006 11 STECKER DATENSAMMLER connector data collector
X27:2 006 5 STECKER DATENSAMMLER connector data collector
106

X27:3 006 10 STECKER DATENSAMMLER connector data collector

X27:4 006 6 STECKER DATENSAMMLER connector data collector
1360 X27:5 006 11 STECKER DATENSAMMLER BOMAG
connector data collector 008 914 20
Name Bl. Pf. Benennung title TYP
X27:6

X27:8
006
Wiring diagram 582 702 32
X27:7 006
006
9
10
2
STECKER DATENSAMMLER
STECKER DATENSAMMLER
STECKER DATENSAMMLER
connector data collector
connector data collector
connector data collector
21.3
X27:9 006 7 STECKER DATENSAMMLER connector data collector
X27:10 006 10 STECKER DATENSAMMLER connector data collector
X27:11 006 10 STECKER DATENSAMMLER connector data collector
X27:12 006 10 STECKER DATENSAMMLER connector data collector
X28:1 006 16 STECKER LC−DISPLAY 1 connector LC−display 1
X28:2 006 13 STECKER LC−DISPLAY 1 connector LC−display 1
X28:3 006 13 STECKER LC−DISPLAY 1 connector LC−display 1
X28:4 006 14 STECKER LC−DISPLAY 1 connector LC−display 1
X28:5 006 16 STECKER LC−DISPLAY 1 connector LC−display 1
X28:6 006 17 STECKER LC−DISPLAY 1 connector LC−display 1
X29:1 006 14 STECKER LC−DISPLAY 2 connector LC−display 2
Seis
08.03.2007
Vogt
08.03.2007

X29:2 006 14 STECKER LC−DISPLAY 2 connector LC−display 2

X29:3 006 15 STECKER LC−DISPLAY 2 connector LC−display 2
X29:4 006 15 STECKER LC−DISPLAY 2 connector LC−display 2
X29:5 006 17 STECKER LC−DISPLAY 2 connector LC−display 2
X29:6 006 17 STECKER LC−DISPLAY 2 connector LC−display 2
X29:7 006 18 STECKER LC−DISPLAY 2 connector LC−display 2
X29:8 006 17 STECKER LC−DISPLAY 2 connector LC−display 2
X30:1 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:1 004 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:2 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:2 004 18 EMR−Stecker Fahrzeug EMR−connector compactor
X30:3 003 8 EMR−Stecker Fahrzeug EMR−connector compactor
X30:3 004 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:4 003 7 EMR−Stecker Fahrzeug EMR−connector compactor
X30:4 004 18 EMR−Stecker Fahrzeug EMR−connector compactor
X30:5 003 7 EMR−Stecker Fahrzeug EMR−connector compactor
X30:5 004 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:6 004 19 EMR−Stecker Fahrzeug EMR−connector compactor
X30:10 003 2 EMR−Stecker Fahrzeug EMR−connector compactor
X30:11 003 2 EMR−Stecker Fahrzeug EMR−connector compactor
X30:12 003 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:13 003 3 EMR−Stecker Fahrzeug EMR−connector compactor
X30:14 003 2 EMR−Stecker Fahrzeug EMR−connector compactor
X30:15 003 7 EMR−Stecker Fahrzeug EMR−connector compactor
X30:17 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X30:22 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:23 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X30:24 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
X30:25 003 6 EMR−Stecker Fahrzeug EMR−connector compactor
component listing

X30:25 004 13 EMR−Stecker Fahrzeug EMR−connector compactor

X30:28 004 9 EMR−Stecker Fahrzeug EMR−connector compactor
Bauteilliste

X30:60 004 13 EMR−Stecker Fahrzeug EMR−connector compactor

X30:61 004 14 EMR−Stecker Fahrzeug EMR−connector compactor
X30:62 004 14 EMR−Stecker Fahrzeug EMR−connector compactor
X30:63 004 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:64 004 5 EMR−Stecker Fahrzeug EMR−connector compactor
X30:72 004 2 EMR−Stecker Fahrzeug EMR−connector compactor
X30:82 004 13 EMR−Stecker Fahrzeug EMR−connector compactor
X31:1 003 16 EMR−Stecker Motor EMR−connector engine
X31:1 004 5 EMR−Stecker Motor EMR−connector engine
X31:2 003 17 EMR−Stecker Motor EMR−connector engine
X31:3 003 17 EMR−Stecker Motor EMR−connector engine
X31:4 003 12 EMR−Stecker Motor EMR−connector engine
X31:5 003 14 EMR−Stecker Motor EMR−connector engine
X31:6 003 15 EMR−Stecker Motor EMR−connector engine
X31:7 003 17 EMR−Stecker Motor EMR−connector engine
X31:7 004 9 EMR−Stecker Motor EMR−connector engine
X31:8 003 13 EMR−Stecker Motor EMR−connector engine
X31:8 004 14 EMR−Stecker Motor EMR−connector engine
X31:9 003 13 EMR−Stecker Motor EMR−connector engine
X31:10 003 8 EMR−Stecker Motor EMR−connector engine
X31:10 004 7 EMR−Stecker Motor EMR−connector engine
X31:11 003 8 EMR−Stecker Motor EMR−connector engine
X31:11 004 17 EMR−Stecker Motor EMR−connector engine
X31:12 003 7 EMR−Stecker Motor EMR−connector engine
X31:12 004 8 EMR−Stecker Motor EMR−connector engine
X31:13 003 7 EMR−Stecker Motor EMR−connector engine
X31:13 004 16 EMR−Stecker Motor EMR−connector engine
X31:14 003 9 EMR−Stecker Motor EMR−connector engine
X31:14 004 12 EMR−Stecker Motor EMR−connector engine
X31:15 003 9 EMR−Stecker Motor EMR−connector engine
X31:16 003 11 EMR−Stecker Motor EMR−connector engine
X31:16 004 1 EMR−Stecker Motor EMR−connector engine
X31:17 003 10 EMR−Stecker Motor EMR−connector engine
X31:18 003 10 EMR−Stecker Motor EMR−connector engine
X31:19 003 10 EMR−Stecker Motor EMR−connector engine
X31:19 004 10 EMR−Stecker Motor EMR−connector engine
X31:20 003 6 EMR−Stecker Motor EMR−connector engine
7

X31:20 004 8 EMR−Stecker Motor EMR−connector engine

X31:21 003 6 EMR−Stecker Motor EMR−connector engine
X31:22 003 6 EMR−Stecker Motor EMR−connector engine
X31:23 003 11 EMR−Stecker Motor EMR−connector engine
X31:23 004 11 EMR−Stecker Motor EMR−connector engine
11

X31:24 003 11 EMR−Stecker Motor EMR−connector engine

X31:24 004 19 EMR−Stecker Motor EMR−connector engine
X31:25 003 12 EMR−Stecker Motor EMR−connector engine
X31:26 004 13 EMR−Stecker Motor EMR−connector engine
582 702 32

X31:27 004 9 EMR−Stecker Motor EMR−connector engine

X31:31 004 4 EMR−Stecker Motor EMR−connector engine
X31:32 004 6 EMR−Stecker Motor EMR−connector engine
X31:33 004 3 EMR−Stecker Motor EMR−connector engine
X31:34 004 20 EMR−Stecker Motor EMR−connector engine
107

X31:40 004 12 EMR−Stecker Motor EMR−connector engine

X31:41 004 15 EMR−Stecker Motor EMR−connector engine
008 914
X31:4320 004 13 EMR−Stecker Motor BOMAG
EMR−connector engine 1361
Name Bl. Pf. Benennung title TYP

21.3 X31:46
X31:47
X31:48
004
004
004
2
1
5
EMR−Stecker Motor
EMR−Stecker Motor
EMR−Stecker Motor
EMR−connector engine
EMR−connector engine
EMR−connector engine
Wiring diagram 582 702 32
X31:49 004 11 EMR−Stecker Motor EMR−connector engine
X31:50 004 7 EMR−Stecker Motor EMR−connector engine
X31:51 004 15 EMR−Stecker Motor EMR−connector engine
X31:53 004 13 EMR−Stecker Motor EMR−connector engine
X31:54 004 18 EMR−Stecker Motor EMR−connector engine
X31:56 004 16 EMR−Stecker Motor EMR−connector engine
X31:57 004 17 EMR−Stecker Motor EMR−connector engine
X31:58 004 14 EMR−Stecker Motor EMR−connector engine
X32:A 003 2 EMR − Diagnose EMR−diagnosis
X32:A 004 12 EMR − Diagnose EMR−diagnosis
X32:B 003 3 EMR − Diagnose EMR−diagnosis
Seis
08.03.2007
Vogt
08.03.2007

