Service - Manual

BW 211 D-4 / PD-4

BW 213 D-4 / PD-4
S/N 101 583 09 ....> S/N 101 583 10 ....>
S/N 101 583 08 ....> S/N 101 583 13 ....>

Single drum roller

Catalogue number.
008 911 49 03/2007
 Table of Contents

General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 24
Technical data 29
2.1 Technische Daten 30
2.2 Maintenance chart 38
2.3 Table of fuels and lubricants 40
2.4 Fuels and lubricants 40
Connection overview 45
3.1 Connection overview 46
Tests and adjustments 49
4.1 Special tools, tests and adjustments 50
4.2 Checking the rotation speeds 54
4.3 Checking / adjusting the neutral positions of the travel pump 56
4.4 Pressure tests in the travel circuit 58
4.5 Checking / adjusting the vibrator shaft speeds 60
4.6 Pressure measurements in the vibration circuit 61
4.7 Check the leakage rate of the vibration motor 62
4.8 Pressure test in steering circuit 63
Flushing and bleeding 65
5.1 Special tools for flushing 66
5.2 Flushing - general 71
5.3 Flushing schematic travel circuit (distribution travel pump) 73
5.4 Flushing the travel circuit (travel pump distribution) 75
5.5 Flushing schematic travel circuit (distribution axle motor) 81
5.6 Flushing the travel circuit (axle motor distribution) 86
5.7 Flushing schematic for vibration drive 91
5.8 Flushing the vibration circuit 92
5.9 Bleeding the travel circuit 96
5.10 Bleeding the vibration circuit 98
Fundamental electrics 101
6.1 Understanding circuit diagrams 102
6.2 Terminal designations 106
6.3 Current and voltage 110
6.4 Resistance 114
6.5 Series / parallel connection 116
6.6 Ohm's law 118
6.7 Electrical energy 118
6.8 Formula diagram 119
6.9 Metrology 120
6.10 Diodes, relays, fuses 122
6.11 Batteries 125
6.12 Three-phase generator 128
6.13 Electric starter 135

008 911 49 BOMAG 3

Table of Contents

6.14 Telemecanique switch 138

6.15 Inductive proximity switches 141
6.16 Angle sensor with current output 142
6.17 Plug connectors 143
6.18 Deutsch plug, series DT and DTM 144
6.19 Plugs and terminals in spring clamping technology 150
Special tools, electrics 155
7.1 Special tools, electrics 156
Electronic modules 165
8.1 Seat contact module 167
Speedometer Module 175
9.1 Speedometer module 176
Service Training 179
10.1 Electrics BEM (BOMAG Evib-meter) 181
10.2 Service Training 239
Engine 301
11.1 Diesel engine 302
11.2 Fuel filter and check valve 310
11.3 Check, clean the water separator 313
11.4 Change the fuel pre-filter cartridge 313
11.5 Change the fuel filter cartridge 314
11.6 Oil pressure switch and low oil pressure circuitry 315
11.7 Changing engine oil and oil filter cartridges 316
11.8 Coolant temperature switch 318
11.9 Disassembling and assembling the coolant temperature switch 319
11.10 Removing and installing the thermostat 320
11.11 Checking the thermostat in disassembled state 321
11.12 Change the coolant 322
11.13 Three-phase generator 324
11.14 Checking / replacing the ribbed V-belt 325
11.15 Boost fuel solenoid valve 327
11.16 Engine shut-down solenoid 328
11.17 Air filter, differential pressure switch 329
11.18 Service the combustion air filter 330
11.19 Heating flange on engine 332
11.20 Checking the heating flange control 335
11.21 Electric throttle control 336
11.22 Crankcase - disassembling and assembling the ventilation valve 337
11.23 Disassembling and assembling the starter 339
11.24 Engine monitoring 340
11.25 Adjusting the valve clearance 343
11.26 Adjusting the control piston play 345
11.27 Checking the compression 346
11.28 Engine 348
11.29 Special tools, Deutz engine (TCD 2013 2V) 350
Air conditioning system 369
12.1 Physical basics 370

4 BOMAG 008 911 49

 Table of Contents

12.2 Refrigerant R134a 373

12.3 Compressor oil / refrigeration oil 374
12.4 Working principle of the air conditioning system 375
12.5 Monitoring devices 375
12.6 Description of components 376
12.7 Checking the compressor oil level 382
12.8 Checking the magnetic clutch 383
12.9 Inspection and maintenance work 384
12.10 Checking, replacing the refrigerant compressor V-belt 384
12.11 Service the air conditioning 385
12.12 Drying and evacuation 388
12.13 Emptying in case of repair 388
12.14 Leak test 389
12.15 Filling instructions 390
12.16 Trouble shooting in refrigerant circuit, basic principles 393
12.17 Trouble shooting, refrigerant circuit diagram 397
12.18 Trouble shooting procedure 398
12.19 Steam table for R134a 408
12.20 Heating control / air conditioning control 413
Replacing the cab window panes 419
13.1 Assembly of window panes 420
13.2 Special tools 421
13.3 Auxiliary materials 422
13.4 Removing and installing the window pane 424
Drum 429
14.1 Special tools, drum, single drum rollers 430
14.2 Repair overview for drum 432
14.3 Removing and installing the drum 440
14.4 Repairing the drum 446
14.5 Dismantling, assembling the change-over weights 479
14.6 Changing the rubber buffers and adjusting the pretension 482
Oscillating articulated joint 485
15.1 Special tools 486
15.2 Repair overview oscillating articulated joint 488
15.3 Removing and installing the oscillating articulated joint 491
15.4 Dismantling the oscillating articulated joint 493
15.5 Assembling the oscillating articulated joint 498
Suppliers documentation 509
16.1 Travel pump series 90R 511
16.2 Travel drive series 51 601
16.3 Vibration pump 42R 041 683
16.4 Vibration motor A10FM 721
16.5 MS/MSE 02 ..... 18 745
16.6 Axle DANA 192 795
Circuit diagrams 919
17.1 Wiring diagram 921
17.2 Wiring diagram 957

008 911 49 BOMAG 5

Table of Contents

17.3 Hydraulic diagram 991

6 BOMAG 008 911 49

 1 General

008 911 49 BOMAG 7

1.1 Introduction

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

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

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

You should only use genuine BOMAG spare parts.