X32:B 004 14 EMR − Diagnose EMR−diagnosis

X32:F 004 13 EMR − Diagnose EMR−diagnosis
X32:G 003 3 EMR − Diagnose EMR−diagnosis
X32:G 004 14 EMR − Diagnose EMR−diagnosis
X32:H 003 3 EMR − Diagnose EMR−diagnosis
X32:H 004 14 EMR − Diagnose EMR−diagnosis
X32:K 003 2 EMR − Diagnose EMR−diagnosis
X32:K 004 13 EMR − Diagnose EMR−diagnosis
X32:L 003 2 EMR − Diagnose EMR−diagnosis
X32:M 004 13 EMR − Diagnose EMR−diagnosis
X33:1 003 19 Trennstelle EMR II conector EMR II
X33:2 003 18 Trennstelle EMR II conector EMR II
X33:3 003 18 Trennstelle EMR II conector EMR II
X33:4 003 19 Trennstelle EMR II conector EMR II
X33:5 003 18 Trennstelle EMR II conector EMR II
X33:6 003 19 Trennstelle EMR II conector EMR II
X33:7 003 17 Trennstelle EMR II conector EMR II
X33:8 003 20 Trennstelle EMR II conector EMR II
X34:A 005 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:B 005 16 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:C 005 12 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:D 005 13 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:G 005 10 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:H 005 11 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:J 007 3 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:N 003 4 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:P 002 13 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:R 006 2 DIAGNOSESTECKER ESX connector diagnosis ESX
X35:1 007 4 ESX STECKER esx connector
component listing

X35:2 007 12 ESX STECKER esx connector

X35:3 007 16 ESX STECKER esx connector
Bauteilliste

X35:4 005 11 ESX STECKER esx connector

X35:5 005 10 ESX STECKER esx connector
X35:12 005 3 ESX STECKER esx connector
X35:15 005 10 ESX STECKER esx connector
X35:16 007 4 ESX STECKER esx connector
X35:17 007 18 ESX STECKER esx connector
X35:18 007 11 ESX STECKER esx connector
X35:19 007 11 ESX STECKER esx connector
X35:20 007 5 ESX STECKER esx connector
X35:21 007 6 ESX STECKER esx connector
X35:22 007 11 ESX STECKER esx connector
X35:23 007 5 ESX STECKER esx connector
X35:24 005 11 ESX STECKER esx connector
X35:26 005 16 ESX STECKER esx connector
X35:27 005 15 ESX STECKER esx connector
X35:28 005 2 ESX STECKER esx connector
X35:29 007 4 ESX STECKER esx connector
X35:30 005 9 ESX STECKER esx connector
X35:31 005 5 ESX STECKER esx connector
X35:33 005 13 ESX STECKER esx connector
X35:34 005 6 ESX STECKER esx connector
X35:35 007 15 ESX STECKER esx connector
X35:37 005 5 ESX STECKER esx connector
X35:38 005 2 ESX STECKER esx connector
X35:40 007 11 ESX STECKER esx connector
X35:41 007 11 ESX STECKER esx connector
X35:43 007 10 ESX STECKER esx connector
X35:46 005 15 ESX STECKER esx connector
X35:47 005 16 ESX STECKER esx connector
X35:48 007 14 ESX STECKER esx connector
X35:49 005 12 ESX STECKER esx connector
X35:53 005 12 ESX STECKER esx connector
X35:54 005 9 ESX STECKER esx connector
X35:55 005 18 ESX STECKER esx connector
X35:56 005 7 ESX STECKER esx connector
X35:57 005 7 ESX STECKER esx connector
X35:58 005 8 ESX STECKER esx connector
8

X35:59 005 8 ESX STECKER esx connector

X35:60 005 8 ESX STECKER esx connector
X35:61 007 17 ESX STECKER esx connector
X35:64 005 13 ESX STECKER esx connector
X35:65 005 18 ESX STECKER esx connector
11

X35:66 005 19 ESX STECKER esx connector

X35:67 005 19 ESX STECKER esx connector
X35:68 005 19 ESX STECKER esx connector
X36:A 002 6 EINSPEISUNG SCHALTKAS supply e−box
582 702 32

X36:B 002 5 EINSPEISUNG SCHALTKAS supply e−box

X37:A 002 11 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X37:B 002 12 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 13 STECKER STARTER E−KAS connector starter, e−Box
X39:1 007 9 STECKER 1 LENKRAD connector 1 steering unit
108

X39:2 007 10 STECKER 1 LENKRAD connector 1 steering unit

X39:3 007 10 STECKER 1 LENKRAD connector 1 steering unit
1362 X39:4 007 9 STECKER 1 LENKRAD BOMAG
connector 1 steering unit 008 914 20
Name Bl. Pf. Benennung title TYP
X40:1

X40:3
007
Wiring diagram 582 702 32
X40:2 007
007
9
10
10
STECKER 2 LENKRAD
STECKER 2 LENKRAD
STECKER 2 LENKRAD
connector 2 steering unit
connector 2 steering unit
connector 2 steering unit
21.3
X40:4 007 9 STECKER 2 LENKRAD connector 2 steering unit
X41:1 007 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:2 007 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:3 007 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:4 007 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:5 007 11 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:6 007 11 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:7 007 11 ST. LENKRADKABELBAUM conn. steer. wire harn.
X41:8 007 11 ST. LENKRADKABELBAUM conn. steer. wire harn.
X42:1 009 18 STECKER ADAPTER BOP conector adapter BOP
X42:2 009 19 STECKER ADAPTER BOP conector adapter BOP
Seis
08.03.2007
Vogt
08.03.2007

X42:3 009 19 STECKER ADAPTER BOP conector adapter BOP

X42:4 009 18 STECKER ADAPTER BOP conector adapter BOP
X42:5 009 18 STECKER ADAPTER BOP conector adapter BOP
X43:1 007 2 STECKER SCHALTER ARML connector switch arm rest
X43:2 007 1 STECKER SCHALTER ARML connector switch arm rest
X44:1 009 13 MESX STECKER MESX Stecker
X44:3 009 15 MESX STECKER MESX Stecker
X44:4 009 14 MESX STECKER MESX Stecker
X44:5 009 14 MESX STECKER MESX Stecker
X44:7 009 10 MESX STECKER MESX Stecker
X44:9 009 12 MESX STECKER MESX Stecker
X44:14 009 5 MESX STECKER MESX Stecker
X44:15 009 4 MESX STECKER MESX Stecker
X44:23 009 11 MESX STECKER MESX Stecker
X44:25 009 16 MESX STECKER MESX Stecker
X44:26 009 18 MESX STECKER MESX Stecker
X44:27 009 17 MESX STECKER MESX Stecker
X44:28 009 2 MESX STECKER MESX Stecker
X44:29 009 7 MESX STECKER MESX Stecker
X44:30 009 9 MESX STECKER MESX Stecker
X44:31 009 8 MESX STECKER MESX Stecker
X44:32 009 5 MESX STECKER MESX Stecker
X44:33 009 18 MESX STECKER MESX Stecker
X44:35 009 5 MESX STECKER MESX Stecker
X44:36 009 6 MESX STECKER MESX Stecker
X44:37 009 6 MESX STECKER MESX Stecker
X44:38 009 4 MESX STECKER MESX Stecker
X44:41 009 7 MESX STECKER MESX Stecker
X44:46 009 11 MESX STECKER MESX Stecker
component listing

X44:47 009 10 MESX STECKER MESX Stecker

X44:53 009 17 MESX STECKER MESX Stecker
Bauteilliste

X44:54 009 6 MESX STECKER MESX Stecker

X44:55 009 13 MESX STECKER MESX Stecker
X44:56 009 4 MESX STECKER MESX Stecker
X44:57 009 5 MESX STECKER MESX Stecker
X44:58 009 5 MESX STECKER MESX Stecker
X44:59 009 5 MESX STECKER MESX Stecker
X44:60 009 6 MESX STECKER MESX Stecker
X44:65 009 13 MESX STECKER MESX Stecker
X44:66 009 13 MESX STECKER MESX Stecker
X44:67 009 14 MESX STECKER MESX Stecker
X44:68 009 14 MESX STECKER MESX Stecker
X46:A 009 19 STECKER BOP Connector BOP
X46:B 009 18 STECKER BOP Connector BOP
X46:D 009 18 STECKER BOP Connector BOP
X46:E 009 19 STECKER BOP Connector BOP
X46:F 009 18 STECKER BOP Connector BOP
X47:A 009 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 009 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:C 009 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X48:1 009 8 STECKER AUFN. VORNE conn. sender front
X48:2 009 7 STECKER AUFN. VORNE conn. sender front
X48:3 009 7 STECKER AUFN. VORNE conn. sender front
X48:4 009 8 STECKER AUFN. VORNE conn. sender front
X49:1 009 10 STECKER AUFN. HINTEN conn. sender rear
X49:2 009 9 STECKER AUFN. HINTEN conn. sender rear
X49:3 009 9 STECKER AUFN. HINTEN conn. sender rear
X49:4 009 10 STECKER AUFN. HINTEN conn. sender rear
X50:1 008 13 ST. PLATTENFREQ. conn. plate−freq.
X50:2 008 13 ST. PLATTENFREQ. conn. plate−freq.
X50:3 008 13 ST. PLATTENFREQ. conn. plate−freq.
X51:1 007 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X51:2 007 1 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X51:3 007 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X52:1 005 3 STECKER DRUCKSENSOR connector pressure sensor
X52:2 005 3 STECKER DRUCKSENSOR connector pressure sensor
X53:B 014 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 014 4 STECKER LÜFTERSCHALTE conn. blowerswitch
9

X53:H 014 4 STECKER LÜFTERSCHALTE conn. blowerswitch

X53:L 014 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 014 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 014 11 STECKER HEIZSTEUERUNG conn. heating controller
X54:2 014 11 STECKER HEIZSTEUERUNG conn. heating controller
11

X54:3 014 10 STECKER HEIZSTEUERUNG conn. heating controller

X54:4 014 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:6 014 7 STECKER HEIZSTEUERUNG conn. heating controller
X54:11 014 10 STECKER HEIZSTEUERUNG conn. heating controller
582 702 32

X54:12 014 11 STECKER HEIZSTEUERUNG conn. heating controller

X55:1 013 11 STECKER WISCHER HINTE connector wiper rear
X55:2 013 10 STECKER WISCHER HINTE connector wiper rear
X55:3 013 10 STECKER WISCHER HINTE connector wiper rear
X55:4 013 10 STECKER WISCHER HINTE connector wiper rear
109

X56:1 013 14 STECKER WISCHER VORNE conn. wiper front

X56:2 013 13 STECKER WISCHER VORNE conn. wiper front
008 914
X56:3 20 013 13 STECKER WISCHER VORNE BOMAG
conn. wiper front 1363
Name Bl. Pf. Benennung title TYP

21.3 X56:4
X57:1
X57:1
013
003
004
12
15
9
STECKER WISCHER VORNE
Stecker Motor
Stecker Motor
conn. wiper front
connector engine
connector engine
Wiring diagram 582 702 32
X57:2 003 13 Stecker Motor connector engine
X57:3 003 14 Stecker Motor connector engine
X57:4 003 12 Stecker Motor connector engine
X57:5 003 14 Stecker Motor connector engine
X57:6 003 15 Stecker Motor connector engine
X57:8 003 13 Stecker Motor connector engine
X57:9 003 13 Stecker Motor connector engine
X57:9 004 8 Stecker Motor connector engine
X57:10 003 8 Stecker Motor connector engine
X57:11 003 8 Stecker Motor connector engine
X57:12 003 7 Stecker Motor connector engine
Seis
08.03.2007
Vogt
08.03.2007

X57:13 003 7 Stecker Motor connector engine

X57:13 004 7 Stecker Motor connector engine
X57:14 003 9 Stecker Motor connector engine
X57:14 004 7 Stecker Motor connector engine
X57:15 003 9 Stecker Motor connector engine
X57:15 004 9 Stecker Motor connector engine
X57:16 003 11 Stecker Motor connector engine
X57:17 003 10 Stecker Motor connector engine
X57:18 003 10 Stecker Motor connector engine
X57:19 003 10 Stecker Motor connector engine
X57:19 004 10 Stecker Motor connector engine
X57:20 003 6 Stecker Motor connector engine
X57:20 004 11 Stecker Motor connector engine
X57:21 003 6 Stecker Motor connector engine
X57:21 004 8 Stecker Motor connector engine
X57:22 003 6 Stecker Motor connector engine
X57:22 004 12 Stecker Motor connector engine
X57:23 003 11 Stecker Motor connector engine
X57:23 004 12 Stecker Motor connector engine
X57:23 004 17 Stecker Motor connector engine
X57:24 003 11 Stecker Motor connector engine
X57:24 004 15 Stecker Motor connector engine
X57:25 003 12 Stecker Motor connector engine
X57:25 004 13 Stecker Motor connector engine
X57:26 004 16 Stecker Motor connector engine
X57:27 004 15 Stecker Motor connector engine
X57:28 004 11 Stecker Motor connector engine
X57:28 004 17 Stecker Motor connector engine
X57:29 004 13 Stecker Motor connector engine
component listing

X57:29 004 18 Stecker Motor connector engine

X57:30 004 14 Stecker Motor connector engine
Bauteilliste

X57:31 004 14 Stecker Motor connector engine

X57:32 004 13 Stecker Motor connector engine
X57:33 004 16 Stecker Motor connector engine
X57:34 004 1 Stecker Motor connector engine
X57:35 004 1 Stecker Motor connector engine
X57:36 004 3 Stecker Motor connector engine
X57:37 004 5 Stecker Motor connector engine
X57:39 004 2 Stecker Motor connector engine
X57:40 004 4 Stecker Motor connector engine
X57:41 004 6 Stecker Motor connector engine
X57:42 004 5 Stecker Motor connector engine
X58:2 012 17 STECKER STVZO VL Con. STVZO FL
X58:3 012 7 STECKER STVZO VL Con. STVZO FL
X58:5 012 2 STECKER STVZO VL Con. STVZO FL
X58:6 012 2 STECKER STVZO VL Con. STVZO FL
X58:6 012 7 STECKER STVZO VL Con. STVZO FL
X58:6 012 17 STECKER STVZO VL Con. STVZO FL
X59:2 012 19 STECKER STVZO VR Con. STVZO FR
X59:3 012 7 STECKER STVZO VR Con. STVZO FR
X59:5 012 2 STECKER STVZO VR Con. STVZO FR
X59:6 012 2 STECKER STVZO VR Con. STVZO FR
X59:6 012 7 STECKER STVZO VR Con. STVZO FR
X59:6 012 19 STECKER STVZO VR Con. STVZO FR
X60:1 012 18 STECKER STVZO HL Con. STVZO BL
X60:2 012 18 STECKER STVZO HL Con. STVZO BL
X60:3 012 6 STECKER STVZO HL Con. STVZO BL
X60:4 012 6 STECKER STVZO HL Con. STVZO BL
X61:1 012 19 STECKER STVZO HR Con. STVZO BR
X61:2 012 19 STECKER STVZO HR Con. STVZO BR
X61:3 012 8 STECKER STVZO HR Con. STVZO BR
X61:4 012 8 STECKER STVZO HR Con. STVZO BR
X62:1 008 19 STECKER DIOS PLATTEN con. DIOS−plates
X62:2 008 19 STECKER DIOS PLATTEN con. DIOS−plates
X62:3 008 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:4 008 16 STECKER DIOS PLATTEN con. DIOS−plates
X62:5 008 16 STECKER DIOS PLATTEN con. DIOS−plates
X62:6 008 17 STECKER DIOS PLATTEN con. DIOS−plates
10

X62:7 008 17 STECKER DIOS PLATTEN con. DIOS−plates

X62:8 008 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:9 008 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:10 008 18 STECKER DIOS PLATTEN con. DIOS−plates
X62:11 008 15 STECKER DIOS PLATTEN con. DIOS−plates
11

X62:12 008 17 STECKER DIOS PLATTEN con. DIOS−plates

X62:13 008 19 STECKER DIOS PLATTEN con. DIOS−plates
X62:14 008 20 STECKER DIOS PLATTEN con. DIOS−plates
X62:15 008 19 STECKER DIOS PLATTEN con. DIOS−plates
582 702 32

X63:1 008 13 SCHNELLVERSCHLUSSKUPP quick connecting clutch

X63:1 008 14 SCHNELLVERSCHLUSSKUPP quick connecting clutch
X63:2 008 13 SCHNELLVERSCHLUSSKUPP quick connecting clutch
X63:2 008 14 SCHNELLVERSCHLUSSKUPP quick connecting clutch
X65:1 011 5 KEYBOARD Keyboard
110

X65:2 011 5 KEYBOARD Keyboard

X65:3 011 5 KEYBOARD Keyboard
1364 X65:4 011 5 KEYBOARD BOMAG
Keyboard 008 914 20
Name Bl. Pf. Benennung title TYP
X65:5