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

Danger
!

Please observe strictly the safety regulations in

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

8 BOMAG 008 911 49

Safety regulations
Important notes
1.2 Safety regulations
These safety regulations must be read and ap-
plied by every person involved in the repair of this
machine. The applicable accident prevention in-
structions and the safety regulations in the oper-
ating and maintenance instructions must be
additionally observed.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Any suggestions, safety precautions and warn-
ings in this section are intended as a mnemonic
aid for well trained and experienced expert me-
chanics. This manual should not be considered a
bible on workshop safety.
Workshop equipment and facilities as well as the
use and waste disposal of solvent, fluids, gases
and chemicals are subject to legal regulations,
which are intended to provide a minimum on safe-
ty. It is obviously your own responsibility to know
and adhere to these regulations.
This manual contain headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to avoid dangers for health and
for the environment.
Danger
! welding work
Paragraphs marked like this highlight possible
dangers for persons.
Caution
! Danger
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
i Note
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine.
Environment
Paragraphs marked like this point out practices
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Observe the regulations for the protection of the
environment.
General
l
Before starting repair work stand the machine on
level and solid ground.
l Always secure the machine against unintended roll-
ing.
l Secure the engine reliably against unintentional
starting.
008 911 49 BOMAG
1.2
Mark a machine that is defective or being repaired
l
by attaching a clearly visible warning tag to the
steering wheel.
l On machines with articulated joint keep the articu-
lated joint locked during work.
l Use protective clothes like hard hat, safety boots
and gloves.
l Keep unauthorized persons away from the machine
during repair work.
l Tools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
safe condition.
l Use only safe and approved lifting gear of sifficient
load bearing capacity to remove and install parts or
components from and to the machine.
l Be careful with cleansing agents. Do not use easily
inflammable or harmful substances, such as gaso-
line or paint thinners for cleaning.
l Cleaning or repair work on the fuel tank is very dan-
gerous. Do not smoke or allow any ignitable sparks
or open fire in the vicinity when cleaning or repairing
a tank. .
l
When performing welding work strictly comply with
the respective welding instructions.
Precautions and codes of conduct for
Welding work should only be performed by specially
instructed expert personnel.
!
Electric shock!
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
eyes!
Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
l Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
l Ensure good conductivity between earth cable and
work piece.
l Start the extraction fan before starting work and
guide with the progressing work as required.
l
Always isolate the burner when laying it down (re-
move possible electrode residues).
l Protect cables from being damaged, use cables
with insulated couplings.
l
Ensure sufficient fire protection, keep a fire extin-
guisher at hand.
9
1.2
l In case of welding work in fire or explosion endan-
gered environments, you should always ask for a
welding permission.
l Remove combustible parts from the vicinity or cover
such parts.
l Name a fire watch during and after welding work.
l Do not clamp the welding rod holder and the inert
gas welding gun under your arm and lay these parts
only on an insulated top.
l Place the inert gas bottles in a safe place and se-
cure them against falling over.
l Use a protective screen or an arcing shield with
welding glass, wear welding gloves and clothes,
this applies also for assisting persons.
l Switch the welding unit off before connecting weld-
ing cables.
Behaviour in case of faults
l Check electrode holders and electric cables at reg-
ular intervals.
l
In case of deficiencies switch off the welding unit
and inform supervising persons.
l
In case of an extractor fan failure or any other fault
inform the supervising persons.
Maintenance; waste disposal
l
Replace damaged insulating jaws and welding rod
holders immediately.
l
Replace the welding wire reels only in deenergized
state.
What to do in case of accidents; First Aid
l
Keep calm.
l
Call first air helpers.
l
Report the accident.
l In case of an electric accident: Interrupt the power
supply and remove the injured person from the
electric circuit. If breathing and heart have stopped
apply reactivation measures and call for an emer-
gency doctor.
Old oils
Prolonged and repetitive contact with mineral oils will
remove the natural greases from the skin and causes
dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
which could cause skin cancer. Appropriate skin pro-
tection agents and washing facilities must therefore
be provided.
l
Wear protective clothes and safety gloves, if possi-
ble.
l If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
10 BOMAG
Safety regulations
full face visor; a facility suitable for rinsing the eyes
should also be available.
l Avoid prolonged and repetitive contact with oil, es-
pecially with old oil. In case of open incisions and in-
juries seek medical advice immediately.
l Apply protective cream before starting work, so that
oil can be easier removed from the skin.
l Wash with soap and water to ensure that all oil has
been removed (a skin cleaning agent and a nail
brush will help). Lanolin containing agents will re-
place natural skin oils that were lost.
l Do not use gasoline, kerosene, diesel, thinner or
solvents to wash the skin.
l Do not put oil soaked cloths into your pockets.
l Avoid clothes, especially underpants, getting soiled
by oil.
l Overalls must be washed at regular intervals.
Clothes that cannot be washed, must be disposed
of.
l
If possible degrease components before handling.
Environment
It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Entrust
special companies with the waste disposal of old
oil. If in doubt you should consult your local au-
thorities.
Hydraulics
l Hydraulic oil escaping under pressure can pene-
trate the skin and cause severe injury. You should
therefore relieve the pressure in the system before
disconnecting any lines.
l Before applying pressure to the system make sure
that all line connections and ports have been prop-
erly tightened and are in perfect condition.
l Hydraulic oil leaking out of a small opening can
hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When
being injured by hydraulic oil consult a physician im-
mediately, as otherwise this may cause severe in-
fections.
l Do not step in front of or behind the drums/wheels/
crawler tracks when performing adjustment work in
the hydraulic system while the engine is running.
Block drums and/or wheels / crawler tracks with
wedges.
008 911 49
Safety regulations
Reattach all guards and safety installations after
all work has been completed.
Environment
It is strictly prohibited to drain off hydraulic oil
into the soil, the sewer system or into natural wa-
ters. Entrust special companies with the waste
disposal of old oil. If in doubt you should consult
your local authorities.
Fuels
Danger
!
Repair work on fuel systems must only be per-
formed by appropriately trained personnel.
The following notes refer to general safety precau-
tions for danger free handling of fuel. These notes are
only general instructions; in case of uncertainties you
should consult the person responsible for fire protec-
tion.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu-
tion with air creates an easily inflammable mixture.
The vapours are heavier than air and therefore sink
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por-
tion of spilled fuel is therefore potentially dangerous.