X65:8
011
Wiring diagram 582 702 32
X65:7 011
011
5
5
12
KEYBOARD
KEYBOARD
KEYBOARD
Keyboard
Keyboard
Keyboard
21.3
X65:9 011 5 KEYBOARD Keyboard
X65:10 011 5 KEYBOARD Keyboard
X65:11 011 5 KEYBOARD Keyboard
X65:12 011 5 KEYBOARD Keyboard
X66:2 004 19 ANSCHLUß EMR3 VORGLÜH connector EMR3 preglow
X66:3 004 20 ANSCHLUß EMR3 VORGLÜH connector EMR3 preglow
X67:1 002 15 STECKER KRAFTSTOFFHEI connector fuel pre−heater
X67:2 002 15 STECKER KRAFTSTOFFHEI connector fuel pre−heater
X68:1 011 15 STECKER LED connector led
X68:2 011 16 STECKER LED connector led
X69:1 014 13 STECKER FRISCHLUFT LÜ connector fresh air blower
Seis
08.03.2007
Vogt
08.03.2007

X69:2 014 13 STECKER FRISCHLUFT LÜ connector fresh air blower

X70:2 010 16 SUB−D STECKER SUB−D Connector
X70:3 010 16 SUB−D STECKER SUB−D Connector
X70:5 010 16 SUB−D STECKER SUB−D Connector
X71:3 010 9 STECKER GPS ANTENNE connector GPS Receiver
X71:5 010 9 STECKER GPS ANTENNE connector GPS Receiver
X71:6 010 9 STECKER GPS ANTENNE connector GPS Receiver
X71:7 010 9 STECKER GPS ANTENNE connector GPS Receiver
X71:8 010 9 STECKER GPS ANTENNE connector GPS Receiver
X71:10 010 9 STECKER GPS ANTENNE connector GPS Receiver
X71:12 010 9 STECKER GPS ANTENNE connector GPS Receiver
X72:A 010 12 STECKER ANSCHL. GPS Connector GPS
X72:B 010 12 STECKER ANSCHL. GPS Connector GPS
X72:C 010 12 STECKER ANSCHL. GPS Connector GPS
X72:D 010 12 STECKER ANSCHL. GPS Connector GPS
X72:E 010 12 STECKER ANSCHL. GPS Connector GPS
X73:A 010 13 STECKER VERS. GPS Connector Supply GPS
X73:B 010 13 STECKER VERS. GPS Connector Supply GPS
X73:C 010 13 STECKER VERS. GPS Connector Supply GPS
X74:1 009 14 STECKER DRUCKER con. printer
X74:2 009 14 STECKER DRUCKER con. printer
X74:3 009 14 STECKER DRUCKER con. printer
X74:4 009 15 STECKER DRUCKER con. printer
X74:5 009 14 STECKER DRUCKER con. printer
X75:2 010 18 SUB D STECKER BCM INT SUB D Connector BCM
X75:7 010 17 SUB D STECKER BCM INT SUB D Connector BCM
X76:1 010 16 STECKER VERS. BCM con. Power−sup. BCM
X76:2 010 16 STECKER VERS. BCM con. Power−sup. BCM
X77:1 014 15 STECKER PUMPE STANDHE Conn. pump add. heater
component listing

X77:2 014 15 STECKER PUMPE STANDHE Conn. pump add. heater

X78:1 010 10 STECKER RTK−MODUL GPS Connector RTK−module GPS
Bauteilliste

X78:2 010 11 STECKER RTK−MODUL GPS Connector RTK−module GPS

X78:3 010 11 STECKER RTK−MODUL GPS Connector RTK−module GPS
X78:4 010 11 STECKER RTK−MODUL GPS Connector RTK−module GPS

Y04 007 17 Magnetventil Bremse Solenoid valve, brake MAX. 1.8A

Y07 007 15 D*Prop. Ventil Vibration groß E*prop. Valve vibration high 0.4 .. 1.2A
Y08 007 13 D*Prop. Ventil Vibration groß E*prop. Valve vibration high 0.4 .. 1.2A
Y14 014 15 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 014 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y16 005 13 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 0.4 .. 1.2A
Y17 005 12 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 0.4 .. 1.2A
Y30 005 15 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 0.4 .. 1.2A
Y31 005 16 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear 0.4 .. 1.2A
Y92 007 6 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. 0.4 .. 1.2A
Y93 007 5 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. 0.4 .. 1.2A
Y98 008 14 Magnetventil Vibrationsfrequenz, hinten Solenoid valve, vibrat.freq.,rear 0.4 .. 1.2A
Y122 008 16 Magnetventil Platten heben Solenoid valve, lift plates MAX. 1.8A
Y123 008 17 Magnetventil Platten senken Solenoid valve, let down plates MAX. 1.8A
Y137 003 10 EMR Verstellung EMR adjustment
Y137 004 10 EMR Verstellung EMR adjustment
Y138 014 10 Magnetveentil Heizung Solenoid valve, heating unit 1A
Y140 009 10 Magnetventil Erreger auf solenoid valve exciter up 0.4 .. 1.2A
Y141 009 11 Magnetventil Erreger ab solenoid valve exciter down 0.4 .. 1.2A
Y142 008 17 Magnetventil Plattenverschieben Links solenoid valve, plate displace left MAX. 1.8A
Y143 008 18 Magnetventil Plattenverschieben rechts solenoid−valve, plate displace right MAX. 1.8A
Y144.1 008 19 MAX. 1.8A
Y144.2 008 19 MAX. 1.8A
Y145 008 20 Magnetventil Platten (Priorität) solenoid−valve, plate (priority) MAX. 1.8A
Y147 004 1 Injektor A1 jet pump A1
Y148 004 3 Injektor A2 jet pump A2
Y149 004 5 Injektor A3 jet pump A3
Y166 004 2 Injektor A4 jet pump A4
Y169 004 6 Injektor A6 jet pump A6
Y170 004 4 Injektor A5 jet pump A5
11
11
582 702 32
111

008 914 20 BOMAG 1365

1366
21.3

X38
X37
X36

A80

BOMAG
Nur bei StvzO
only acc. To StvZO illumination

A02 R10 K05

K11 K16 K06

Nur bei Klimaanlage

K09 K43
only acc. to aircond.

K48

K61
B57
K41

X32:1-12 X34:1-19
Wiring diagram 582 702 32

008 914 20
Gez.: 08.03.2007 Seite: 1 von: 2
Name: Vogt Übersicht Schaltkasten BW 177...226 DH/BVC-4 page: 1 from: 2
582 702 32
Gepr.: 08.03.2007 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box BW 177...226 DH/BVC-4 Replaces: Sheet No.: 201
Nur bei VM8
only acc. To VM8

F1 F2 CAN 1

008 914 20
Wiring diagram 582 702 32

LCD+
CAN 1
Datensammler

A34
Fahrsteuerung

CAN 2 EMR + Fahrhebel

BOMAG
CAN 1 OPUS 21

A83
Messtechnik Steuerung

CAN 3 BCM

Gez.: 08.03.2007 Seite: 2 von: 2

Name: Vogt Übersicht Schaltkasten-Tür BW 177...226 DH-4 page: 2 from: 2
582 702 32
21.3

1367
Gepr.: 08.03.2007 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box door BW 177...226 DH-4 Replaces: Sheet No.: 201
21.3 Wiring diagram 582 702 32
WAGO smart DESIGNER 4.1

1 057 564 17

2 280-315
3 2 x 057 564 25 "L" + 793-501

5 2 x 057 564 25 "L" + 057 564 20 + 793-501

7 057 564 22
8 4 x 057 564 23 "L" + 057 564 19 + 793-501

12 18 x 057 564 36 "R" + 057 564 19

+ 793-501

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

12.03.2007 12:11:33 Seite 1

1368 BOMAG 008 914 20

Wiring diagram 582 702 32 21.3
WAGO smart DESIGNER 4.1

30 4 x 057 564 36 "R" + 793-501

34 057 564 35
35 057 564 17

36 057 564 21
37 2 x 057 564 25 "L" + 793-501

39 3 x 057 564 25 "L" + 057 564 20 + 793-501

42 5 x 057 564 25 "L" + 793-501

47 8 x 057 564 25 "L" + 057 564 20 + 793-501

55 057 564 25 "L" + 793-501

56 4 x 057 564 38 "L" + 793-501

60 057 564 17

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

12.03.2007 12:11:33 Seite 2

008 914 20 BOMAG 1369

21.3 Wiring diagram 582 702 32
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

12.03.2007 12:11:46 Seite 3

1370 BOMAG 008 914 20

Wiring diagram 582 702 32 21.3
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