l Fire extinguishers charged with FOAM, SCHAUM,
CO2 GAS or POWDER must be available wherever
fuel is stored, filled in, drained off, or where work on
fuel systems is performed.
l The vehicle battery must always be disconnected,
BEFORE work in the fuel system is started. While
working on the fuel system you should not discon-
nect the battery, because this could generate
sparks, which would ignite explosive fuel vapours.
l
Wherever fuel is stored, filled, drained off or where
work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
against possible contact with running out fuel.
Hot fuels
Before draining fuel off the tank for repair work, you
must strictly apply the following measures:
l Allow the fuel to cool down, to prevent any contact
with a hot fluid.
l Vent the system, by removing the filler cap in a well
ventilated area. Screw the filler cap back on, until
the tank is finally emptied.
Synthetic rubber
Many O-rings, hoses and similar parts, which are ap-
parently made of natural rubber, are actually made of
008 911 49 BOMAG
1.2
plastic material, a so-called fluoroelastomer. Under
normal operating conditions this material is safe and
does not impose any danger to health.
However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
caustic hydrofluoric acid, which can cause severe
burns in contact with skin.
l If the material is in such a state it must only be
touched with special protective gloves. These
gloves must be disposed of directly after use.
l If the material has contacted the skin despite these
measures, take off the soiled clothes and seek
medical advice immediately. In the meantime wash
the affected parts of the skin for 15 to 60 minutes
with cold water or lime water.
Poisonous substances
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
Skin contact, especially with open wounds, should be
strictly avoided.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, washing additives,
lubricants and various bonding agents.
Engine
Danger
!
Do not work on the fuel system while the engine is
running - danger to life!
After the engine has stopped wait until the pres-
sure has dropped (on Commonm Rail engines ap-
prox. 5 minutes, other engines 1 minute), because
the system is under high pressure - danger to life!
Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
leaks - danger to life!
When performing work on the fuel system make
sure that the motor cannot be started unitention-
ally - danger to life!
l Maintenance and cleaning work on the engine must
onyl be performed with the engine stopped and
cooled down. Make sure that the electric system
has been switched off (ignition key pulled out).
l Observe the accident prevention regulations for
electric systems (e.g. -VDE-0100/-0101/-0104/-
0105 Electric precautions against dangerous con-
tact voltages).
l Cover all electric components properly before wet
cleaning.
11
1.2
Air conditioning system
Caution
!
Lines in the air conditioning system must only be
loosened by trained and explicitly instructed ex-
perts.
l Wear safety goggles! Put on your safety goggles.
This will protect your eyes against coming into con-
tact with refrigerant, which could cause severe
damage by freezing.
l Wear safety gloves and an apron! Refrigerant are
excellent solvents for greases and oils. In contact
with skin they will remove the protective grease film.
However, degreased skin is very sensitive against
cold temperatures and germs.
l Do not allow liquid refrigerants to come into contact
with skin! Refrigerant takes the heat required for
evaporation from the environment. Very low tem-
peratures may be reached. The results may be local
frost injuries (boiling point of R134a -26.5°C at am-
bient pressure).
l Do not inhale higher concentrations of refrigerant
vapours! Escaping refrigerant vapours will mix with
the ambient air and displace the oxygen required for
breathing.
l Smoking is strictly prohibited! Refrigerants may be
decomposed by a glowing cigarette. The resulting
substances are highly toxic and must not be in-
haled.
l Welding and soldering on refrigeration equipment!
Before starting welding or soldering work on vehi-
cles, (in the vicinity
of air conditioning components) all refrigerant must
be drawn out and the rests removed by blowing out
the system with nitrogen. The decomposition prod-
ucts created from the refrigerant under the influence
of heat not only are highly toxic, but also have a
strong corrosive effect, so that pipes and system
components may be attacked. The substance is
mainly fluorohydrogen.
l Pungent smell! In case of a pungent smell the afore
mentioned decomposition products have already
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respi-
ratory system, the lungs and other organs may be
harmed.
l When blowing out components with compressed air
and nitrogen the gas mixture escaping from the
components must be extracted via suitable exhaust
facilities (workshop exhaust systems).
Handling pressure vessels
l Since the fluid container is pressurized, the manu-
facture and testing of these pressure vessels is gov-
erned by the pressure vessel directive. (New edition
12 BOMAG
Safety regulations
from April 1989). Paragraph 10 of the pressure ves-
sel directive demands that these pressure contain-
ers must be periodically inspected and tested by a
specialist, according to paragraph 32. In this case
periodically recurring inspections consist of external
examinations, normally on containers in operation.
The refrigerant container must be visually inspected
two times per year, within the frame work of major
inspections. Special attention must thereby be paid
to signs of corrosion and mechanical damage. If the
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
erator or third parties against the dangers when
handling or operating pressure vessels.
l Secure pressure vessels against tipping over or roll-
ing away.
l Do not throw pressure vessels. Pressure vessels
may thereby be deformed to such an extent, that
they will crack. The sudden evaporation and escape
of refrigerant releases excessive forces. This ap-
plies also when snapping off valves on bottles. Bot-
tles must therefore only be transported with the
safety caps properly installed.
l
Refrigerant bottles must never be placed near heat-
ing radiators. Higher temperatures will cause higher
pressures, whereby the permissible pressure of the
vessel may be exceeded. The pressure vessel di-
rective therefore specifies that a pressure vessel
should not be warmed up to temperatures above 50
°C.
l
Do not heat up refrigerant bottles with an open
flame. Excessive temperatures can damage the
material and cause the decomposition of refriger-
ant.
l
Do not overfill refrigerant bottles, since any temper-
ature increase will cause enormous pressures.
Environment
In operation, during maintenance and repair work
and when taking refrigeration systems our of
service it is not permitted to let refrigerant escape
into the atmosphere, which would contradict the
current status of technology.
Battery
l Wear goggles and face protection (acid).
l Wear suitable clothes to protect face, hands and
body (acid).
l
Work and store accumulators only well ventilated
rooms. (Development of oxyhydrogen gas).
l Do not lean over the battery while it is under load,
being charged or tested. (Danger of explosion).
l Burning cigarettes, flames or sparks can cause ex-
plosion of the accumulator
l Keep ignition sources away from the battery.
008 911 49
Safety regulations
l Always shield eyes and face towards the battery.
l Do not use battery chargers or jump leads without
following the operating instructions.
l Keep the cell plugs closed.
l After an accident with acid flush the skin with water
and seek medical advice.
l Do not allow children access to batteries.
l When mixing battery fluid always pour acid into wa-
ter, never vice-versa.
1.2
l There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature.
l on machines with rubber tires a tire may busr if in-
correctly assembled. This can cause severe injury.
l Do not exceed the specified highest permissible tire
pressure.

Special safety regulations

l Use only genuine BOMAG spare parts for repair
purposes. Original parts and accessories have
been specially designed for this machine.
l We wish to make explicitly clear that we have not
tested or approved any parts or accessories not
supplied by us. The installation and/or use of such
products may therefore have an adverse effect on
the specific characteristics of the machine and
thereby impair the active and/or passive driving
safety. The manufacturer explicitly excludes any li-
ability for damage caused by the use of non-original
parts or accessories.
l
Unauthorized changes to the machine are prohibit-
ed for safety reasons.
l
If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine, danger of injury!
l
Do not perform cleaning work while the engine is
running.
l
If tests must be performed with the engine running
do not touch rotating parts of the engine, danger of
injury.
l Exhaust gases are highly dangerous. Always en-
sure an adequate supply of fresh air when starting
the engine in closed rooms.
l
Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
l Keep used filters in a separate waste container and
dispose of environmentally.
l
Dispose of oils and fuel environmentally when per-
forming repair or maintenance work.
l
Do not refuel in closed rooms.
l Do not heat up oil higher than 160 °C because it
may ignite.
l
Wipe off spilled oil and fuel.
l Do not smoke when refuelling or when checking the
acid level in the battery.
l Do not check the acid level of the battery with a na-
ked flame, danger of explosion!
l Old batteries contain lead and must be properly dis-
posed of.

008 911 49 BOMAG 13

1.3 General repair instructions

General Electrics
1.3 General repair instructions

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

Diagnostics according to plan

A structured approach in trouble shooting saves time
and helps to avoid mistakes and expenses, especially
in the fields of electrics and electronics. Understand-
ing electronic controls requires the knowledge of
some basic terms concerning their general perform-
ance. In many cases error logs are just simply read
out and control units are replaced without any further
trouble shooting. This is in most cases unnecessary
and, even more important, very expensive.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l
In approx. 10 % of the examined cases the prob-
lems were caused by control units.
l
In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).