12.03.2007 12:11:46 Seite 4

008 914 20 BOMAG 1371

21.3 Wiring diagram 582 702 32
WAGO smart DESIGNER 4.1

1 057 564 17

2 3 x 057 565 40 "R" + 793-501

5 057 565 35 "R" + 793-501

6 057 565 37
7 3 x 057 565 40 "R" + 793-501

10 057 565 37
11 057 565 40 "R" + 793-501
12 057 565 35 "R" + 793-501

13 057 565 37
14 2 x 057 565 38 "R" + 793-501

16 2 x 057 565 39 "R" + 793-501

18 057 565 37
19 4 x 057 565 40 "R" + 793-501

23 057 565 37
24 4 x 057 565 40 "R" + 793-501

28 2 x 057 565 39 "R" + 793-501

30 057 565 37
31 057 565 40 "R" + 793-501
32 057 565 39 "R" + 793-501

33 057 565 37
34 4 x 057 565 40 "R" + 793-501

38 057 565 35 "R" + 793-501

39 057 565 37
40 4 x 057 565 40 "R" + 793-501

44 057 565 37
45 057 565 40 "R" + 793-501
46 057 565 35 "R" + 793-501

47 057 565 37
48 057 565 40 "R" + 793-501
49 057 565 35 "R" + 793-501

50 057 565 37

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

12.03.2007 12:15:44 Seite 1

1372 BOMAG 008 914 20

Wiring diagram 582 702 32 21.3
WAGO smart DESIGNER 4.1

51 057 565 38 "R" + 793-501

52 2 x 057 565 40 "R" + 793-501

54 057 565 38 "R" + 793-501

55 057 565 37
56 3 x 057 565 40 "R" + 793-501

59 057 565 38 "R" + 793-501

60 057 565 37
61 3 x 057 565 40 "R" + 793-501

64 057 565 35 "R" + 793-501

65 057 565 37
66 2 x 057 565 40 "R" + 793-501

68 057 565 35 "R" + 793-501

69 057 565 37
70 3 x 057 565 40 "R" + 793-501

73 057 565 35 "R" + 793-501

74 057 565 37
75 2 x 057 565 40 "R" + 793-501

77 2 x 057 565 35 "R" + 793-501

79 057 565 37
80 057 565 40 "R" + 793-501
81 057 565 39 "R" + 793-501

82 057 565 37
83 057 564 17

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

12.03.2007 12:15:44 Seite 2

008 914 20 BOMAG 1373

21.3 Wiring diagram 582 702 32
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

12.03.2007 12:15:57 Seite 3

1374 BOMAG 008 914 20

Wiring diagram 582 702 32 21.3
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

12.03.2007 12:15:57 Seite 4

008 914 20 BOMAG 1375

21.3 Wiring diagram 582 702 32
WAGO smart DESIGNER 4.1

1 057 564 17

2 2 x 057 565 40 "R" + 793-501

4 057 565 37
5 2 x 057 565 40 "R" + 793-501 + 057 565 36

7 057 565 39 "R" + 793-501

8 057 565 37
9 057 565 38 "R" + 793-501
10 2 x 057 565 40 "R" + 793-501

12 057 565 38 "R" + 793-501

13 057 565 37
14 2 x 057 565 40 "R" + 793-501

16 057 565 39 "R" + 793-501

17 057 565 37
18 057 565 40 "R" + 793-501
19 057 565 38 "R" + 793-501

20 057 565 40 "R" + 793-501

21 057 565 37
22 057 565 40 "R" + 793-501
23 057 565 39 "R" + 793-501

24 057 565 37
25 057 564 21
26 2 x 057 564 38 "L" + 793-501

28 057 564 25 "L" + 793-501

29 057 564 36 "R" + 793-501

30 057 564 35
31 057 564 17

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Messtechnik DH / BVC* Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Klemmenleiste X2 Lieferadresse :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Optional7 : Größe der Bohrung : 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

12.03.2007 12:49:55 Seite 1

1376 BOMAG 008 914 20

Wiring diagram 582 702 32 21.3
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

12.03.2007 12:50:02 Seite 2

008 914 20 BOMAG 1377

21.3 Wiring diagram 582 702 32
WAGO smart DESIGNER 4.1

1 057 564 17

2 4 x 057 565 40 "R" + 793-501

6 057 565 37
7 2 x 057 565 40 "R" + 793-501

9 4 x 057 565 38 "R" + 793-501

13 2 x 057 565 39 "R" + 793-501

15 057 565 37
16 057 564 17

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : E2 Beleuchtung Artikelnummer lang :
Zeichnung : gezeichnet: : M. Vogt TEE
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Option E2 StvZO Beleuchtung Lieferadresse :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Optional7 : Größe der Bohrung : 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

03.01.2007 10:28:28 Seite 1

1378 BOMAG 008 914 20

Wiring diagram 582 702 32 21.3
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Copyright WAGO. Technische Änderungen vorbehalten.

03.01.2007 10:28:30 Seite 2

008 914 20 BOMAG 1379

X71 X72
X70 X73

1380
X74 X75 X77
X55
X56 X76 X53 X54
21.3

X29
X28 X21
X39 X23
X11 X24
X12 X50
X59 X40 X25 X41
X13
X58 X42 X51 X43 X57
X20
X69 X46 X14

X18 X30 X77

X33 X6 X7
X17 X52
X47 X19 X31 X4 X3
X67 X8 X15 X16
X48 X49 X10
(BVC) (BVC)
X36 X26 X60
X37 X1 X27 X61 X62
X38 X2
X9
X44
X35
X32 X34

BOMAG
X71
X61
X72
X77 X9
X21
X73 X74 X70
X59 X62
X75 X76
X67 X8
X42 X23
X11 X24
X12 X50 X57
X10
X46 X25 X41
X13 X51
X56
X53
X20
X29 X18
X17 X14
X28 X19 X55 X6 X7
X54 X15 X16
X69 X39
X43
X40

X77 X30
X58 X52 X33
X31 X4 X3
X36 X35 X1 X26
X37 X44 X2 X27
X38 X32 X60
X47
X48 X49
(BVC) (BVC)
Wiring diagram 582 702 32

008 914 20
Gez.: 08.03.2007 Seite: 1 von: 1
Name: Vogt Übersicht Schaltkasten-Tür BW 177...226 DH-4 page: 1 from: 1
582 702 32
Gepr.: 08.03.2007 Ers. f.: Blatt Nr.: 301
Name: Seis overview e-box door BW 177...226 DH-4 Replaces: Sheet No.: 301
21.4 Wiring diagram 582 702 39

008 914 20 BOMAG 1381

21.4 Wiring diagram 582 702 39

S/N Wiring diagram 582 702 39

S/N 101 582 121 007  101 582 121 023 Variocontrol
S/N 101 582 131 002  101 582 131 005 Variocontro +l
S/N 101 582 641 097  101 582 641 150 BW 216 DH-4
S/N 101 582 651 006  101 582 651 007 BW 216 PDH-4
S/N 101 582 771 293  101 582 771 515 BW 219 DH-4
S/N 101 582 781 021  101 582 781 034 BW 219 PDH-4
S/N 101 582 861 043  101 582 861 108 BW 226 DH-4 BVC
S/N 101 582 881 015  101 582 881 034 BW 226 DH-4
S/N 101 582 891 007  101 582 891 008 BW 226 PDH-4
S/N 101 583 141 138  101 583 141 362 BW 213 DH-4
S/N 101 583 151 012  101 583 151 035 BW 213 PDH-4
S/N 101 583 161 074  101 583 161 175 BW 213 DH-4 BVC
S/N 101 583 191 011  101 583 191 019 BW 214 DH-4
S/N 101 583 281 001  101 583 281 037 BW 177 DH-4 BVC
S/N 101 583 321 001  101 583 321 012 BW 177 DH-4
S/N 101 583 331 001  101 583 331 053 BW 179 DH-4
S/N 101 583 371 006  101 583 371 033 BW 213 DH-4 with attachment plate
S/N 101 583 061 031  101 583 061 082 BW 213 DH-4 BVC with attachment plate

1382 BOMAG 008 914 20

Inhaltsverzeichnis: BW 177..226 DH−4

008 914 20
table of contents: BW 177..226 DH−4
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 582 702 39 Stromlaufplan Circuit Diagram
002 582 702 39 Versorgung, Starten, Hupe supply, starting unit, signal horn
003 582 702 39 Vorglühen, Kraftstoffvorheizung Glowing, Fuel pre heating
004 582 702 39 Motor Deutz EMR II engine Deutz EMR II
005 582 702 39 Motor Deutz EMR III engine Deutz EMR III
Wiring diagram 582 702 39

006 582 702 39 Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch
007 582 702 39 Datensammler, LC−Display data−collector, LC−display
008 582 702 39 Lenkung, Vibration steering, vibration
009 582 702 39 Fahrhebel, Vibrationsplatten joystick, vibration−plates
010 582 702 39 Variocontrol, Messtechnik Variocontrol, measurement equipm.
011 582 702 39 Bomag Compaction Management BCM, GPS Bomag Compaction Management BCM, GPS
012 582 702 39 Diebstahlschutz System DH−4 anti − theft system
013 582 702 39 Beleuchtung und StvZO illumination and StvZO
014 582 702 39 Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph
015 582 702 39 Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater
101 582 702 39 Bauteilliste component listing