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

14 BOMAG 008 911 49

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

Electrical system and welding work

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

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

008 911 49 BOMAG 15

1.3
Hydraulic system
Caution
!
Do not open any hydraulic components if you
have not been properly trained and without exact
knowledge.
Please note
Cleanliness is of utmost importance. Make sure that
no dirt or other contaminating substances can enter
into the system.
l Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt.
l Before disconnecting hoses, pipes or similar relieve
the system pressure with the engine shut down.
l During repair work keep all openings closed with
clean plastic plugs and caps.
l Do not run pumps and motors without oil.
l When cleaning hydraulic components take care not
to damage any fine machine surfaces.
l Chemical and rubber soluble cleansing agents may
only be used to clean metal parts. Do not let such
substances come in contact with sealing material.
l Rinse of cleaned parts thoroughly, dry them with
compressed air and apply anti-corrosion oil immedi-
ately. Do not install parts that show traces of corro-
sion.
l Avoid the formation of rust on fine machined caused
by hand sweat.
l Grease must not used as a sliding agent for assem-
bly work. Use hydraulic oil.
l
Do not start the engine after the hydraulic oil has
been drained off.
l Use only the specified pressure gauges. Risk of
damaging the pressure gauges under too high pres-
sure.
l Clean ports and fittings before removal so that no
dirt can enter into the hydraulic system.
l
Check the hydraulic oil level before and after the
work.
l Use only clean oil according to specification.
l Check the hydraulic system for leaks, find and rec-
tify the cause.
l Fill new hydraulic units with hydraulic oil before
starting operation.
l
After changing a component thoroughly flush and
bleed the entire hydraulic system.
l Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).
16 BOMAG
General repair instructions
l After changing a component perform a high and
charge pressure test, if necessary check the speed
of the exciter shaft.
l The operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
ing drum. If the soil is too hard place the drums on
old rubber tires. Do not activate the vibration on a
hard, concreted base, danger of bearing damage.
l
After the completion of all tests perform a test run
and then check all connections and fittings for leaks
with the engine still stopped and the hydraulic sys-
tem depressurized.
Before commissioning
l After changing a component clean the hydraulic oil
tank thoroughly.
l Fill the housings of hydraulic pumps and motors
with hydraulic oil.
l Use only hydraulic oils according to the specifica-
tion in the maintenance instructions.
l
After changing a component clean the hydraulic
system as described in the flushing instructions in
order to prevent all other components from being
damaged by abrasion and metal chips remaining in
the system.
l
Change the hydraulic oil filter.
Commissioning
l
Bleed the hydraulic circuits.
l
Start up the system without load.
l
Check the hydraulic oil level in the tank, fill up oil if
necessary.
After commissioning
l
Check system pressures and speeds.
l Check fittings and flanges for leaks.
l After each repair check all adjustment data, rota-
tional speeds and nominal values in the hydraulic
system, adjust if necessary.
l Do not adjust pressure relief valves and control
valves to values above their specified values.
008 911 49
General repair instructions
Air conditioning system
CFC - halon prohibition
The CFC - halon prohibition from May 06, 1991 regu-
lates the withdrawal from the use of CFC and the han-
dling of these refrigerants.
Contents:
Since 1995 CFC (R12) is no longer permitted for use
in new systems.
In operation, during maintenance and repair work and
when taking refrigeration systems our of service it is
not permitted to let refrigerant escape into the atmos-
phere, which would contradict the current status of
technology.
Work on refrigeration systems must only be carried
out by persons with well founded knowledge about
such systems and who have the necessary technical
equipment available.
The use of refrigerant must be documented.
Old systems should be converted to refrigerants
harmless to ozone (refrigerant substitutes).
For this reason the Federal Environmental Agency at
the end of 1995 published suitable replacement refrig-
erants for R 12. As a consequence old systems must
no longer be filled with R12. As soon as such a system
is opened for service, the system must be converted
to a suitable replacement or service refrigerant. Old
systems may still be used, as long as they are leak
tight. R 134a was nominated as replacement for R 12.
Inside the European Union the "EU-Directive 2037/
2000 on substances causing decomposition of the
ozone layer" regulates the production, use and avail-
ability of CFC and H-CFC.
l In case of a repair on the refrigeration system you
should first evacuate the air conditioning system for
at least 45 minutes to remove any moisture from the
system, before you start to refill. Moisture bonded in
the compressor oil / refrigeration oil (PAG oil) can
only be removed from the system by changing the
oil.
l
During repair work on refrigerant lines and compo-
nents, these must be kept closed as far as possible,
in order to prevent the invasion of air, moisture and
dirt, because the operational reliability of the system
can only be assured if all components in the refrig-
erant circuit are clean and dry from inside.
l Make sure that no dirt or foreign parts can enter into
the compressor or the air conditioning system. The
area around the refrigerant hoses should be
cleaned with a gasoline free solvent.
l All parts to be reused should be cleaned with a
gasoline free solvent and blow-dried with clean
compressed air or dried with a lint-free cloth.
l Before opening all components should have
warmed up to ambient temperature, to avoid that
008 911 49 BOMAG
1.3
damp air is drawn into the component by the differ-
ence in temperatures.
l Damaged or leaking parts of the air conditioning
must not be repaired by welding or soldering, but
must generally be replaced.
l Do not fill up refrigerant, but extract existing refrig-
erant and refill the system.
l Different types of refrigerant must not be mixed.
Only the refrigerant specified for the corresponding
air conditioning system must be used.
l Refrigerant circuits with refrigerant type R134a
must only be operated with the compressor oil / re-
frigeration oil approved for the compressor.
l Used compressor oil / refrigeration oil must be dis-
posed of as hazardous waste.
l Due to its chemical properties compressor oil / re-
frigeration oil must never be disposed of together
with engine or transmission oil.
l Compressor oil / refrigeration oil is highly hydro-
scopic. Oil cans must strictly be kept closed until
use. Oil rests should not be used, if the can had
been opened over a longer period of time.
l
All O-rings as well as pipe and hose fittings must be
oiled with compressor/refrigeration oil be-
foreiassembly.
l
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil / refrigeration oil
lost by exchanging the components, must be re-
placed with fresh oil.
l
A too high compressor oil / refrigeration oil level ad-
versely affects the cooling performance and a too
low oil level has a negative effect on the lifetime of
the compressor.
l
If a air conditioning unit needs to be opened, the
dryer must be replaced in any case.
l Always use new O-rings when reassembling the
unit.
l
Always use two spanners when connecting pipes or
hoses, to prevent the pipe end from being damaged
.
l Tighten screw fittings with the specified torque.
l
Check the connections of pipes, fittings or compo-
nents thoroughly; do not use if damaged.
l
Do not leave the refrigerant circuit unnecessarily
open to the atmosphere. Do not attempt to repair
bent or burst pipes.
l
Compressor valves must only be opened after the
system has been properly sealed.
l The use of leak detection colouring matter is not
permitted, because its chemical composition is un-
known and its effect on compressor oil and rubber
elements is not predictable. The use of leak detec-
17
1.3 General repair instructions

tion colouring matter makes any warranty claims Fuel hoses

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

18 BOMAG 008 911 49

General repair instructions 1.3
Gaskets and mating surfaces threads or splines. If no assembly sleeve is availa-
ble, you should use a plastic tube or adhesive tape to
Leaking or failing seals and gaskets can in most cases
prevent the sealing lip from being damaged.
be tracked down to careless assembly, causing dam-
age not only to the seal or gasket, but also to the mat-
ing surfaces. Careful assembly work is mandatory if
good results are to be achieved.
l Before assembling replacement seals make sure
that the running surface is free of pitting, flutes, cor-
rosion or other damage.
l
Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Sealing compound should only be used if specially
requested in the instructions. In all other cases
these joints should be assembled in dry condition.
l Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the Fig. 3
compound does not enter into oil galleries or blind l Lubricate the outer rim 1 (Fig. 3) of the seal and
threaded bores.
press it flat on the housing seat.
l
Before assembly remove any residues of old seal-
ing compound. Do not use any tools that could dam-
age the sealing surfaces. i Note
If possible, use a "bell" 1 (Fig. 3), to make sure that
l
Examine the contact faces for scratches and burrs,
the seal will not skew. In some cases it may be ad-
remove these with a fine file or an oilstone; take
visable to assemble the seal into the housing first, be-
care that no grinding dust and dirt enters into
fore sliding it over the shaft. Under no circumstances
tapped bores or enclosed components.
should the full weight of the shaft rest on the seal.
l
Blow lines, ducts and gaps out with compressed air,
If you have no proper service tools at hand, use a suit-
replace any O-rings and seals that have been dis-
able drift punch with a diameter which is about 0.4mm
lodged by the compressed air.
smaller than the outer diameter of the seal. Use VERY
Assembly of radial seals LIGHT blows with the hammer if no press is available.
l
Press or knock the seal into the housing, until it is
flush with the housing surface.