BOMAG
06.12.2007
001 001
Vogt Stromlaufplan 582 702 39
06.12.2007
21.4

1383
circuit diagram 001
Seis
F48:2

1384
3:2
F158:2 3:2 30
21.4

F159:2 3:2 K11

2:11
87
K30 14:1
30 5:1 K11:87 3:1

X1:15E X1:16E X1:27E X1:28E X1:30E

X1:9
F13 1 F05 1 F95 1 F23 1 F39 1

X1:10
30A 10A 10A 15A 15A
2 2 2 2 2
X1:15A X1:16A X1:27A X1:28A
X1:30A
X37:A X1:151

8:17
6:9

X36:B
30 21 11 31 41 51 61

X36:A
S00 S01 X3:3

22 12 32 42 52 62
Startschalter NOT−Aus
K32:86

2 x 10qmm
starting swwitch 15 54 58 19 17 50a Emerg.−Stop
X1:152 X1:155 14:1

X1:79
S01:22 4:1
X37:B
F05:2
V01 X1:3 X1:4 7:8
K05 30
2 1 9:3 3

Sicherung Heizflansch / Glühstiftkerzen

fuse heating−flange / glow plugs
S03

Sicherung Glühwendelkerze 1
fuse Glow plug 1
Sicherung Glühwendelkerzw 2
fuse glow plug 2
Hauptsicherung
main fuse
125mA
87 87a

X34:P
86

Bei EMR II, bei BW177DH−4 mit Deutz BF2012 Option

Option Winterpaket bei EMR III
at EMR II, at BW177DH−4 with Deutz BF2012 option
option winter package with EMR III
2 2 2 2 K61 1 K61 30
F48 F158 F159 F00
Bei Heizflansch 125A
R10 2:7 Taster Hupe
82 OHM push button, horn 4
at heating flange 125A

nur bei BW177DH−4 mit Deutz TCD2011 Tier 3

only at BW177DH−4 with Deutz TCD2011 Tier 3
Bei Glühstiftkerzen 80A
1 50A
1 50A
1 125A
1 85 2 87 87a X1:7 X1:8
at glow plugs 80A 30

BOMAG
D+ K13
7:2
2:18
B+ 2:12 2:8 B+ 87 87a
D+ MESX 10:2
G03 G01 X38:A X1:98
+ +
− −
X1:1 X1:101 X1:102
X1:109

nur bei Klimaanlage

only acc.to air conditioning
Anzugsw.:50A / Haltew.:10A

30 50
1 B+ D+ 86 86 B11 B11 86
K09 K11 1 2 1 K13

bei BW177DH−4 mit

Deutz BF2012 Option
at BW177DH−4 with
Deutz BF2012 option
G02 M01 XS +
S30 M
12V
2 V03 1 2 −

Option
option
85 85 − 85
2
B− W
X1 X1 X1 X1
X1:110 X1:168 X1:123
31 EMR 103 100 104 104
4:3
31 31 3:1
2:10 15:7 2:15 Signalhörer 2:16 Steckdose
Batterie Batterie Starter
battery battery starter warning horns socket

Trennschalter Batterie Generator Nur bei Geländer/ROPS/SD

break switch battery generator only at hand−rail/ROPS/sun−roof

06.12.2007
1 1
Wiring diagram 582 702 39

008 914 20
Vogt Versorgung, Starten, Hupe 582 702 39
06.12.2007
Seis supply, starting unit, signal horn 002
2:20 K11:87 K11:87 7:1

2:4 F159:2

2:4 F158:2

2:4 F48:2

008 914 20
X1:33E
1
F124
25A
2
X1:33A
Wiring diagram 582 702 39

5 30 30
5
K14.2 K14 K14.3 K15
5:20 4:7 3 4:14 87 4:15 87
3

X1:217

Option Winterpaket mit EMR III

option winter package with EMR III
Bei EMR II, bei BW177DH−4 mit Deutz BF2012 Option
at EMR II, at BW177DH−4 with Deutz BF2012 option
Serie bei EMR II in BW177DH−4 mit Deutz TCD2011
Series at EMR II on BW 177 DH−4 with Deutz TCD2011
Option Winterpaket
option winter package

BOMAG
X67:1

1
1 1 1 R79

R81
R83
R85
167A
50A
50A
2 2 2 2
1 1 1 1 1 1 X67:2
R19 R02 R78

nur bei 6 Zyl.

only at 6 Cyl.

R86

R82
R84
2 2 2 2 2 2

X1:218

2:20 31 31 4:1

Glühstiftkerzen Heizflansch Glühwendelkerze 1 Kraftstoffvorwärmung

glow plugs heating−flange glow plug 1 fuel pre−heater

Glühwendelkerze 2
glow plug 2

06.12.2007
001 001 582 702 39
Vogt Vorglühen, Kraftstoffvorheizung
06.12.2007
21.4

1385
Seis Glowing, Fuel pre heating 003
1386
2:16 S01:22 S01:22 5:1
21.4

X1:95 Bei BW177DH−4 mit X1:95

Deutz BF2012 Option
1 86 86
at BW177DH−4 with
Relais Heizflansch K14 Deutz BF2012 option Relais Glühwendelkerze 1 K14.3 K15 Relais Glühwendelkerze 2
Relay Glowplug 1 Relay Glowplug 2
relay heating−flange
2 85 85

X1:96 X1:96
X1:185 X1:185 Serie bei BW177DH−4
Steckerschnittstelle Deutz Steckerschnittstelle Deutz mit Deutz TCD2011
X1:179 connector interface Deutz connector interface Deutz Series at BW 177 DH−4
with Deutz TCD2011

X33:5
X33:10
X33:8
X33:11
X33:5
X33:6
X33:10
X33:7
EPC−Stecker 12pol EPC−Stecker 12pol

max 7A
A48
Motorsteuerung EMR2
engine−controller EMR2

X31:1
X31:2
X31:3
X31:7
X31:1
X31:6
X31:3
X31:7

X30:14
X31:21
X31:22
X31:13
X31:11
X31:14
X31:15
X31:24
X31:25
X31:4
X31:9
X31:5

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

L
K
+5V
STG−

AGND
AGND
AGND

Signal
Signal
Signal

Ubat −

CAN low

CAN high

BOMAG
X1:180
X1:181
CAN2− 5:15
CAN2+ 5:15

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

X1:183
X1:184
ESX Fahrst.
RF−
RF REF
3 2 1 1 2 1 2 7 2 6 1 1 4 3 2 1 2

RF MESS
EMR Stellglied
EMR commander
B88 B114 B130 Y137 5 B115 B113

X32:L
X32:K
X32:B

X32:H
X32:G

X32:A
X1:186
X34:N
X1:182
Diagnosestecker EMR
diagnosis interface EMR
2:6 5:18
31 31 EMR 31 EMR
3:20 31 5:1
3:7
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

06.12.2007
1 1
Wiring diagram 582 702 39

008 914 20
Vogt Motor Deutz EMR II 582 702 39
06.12.2007
Seis engine Deutz EMR II 004
2:14 30 30 6:1
4:20 S01:22 S01:22 8:1
Diagnosestecker EMR 4:4 CAN2+ CAN2+ 6:11
X1:14E Wasserabscheider
water−seperator diagnosis interface EMR 4:4 CAN2− CAN2− 6:11
1
F93
25A

008 914 20
2

X32:A
X32:K
X32:H
X32:G
X32:M
X32:F
X32:B
X1:14A
B124
86
K41 K41 30

5:2

Nur bei EMRIII

only EMRIII
X1:107 X1:108
87 87a
85
X1:179

X1:191

X1:193
X1:192

X1:194

X1:184
X1:185 X1:183 X1:198 X1:199 max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 3.5m
2.5 qmm in der hier dargestellten Installation (Querschnitt 2,5qmm)

A48
Motorsteuerung EMR3 (EDC 16)
engine−controller EMR3 (EDC16)

X30:1
X30:5
X30:3
X30:61

X30:63
X30:60

X30:72
X30:25
X30:62

X30:28
X30:82

X30:64

X31:47
X31:46
X31:33
X31:31
X31:48
X31:32
X31:50
X31:12
X31:19
X31:40
X31:14
X31:53
X31:43
X31:8
X31:58
X31:56
X31:13
X31:11
X31:57
X31:24
X31:34

X31:16
X31:1
X31:10
X31:20
X31:27
X31:7
X31:49
X31:23
X31:26
X31:41
X31:51
X31:54
X30:2
X30:4
X30:6

Sign.
Sign.