Fig. 2
l
Lubricate sealing lips 1 (Fig. 2) with clean grease; in
case of double seals fill the space between the seal-
ing lips with a generous amount of grease.
l
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.

i Note
If possible, use an assembly sleeve 1 (Fig. 2), to pro-
tect the lip from being damaged by sharp edges,

008 911 49 BOMAG 19

1.3 General repair instructions

Feather keys and keyways Ball and roller bearings

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

Fig. 4
l Clean and thoroughly examine the feather key.
l Debur and thoroughly clean the edges of the key-
way with a fine file before reassembling.

Fig. 5
l Remove any lubricant residues from the bearing to
be examined by washing it with gasoline or any oth-
er appropriate degreasing agent. Cleanliness is of
utmost importance for all related work.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. If necessary replace the bearing with
a new one, since these symptoms are first signs of
wear.
l
Hold the bearing with you thumb and the index fin-
ger by the inner race, rotate the outer race and
make sure that it runs without friction. Hold the
bearing by the outer race and repeat this test with
the inner race.
l
Move the outer race gently to and fro while holding
it by the inner race; check for resistance while rotat-
ing and replace the bearing if it does not work cor-
rectly.
l Lubricate the bearing with an appropriate lubricant
before reinstalling.

20 BOMAG 008 911 49

General repair instructions
l Check shaft and bearing housing for discolouration
or other signs of movement between bearing and
seats.
l Make sure that shaft and housing are free of burrs
before assembling the bearing.
l If a bearing of a pair of bearings shows any defects,
we highly recommend the replacement of both
bearings.
l On greased bearings (e.g. wheel bearings) fill the
space between bearing and outer seal with the rec-
ommended type of grease before assembling the
seal.
l Always mark the individual parts of separable bear-
ings (e.g. taper roller bearings) to enable correct re-
assembling. Never assemble the rollers to an outer
race that has already been used, replace the com-
plete bearing instead.
Fig. 6
Caution
!
When assembling the bearing to the shaft load
must only be applied to the inner race 1 (Fig. 6).
When fitting the bearing into the housing load
must only be applied to the outer race (2).
008 911 49 BOMAG
1.3
Screws and nuts
Tightening torque
!Caution
Always tighten nuts or screws to the specified
tightening torque. Tightening torques deviating
from the ones in the table are specially mentioned
in 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 be generally renewed.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
specified tightening torque you should first relieve
by a quarter turn and then tighten to the correct
torque.
l Before tightening you should lightly oil the thread, in
order to ensure low friction movement. The same
applies for self-locking nuts.
l Make sure that no oil or grease will enter into tapped
bores. The hydraulic power generated when turning
in the screw could cause breakage of the effected
part.
21
1.3
Strength classes of metric screws
The strength classes (from 3.6 to 12.9) are specified
for all strength classes from a nominal diameter of
5mm. The corresponding identification can be found
where allowed for by the shape of the screw.
Fig. 7 Identification of screws
Example: A screw is identified with 12.9.
The first number corresponds with 1/100 of the nomi-
nal tensile strength (minimum tensile strength) in N/
mm2.
l
The nominal tensile strength is 12 X 100N/mm2 =
1200 N/mm2.
The second number specifies 10-times the ration be-
tween lower yield point and nominal tensile strength
(yield point ratio).
i Note
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas-
tic deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
l The lower tensile strength is 9/10 X 1200 N/mm2 =
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
22 BOMAG
General repair instructions
Strength classes of metric nuts
Nuts are differentiated by three load groups. Each
load group has a special designation system for the
strength class assigned, so that the load group can be
clearly identified.
Nuts for screw joints with full load capability (4, 5,
6, 8, 10, 12)
Fig. 8 Identification of nuts
In a connection with a screw, these nuts 1 (Fig. 8)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
Strength class of Strength class of associated
nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
6 6.8
8 8.8
9 9.8
10 10.8
12 12.8
Nuts for screw joints with limited load factor (04,
05)
The preceding "0" indicates that, due to their low
height, nuts 2 (Fig. 8) in this group are only able to
withstand the force of a screw to a limited extent.
Nut height below 0.8 d (d = nominal dimension).
Nuts for screw joints without specified load factor
(11H, 14H, 17H, 22H)
This standard contains strength classes (hardness
classes) for nuts 3 (Fig. 8), for which no load values
can be specified, e.g. because of their shape and di-
mensions, but which can only be classified by their
hardness.
Nut height below 0,5 d (d = nominal dimension).
008 911 49
General repair instructions 1.3
Identification in clock system

Fig. 9 Identification of nuts in clock system

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

008 911 49 BOMAG 23

1.4 Tightening torques

The values specified in the table apply for screws:

1.4 Tightening torques

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

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

Tightening torques for screws with metric unified thread1

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

Tightening torques for screws with metric unified fine thread1

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

24 BOMAG 008 911 49

Tightening torques 1.4
Tightening torques for screws treated with anti-seizure paste OKS 2401 (copper paste)

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

Tightening torques for wheel nuts (fine thread) 1 2

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

008 911 49 BOMAG 25

1.4 Tightening torques

The values specified in the table apply for screws:

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

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

Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread

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

Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread

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

26 BOMAG 008 911 49

Tightening torques 1.4
Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread

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

008 911 49 BOMAG 27

1.4 Tightening torques

28 BOMAG 008 911 49

 2 Technical data

008 911 49 BOMAG 29

2.1 Technische Daten

BOMAG Central Service Seite 1 von 2

BOMAG Central Service - Technical data and adjustment values

Status: 2007-01-17

Product type: BW 211 D-4

Type No.: 583 09/10
Serial numbers from: 101 583 09/10 1001

Engine:
Type: TCD2013 L04 2V Tier3
Combustion principle: 4-stroke-Diesel
Cooling: Water
Number of cylinders: 4
Power acc. to ISO 9249: 99 kW
Power data at nominal speed of: 2200 1/min
Low idle speed: 700 - 800 1/min
High idle speed: 2200 - 2250 1/min
Spec. fuel consumption: 222 g/kWh
Valve clearance, inlet: 0,35 mm
Valve clearance, outlet: 0,45 mm
Opening pressure, injection valves: DCR/1600bar bar
Starter voltage: 12 V