AGND
AGND
AGND
GND
GND
GND

Signal
AGND
AGND
AGND
AGND
AGND

Signal
Signal
Signal

Signal Druck
Signal Druck

Signal Temperatur

BOMAG
X57:34
X57:35
X57:39
X57:36
X57:40
X57:42
X57:37
X57:41
X57:14
X57:13
X57:9
X57:21
X57:15
X57:1
X57:19
X57:20
X57:28
X57:23
X57:22
X57:29
X57:32
X57:25
X57:31
X57:30
X57:24
X57:27
X57:26
X57:33
X57:28
X57:23
X57:29
X1:180
X1:181
X1:182
X1:186

X66:3

X66:2

3x2.5

4:5
31 31 EMR
4:20 31 6:1
5:3 3:3
EMR Stellglied EMR Kühlmitteltemperatur
EMR commander EMR coolant temperature

Injektor A1 Injektor A2 Injektor A3 Motordrehzahlsensor Ladeluftdruck + Temp EMR Motoröldruck

06.12.2007
1 1 582 702 39
Vogt Motor Deutz EMR III
06.12.2007
21.4

1387
Seis engine Deutz EMR III 005
30

1388
5:20 30 7:1
X1:2 5:20 CAN2+ CAN2+ 9:6
EMR Deutz Fahrhebel
FM3 8:5
5:20 CAN2− CAN2− 9:6
X1:145
21.4

F24:2 7:3 CAN1+ 7:8

31 LC−Display, OPUS 21
CAN1− 7:8
X1:119 X1:120
S01
2:15
120 OHM 120 OHM
X1:146 32 1 2 1 2

X52:1
X52:2
R22 R20
rt sw X1:17E X1:34E
Diagnosestecker Fahrzeug
1 1 1 diagnosis interface equipment
F67 F84 X34:G X34:H X34:C X34:D X34:A X34:B
B112
15A 10A
2 2 2
Drucksensor Fahrpumpe X1:17A X1:34A
pressure sensor drive pump
X1:34A

X1:63 FM3 X1:62

X1:51
X1:52
X1:53
X1:54
X1:47
X1:48
X1:49
X1:50
10:2
120 OHM 120 OHM
1 2 1 2
R23 R21

Drucksensor
Leistung
Elektronik
TxD
RxD
CAN2+
CAN2−
CAN1+
CAN1−

Pot. 15
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
X1:45 X1:44
Bandagenmotor

Fahrpumpe vorw.
Fahrpumpe rückw.

Rückfahrwarnsum.
+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

br
ws
br
ws
bl
+ +
dir. dir.

0,46A
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA

B60 B59 2,5V X14:B X9:1

speed
10:2 speed
DIR MESX S06 + + X16:1 1 X15:1 1 1 1
− X1:172 −
Y17 Y16
14:6 4V H14 Y30 Y31

sw
sw
SPEED TAC − b a
− 2 2 2 2
X1:174 10:2 X1:178 − S X1:46 X14:A X9:2 X16:2 X15:2
SPEED MESX
X1:82
X1:124
X1:142
X1:142
X1:143
X1:143

X1:55 8:4 10:2 X1:149 X1:117 X1:123 X1:123 X1:144 X1:124

31 PITCH MESX
5:20 31 7:1

Rückfahrwarnsummer Prop.−Pumpe Rückw. Prop.−Ventil Achsmotor

back up alarm buzzer prop−pump backwards prop.−Valve axle motor

06.12.2007
1 1
Wiring diagram 582 702 39

008 914 20
Vogt Fahrantrieb, Neigungssensor, Sitzkontakt 582 702 39
06.12.2007
Seis driving system, slope sensor, seat contakt switch 1 006
30
6:20 30 10:1
3:20 K11:87 K11:87 9:14
6:3 F24:2 F24:2 8:13

X1:29E 2:16 F05:2

6:17 CAN1+ CAN1+ 9:14
1

008 914 20
F24 ESX Fahrsteuerung CAN1− DIOS Platten
10A
6:17 CAN1− 9:14
2
X1:29A

X1:87 X1:88 X1:80 X1:86

X1:41

X1:39
X1:40
12:1

X34:R

VCC
CAN1 high
CAN1 low
CAN1 high
CAN1 low
Ub "30"
Ub "15"
not connected
not connected
Ub out
Wiring diagram 582 702 39

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
X27:2
X27:4
X27:9
X26:9
X26:1
X26:2
X26:6
X26:4
X26:11
X27:10
X27:11
X27:12
X27:1
X27:3
X29:1
X29:2
X29:4
X29:3
X29:5
X29:6

X27:5
X26:12
X28:2

GND
GND
GND

UIN1
DIN1
DIN1

AIN1

UIN3
UIN2

DIN3
DIN5
DIN9
DIN6
DIN3
DIN5
DIN6

DIN8
DIN2
DIN2

AIN2

DIN4
DIN4

DIN11

DIN10
Sepa1
Sepa2
GND/UIN3
X1:106 X1:111 X1:112 X1:105 X1:107 X1:108

BOMAG
BL 13:17 ECO
Low High 13 23 down up
BR 13:17 13 23
S127
BEL S139
13:4

14 24 14 24

D+ R03
2:8 P P Q
Schalter Motordrehzahl Schalter Frequenzverstellung
2 2 switch engine−rpm mode switch frequency−control
X21:2 X10:3 X8:2

0 .. 67 OHM
Nur bei EMRII
only EMRII
X1:117 X1:94 X1:94 X1:117 X1:164 X1:149 X1:82
31
6:20 31 8:1

06.12.2007
1 1 582 702 39
Vogt Datensammler, LC−Display
06.12.2007
21.4

1389
Seis data−collector, LC−display 007
S01:22 S01:22

1390
5:20
7:20 F24:2
X1:148 Lenkwinkelsensor
X23:1 steering angle sensor
9:1
21.4

X1:41
X1:201
X51:1 Lenkeinheit X1:187
B65 + A45 steering unit br
Aufnehmer Vibrationsmotor
S X22:1 sensor vibration motor
br +
X1:161 X41:1 X39:1 VCC B X39:2 X22:2 sw
S1 −
−
X1:160 X41:3 X40:1 X40:2 bei BW177 u. 213 m. Sauer Motor sw / bei BW213−226 m. Rexroth Motor bl
VCC B B16
bei BW177 u. 213 m. Sauer Motor bl / bei BW213−226 m. Rexroth Motor sw
X1:159 X41:4 X40:4 S2 X40:3

X1:203
B132 2 2 2 0V A ws X22:3
VIB
X1:162 X41:2 X39:4 0V A X39:3 X22:4 14:6
S1 gg bl

X1:55 X1:202
Lenkwink.
1 1 1

−
BTS BREMSE 9:2

X41:5
X41:7
X41:8
X41:6

Sig.
AGND

X34:J
X1:60 FM5 X1:61
X1:56 FM1 X1:57

X1:58 FM2 X1:59

X1:189
6:3 FM3

armrest−switch
X1:55

Schalter Armlehne
Vib.− Richtung
Vib.− Frequenz
BTS Bremse

6:6

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

X35:16
X35:20
X35:21
X35:43
X35:22
X35:2
X35:48
X35:3
X35:61

BOMAG
Bremse

Armlehne
Prop. out

30 K48 9:2
Warnsummer

X51:3

X51:2
X1:89 87 87a

Umsch. Amplitude
K43 8:12

Pumpe Vib.−Platten
X1:154 X1:196 X1:195 87 87a

Schnellverschl.−Platten
KA MESX
10:2 X1:147
X1:38
X35:22 GA MESX 11
9:13 10:2
X1:37 S01
X35:43
9:13 X1:116 X1:115 2:15
12
X1:150

400 ... 1.200mA

400 ... 1.200mA
150mA

X6:1 X7:1 10:2

X1:113
400 ... 1.200mA

1 1 K43 86 Y08 1 Y07 1 H07 BRAKE MESX

+ Y04 1
Y93 Y92
b d
2 2 85 2 2 − a1 2
X6:2 X7:2
max.1.8A

X1:149 X1:197 X1:197 X1:82 X1:117 X1:190

X1:118
7:20 9:1
31
31 Anbau 177DH: h.r. a Anbau 177DH: h.l. b
8:14 Anbau 213DH: unten Anbau 213DH: oben

Prop.−Ventil Vibration klein Magnetventil Bremse

prop. valve vibration small solenoid valve brake

Prop. Ventil lenken links Prop−Ventil Vibration groß

prop. valve steering left prop. valve vibration big

Prop. Ventil lenken rechts Warnsummer Störung

prop. valve steering right warning buzzer, failure

06.12.2007
1 1
Wiring diagram 582 702 39

008 914 20
Vogt Lenkung, Vibration 582 702 39
06.12.2007
Seis steering, vibration 008
8:2 X23:1 6:17 CAN2+ 7:14 CAN1+ CAN1+ 10:16
ESX Fahrst. LC−Display
6:17 CAN2− 7:14 CAN1− CAN1− 10:16BTM
7:20 K11:87 K11:87 10:1
Taster 1 = Platten rechts
push button 1 = plates right X1:31E
Taster 2 = Platten heben
push button 2 = lift plates