Travel pump:
Type: 90R 075
System: Axial piston-swash plate
Max. displacement: 75 cm3/U
Max. flow ratio: 172,9 l/min
High pressure limitation: 400 +26 bar
Charge pressure, high idle: 26 bar

Travel motor, rear:

Type: 51D110
System: Axial piston-bent axle
Max. displacement (stage 1): 110 cm3/U
Min. displacement (stage 2): 69 cm3/U
Perm. leak oil quantity: 2 l/min
Rinsing oil quantity: 16 l/min
Rinsing oil pressure limitation: 16 bar

Drum drive:
Type: MSE 18 2CX
System: Radial piston
Displacement stage 1: 2800 cm3/U
Displacement stage 2: 1400 cm3/U
Perm. leak oil quantity: 2 l/min

Vibration pump:

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30 BOMAG 008 911 49

Technische Daten 2.1
BOMAG Central Service Seite 2 von 2

Type: 42R 041

System: Axial piston-swash plate
Max. displacement: 41 cm3/U
Starting pressure: 345+26 bar
Operating pressure, soil dependent: ca.100 bar

Vibration motor:
Type: A10FM 45
System: Axial piston-swash plate
Displacement: 45 cm3/U
Frequency: 30/35 Hz
Amplitude: 2 / 1 mm
Rinsing oil quantity: 6 l/min
Rinsing oil pressure limitation: 13 bar

Steering and charge pump:

Type: HY/ZFS11/16
System: Gear pump
Displacement: 16 cm3/U
Max. steering pressure: 175+26 bar

Steering valve:
Type: OSPC 500 ON
System: Rotary valve

Rear axle:
Type: CHC 192/51HD
Differential: No-Spin
Degree of locking: 100 %
Reduction ratio: 43,72

Filling capacities:
Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on
Ethane-diol-basis)
Engine oil: 10 l (SAE 15W-40, API CG-4 (for details see
maintenance manual))
Hydraulic oil: 60 l (HVLP 46 VI 150)
Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF)
Rear axle: 11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs: 2,9 l (SAE 90 EP, API GL 5)
AC refrigerant: 1300 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG Öl)

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008 911 49 BOMAG 31

2.1 Technische Daten

BOMAG Central Service Seite 1 von 2

BOMAG Central Service - Technical data and adjustment values

Status: 2007-01-17

Product type: BW 213 D-4

Type No.: 583 08/13
Serial numbers from: 101 583 08/13 1001

Engine:
Type: TCD2013 L04 2V Tier3
Combustion principle: 4-stroke-Diesel
Cooling: Water
Number of cylinders: 4
Power acc. to ISO 9249: 99 kW
Power data at nominal speed of: 2200 1/min
Low idle speed: 700 - 800 1/min
High idle speed: 2200 - 2250 1/min
Spec. fuel consumption: 226 g/kWh
Valve clearance, inlet: 0,35 mm
Valve clearance, outlet: 0,45 mm
Opening pressure, injection valves: DRC/1600bar bar
Starter voltage: 12 V

Travel pump:
Type: 90R 075
System: Axial piston-swash plate
Max. displacement: 75 cm3/U
Max. flow ratio: 172,9 l/min
High pressure limitation: 400 +26 bar
Charge pressure, high idle: 26 bar

Travel motor, rear:

Type: 51D110
System: Axial piston-bent axle
Max. displacement (stage 1): 110 cm3/U
Min. displacement (stage 2): 69 cm3/U
Perm. leak oil quantity: 2 l/min
Rinsing oil quantity: 16 l/min
Rinsing oil pressure limitation: 16 bar

Drum drive:
Type: MSE 18 2CX
System: Radial piston
Displacement stage 1: 2800 cm3/U
Displacement stage 2: 1400 cm3/U
Perm. leak oil quantity: 2 l/min

Vibration pump:

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32 BOMAG 008 911 49

Technische Daten 2.1
BOMAG Central Service Seite 2 von 2

Type: 42R 041

System: Axial piston-swash plate
Max. displacement: 41 cm3/U
Starting pressure: 345+26 bar
Operating pressure, soil dependent: ca.100 bar

Vibration motor:
Type: A10FM 45
System: Axial piston-swash plate
Displacement: 45 cm3/U
Frequency: 30/35 Hz
Amplitude: 2 / 1 mm
Rinsing oil quantity: 6 l/min
Rinsing oil pressure limitation: 13 bar

Steering and charge pump:

Type: HY/ZFS11/16
System: Gear pump
Displacement: 16 cm3/U
Max. steering pressure: 175+26 bar

Steering valve:
Type: OSPC 500 ON
System: Rotary valve

Rear axle:
Type: CHC 192/51HD
Differential: No-Spin
Degree of locking: 100 %
Reduction ratio: 43,72

Filling capacities:
Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on
Ethane-diol-basis)
Engine oil: 10 l (SAE 15W-40, API CG-4 (for details see
maintenance manual))
Hydraulic oil: 60 l (HVLP 46 VI 150)
Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF)
Rear axle: 11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs: 2,9 l (SAE 90 EP, API GL 5)
AC refrigerant: 1300 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG Öl)

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008 911 49 BOMAG 33

2.1 Technische Daten

Fig. 10

Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 211 D-4 2960 2250 1500 2268 2972 490 5808 60 60 25 2130
BW 211 PD-4 2960 2250 1480 2268 2972 490 5808 60 60 25 2130

1 BW 211 D-4 BW 211 PD-4

Weights
Operating weight (CECE) kg 10950 11930
with ROPS and cabin
Axle load, drum (CECE) kg 6280 7260
Rear axle load (CECE) kg 4670 4670
Static linear load kg/cm 29,5 -

Travel characteristics
Travel speed (1) km/h 0 ... 5 0 ... 5
Travel speed (2) km/h 0 ... 6 0 ... 6
Travel speed (3) km/h 0 ... 9 0 ... 9
Travel speed (4) km/h 0 ... 13,5 0 ... 13,5
Max. gradability (depend- % 47 47
ing on soil)