008 914 20
1 F145
Taster 3 = Vibration EIN/AUS Näherungssch. Platten oben
push button 3 = vibration ON/OFF 20A
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
X1:213
X1:214

Taster 8 = Infotaste 2

X1:156
push button 8 = Info button 2

X1:157
BTS BREMSE
8:18

br
br
3 2 + +

X63:1
X63:1
7
B135 B134
1 Fahrstufenschalter
4 − −
5 8 speed range selector
bl bl

S S

X63:2
X63:2
sw
ws
Wiring diagram 582 702 39

S42

+ −

quick connecting clutch

X35:43 X1:215
Ub in CAN− 8:11

X25:2
X25:4
X25:3
Bremse zu = 0V 1 7

Schnellverschluss − Kupplung
Bremse auf = Ub BTS Bremse CAN+
3 S55 6 X35:22
BTS zus. Fahrhebel +5V out
8:11
X1:153 4 5
travel lever
0V in 0V (Ref PIN5) X62:12
2 8 A54
Add1 AK Ext1 Platten Steuerung
X62:1

X62:3
X62:9
X62:2

9 11
X62:4
X62:10

Add2 AK Ext2
plate−controller
10 12
Stecker X23
Stecker X24
1 2 3 4 5 6 7 8

BOMAG
X62:5
X62:6
X62:7
X62:8

X62:11
X62:13
X62:15
X62:14

Ub out
OV out

DK Ext1
DK Ext3
DK Ext5
DK Ext6

DK Ext2
DK Ext4
X50:2
X50:3
X50:1

S − + Y123 1 Y143 1 Y144.2 1

X1:210
S35 K0G S09 13 S64 13 S36 13 S139
13 23 2 2 2
400 .. 1.200 mA

86 86 1 Y122 1 Y142 1 Y144.1 1 Y145 1

K48 K05 Y98
14 14 14 14
24
2 2 2 2 2
85 85

X1:149 X1:211 X1:212

8:20 31
10:1
8:17 2:12 31

06.12.2007
1 1 582 702 39
Vogt Fahrhebel, Vibrationsplatten
06.12.2007
21.4

1391
Seis joystick, vibration−plates 009
Beschleunigungssensoren Beschleunigungssensoren Aufnehmer Verstellmotor Drucker Bedieneinheit BEM Display Messtechnik BOP

1392
acc. sensor front acc. sensor rear sens. adjust. motor printer control−unit BEM display measurem. BOP
X1:34A
6:9
30
21.4

7:20 30 13:1
Pot 30

9:20 K11:87 K11:87 13:1

Pot 15
X2:47 X2:48 X2:49
F146:1 11:2 + −
X2:66
X2:70 X42:1 X42:2 X42:3

X46:B X46:A X46:E

X1:32E X1:35E
X2:77 P16 F1 F2
1 1 1
F148 F146
nur bei BEM
only at BEM

10A 15A
X2:56 X2:53 X2:60 X2:57 FM4 X2:71
2 2 2
X1:32A X1:35A X48:2 X48:1 X49:2 X49:1 X2:78 P33

CAN+
CAN−

F148:2 B62 B62 X2:67 X2:68

11:2

X4:C
X4:E

X4:D

+/sw
+/sw
−/gg −/gg X47:A X47:B
X46:D X46:F
nur bei BTM+/BTM prof
only at BTM+/BTM prof

X42:4 X42:5
15g/bl 15g/bl

−/sw
X74:3
X74:5
X74:4
9:20
X2:57 B61 P11 CAN1−

20g/br
20g/br
+/rt 9:20
DIOS Platten

X48:3 X48:4 X49:3 X49:4 S/ws

CAN1+

nur bei BTM prof

X74:1 X74:2

only at BTM prof

X2:54 X2:55 X2:58 X2:59 X47:C
X4:A X4:B
X2:50 X2:51
R24
X2:69 X2:64 X2:65 1 2

Pot. 15
Leistung
Elektronik
8.5V
AGND MESX

Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
Erregerpos.
RxD TxD CAN1+ 60 OHM CAN1−

BOMAG
X44:1

X44:7
X44:9
X44:5
X44:27
X44:26

X44:4

X44:31

X44:56
X44:57
X44:59
X44:60
X44:30

X44:58
X44:29
X44:23

X44:28
X44:54
A83
Messtechnik−Rechner
measurement calc. unit

X44:15
X44:38
X44:35
X44:14
X44:32
X44:36
X44:37
X44:41
X44:47
X44:46
X44:25
X44:53
X44:33

X44:3

X44:55
X44:65
X44:66
X44:67
X44:68

CAN3+ CAN3−
8:15 KA MESX
EVIB
GPS

GA MESX

Prop.
Prop.
GND
0..6VDC

8:15
SPEED MESX X1:85 11:2
6:3 CAN3−

400 .. 1.200mA
400 .. 1.200mA

DIR MESX X2:75 X2:73 X2:52 +

6:3
PITCH MESX Y140 1 Y141 1 P07 E X2:79 11:2
6:8 VIB CAN3+
BRAKE MESX

v.l.
v.r.

8:17 − X44:25 11:2

D+ MESX BEL MESX 2 2
2:8 13:4 X2:49 X2:76 X2:74 X2:63 X2:66 X1:82
31 31 11:1
9:20

Prop−Ventil Erreger auf EVIB−Meter

solenoid−valve exciter up EVIB−meter
Prop−Ventil Erreger ab nur bei BEM
solenoid valve exciter down only at BEM

06.12.2007
1 1
Wiring diagram 582 702 39

008 914 20
Vogt Variocontrol, Messtechnik 582 702 39
06.12.2007
Seis Variocontrol, measurement equipm. 010
10:18 CAN3−

10:18 CAN3+
10:4 F148:2

008 914 20
10:17 X44:25

10:5 F146:1

X2 80E
1 CAN3+ R25 CAN3−
F150 1 2
5A
2 60 OHM
X2 80A

X2 X2 X2 X2 X2
43 44 70 61 62
Wiring diagram 582 702 39

X4 X4 X4 X4 X4
H J G N M

X75:7 X75:2

X78:1
X78:2
X78:3
X78:4
X71:12 X72:A X73:A
A93 30 A87
X71:6 X72:B X73:B USB−CAN Schnittst.
15 USB−CAN Interface BCM
X71:5
TxD2 X76:1
X71:8

BOMAG
RxD2
X71:10 X72:E X70:3
TxD1
X71:3 X72:D X70:2
RxD1
X71:7 X72:C X70:5
GND
GPS Empfänger StarFire P15
X73:C X76:2
GPS Receiver StarFire
BCM 05
nur bei BCM
only at BCM
X4:F

nur bei StarFire GPS X2:63

only at StarFire GPS

10:20 31 31 12:1

06.12.2007
1 1 582 702 39
Vogt Bomag Compaction Management BCM, GPS
06.12.2007
21.4

1393
Seis Bomag Compaction Management BCM, GPS 011
1394
21.4

A67 1 2 3
Keyboard
keyboard
4 5 6

7 8 9

ANN 0 VAL

A66
Steuereinheit
control unit

X68:1 X68:2

BOMAG
+
H80
−

ZA
option

06.12.2007
1 1
Wiring diagram 582 702 39

008 914 20
Vogt Diebstahlschutz System DH−4 582 702 39
06.12.2007
Seis anti − theft system 012
10:3 K11:87 K11:87
10:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
F11 F18 F07 F08
15A 10A 15A 15A

008 914 20
30
X1:18A K06 X1:19A X1:25A
X1:26A
13:4 X1:305
X1:83

X3:4 X3:5 with cabin 30 49L 49R

Wiring diagram 582 702 39

STV1

X1:302
14:17 A02
STV2
14:17
X1:23E X1:24E
K16 30 31 82 L R
13:9 F09 F10
10A 10A
87 87a X1:23A X1:24A

BEL 7:9 BL
7:9
13 BR
7:9

S16 14

switch, working head lights

BOMAG
X1:304

13 23

Schalter Arbeitsbele
01

X1:311

X1:310
X1:319
X1:313

X1:312
X1:321
X1:314

X1:309
X1:303

X1:320
X1:322

S14

lights without StvZO

Anschluß Arbeitsschein−
werfer ohne StvZO
connection working head
X1:84
Warnblinkschalter 14 24
BEL MESX
X61:1

X61:3
X60:1

X59:5
X60:3
X59:3

X58:5
X58:3
X59:2

X58:2

switch, hazard light

Arbeitsscheinwerfer hinten links

working head lights, rear lh.
Arbeitsscheinwerfer hinten rechts
working head lights, rear rh.
Arbeitsscheinwerfer vorne links
working head lights, front lh.