Engine
Engine manufacturer Deutz Deutz
Type TCD 2013 L04 2V TCD 2013 L04 2V
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO kW 99 99
3046
Rated speed rpm 2200 2200
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Permissible ambient tem- °C -20 ... +50 -20 ... +50
peratures

34 BOMAG 008 911 49

Technische Daten 2.1
1
BW 211 D-4 BW 211 PD-4

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

Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic

Vibration
Vibrating drum 1 1
Drive system hydrostatic hydrostatic
Frequency Hz 30/36 30/36
Amplitude mm 1,8/0,9 1,64/0,82

Tires
Tire size 23.1-26/12 PR TL C7 23.1-26/12 TL R1
Air pressure bar 1,4 1,4

Filling capacities
Engine Litres 10 10
Fuel Litres 340 340
Hydraulic oil Litres 60 60
Coolant Litres 16 16
1 The right for technical modifications remains reserved

008 911 49 BOMAG 35

2.1 Technische Daten

Fig. 11

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

1
BW 213 D-4 BW 213 PD-4

Weights
Operating weight (CECE) kg 12525 13025
with ROPS and cabin
Axle load, drum (CECE) kg 7000 7725
Rear axle load (CECE) kg 5525 5525
Static linear load kg/cm 32,9 32,9

Travel characteristics
Travel speed (1) km/h 0 ... 6 0 ... 6
Travel speed (2) km/h 0 ... 7 0 ... 7
Travel speed (3) km/h 0 ... 8 0 ... 8
Travel speed (4) km/h 0 ... 11 0 ... 11
Max. gradability without/ % 45/43 47/45
with vibration (soil de-
pendent)

Engine
Engine manufacturer Deutz Deutz
Type TCD 2013 L04 2V TCD 2013 L04 2V
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO kW 99 99
3046
Rated speed rpm 2200 2200
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2

36 BOMAG 008 911 49

Technische Daten 2.1
1
BW 213 D-4 BW 213 PD-4
Permissible ambient tem- °C -20 ... +50 -20 ... +50
perature

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

Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic

Vibration
Vibrating drum 1 1
Drive system hydrostatic hydrostatic
Frequency Hz 30/36 30/36
Amplitude mm 1,9/1,0 1,8/0,94

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

Filling capacities
Engine Litres 12,5 12,5
Fuel Litres 340 340
Hydraulic oil Litres 60 60
Coolant Litres 16 16
1 The right for technical modifications remains reserved

008 911 49 BOMAG 37

2.2 Maintenance chart

2.2 Maintenance chart

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 6000 operating hours

every 250 operating hours

every 500 operating hours

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

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

38 BOMAG 008 911 49

Maintenance chart 2.2

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 6000 operating hours

every 250 operating hours

every 500 operating hours

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

as required
5.29 Oil change in wheel hubs min. 1x per year X X
5.30 Oil change vibration bearings2 see foot note, X X
min. 1 x per year
5.31 Retighten the fastening of the axle X
on the frame
5.32 Tighten the wheel nuts X X
5.33 Check the ROPS X
5.34 Clean the oil bath air filter min. 1x per year X
5.35 Change hydraulic oil and breather fil- at least every 2 X
ter3 years
5.36 Change the hydraulic oil filter4 at least every 2 X
years
5.37 Change the coolant at least every 2 X
years
5.38 Replace the crankcase ventilation at least every 2 X
valve years
5.39 Electronic injector test EMR X
5.40 Service the combustion air filter min. 1x per year, X
safety cartridge
at least every 2
years
5.41 Adjusting the scrapers X
5.42 Adjust the parking brake X
5.43 Change the tires X
5.44 Change the fresh air filter in the cab- X
in
5.45 Tightening torques X
5.46 Engine conservation X
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h.
3 Also in case of repair in the hydraulic system.
4 Also in case of repair in the hydraulic system.

008 911 49 BOMAG 39

2.3 Table of fuels and lubricants

2.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil ACEA: E3-96/E5-02 or approx. 18,5 litres incl. oil
filter

API: CG-4/CH-4

SAE 10W/40

(-20 °C to +40 °C)

SAE 15W/40

(-15 °C to +40 °C)

Fuel

Diesel Winter diesel fuel approx. 340 litres

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

46 mm2/s at 40 °C

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

Drive axle Gear oil SAE 90, API GL5 approx. 9,5 litres

Wheel hubs Gear oil SAE 90, API GL5 approx. 1,9 per side

Air conditioning system Refrigerant R134A approx. 1400 g

Engine cooling system Cooling system protection agent approx. 16 litres

Tires Water approx. 295 litres

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

(MgCl2)

2.4 Fuels and lubricants

Engine oil
Quality
Lubrication oils are classified according to their per-
formance and quality class. Oils according to other
comparable specifications may be used.

Approved engine oils

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

40 BOMAG 008 911 49

Fuels and lubricants
The exact assignment of the approved oil qualities
and oil change intervals can be taken from the follow-
ing section "Lubrication oil change intervals".
Consult your local service station if in doubt.
Oil viscosity
Multi-purpose oils should be generally used.
Since lubrication oil changes its viscosity with the tem-
perature, the ambient temperature at the operating lo-
cation of the engine is of utmost importance when
choosing the viscosity class (SAE-class) .
Optimal operating conditions can be achieved by us-
ing the opposite oil viscosity chart (Fig. 12) as a refer-
ence.
Occasionally falling short of the temperature limits will
impair the cold starting ability, but will not cause any
engine damage. In order to keep the occurring wear
as low as possible, occasional exceeding of the limits
should not happen over a longer period of time.
Fig. 12
With their better temperature and oxidation stability
synthetic lubrication oils offer quite a few benefits.
Oil change intervals
The longest permissible time a lubrication oil should
remain in an engine is 1 year. If the following oil
change intervals are not reached over a period of 1
year, the oil change should be performed at least once
per year, irrespective of the operating hours reached.
008 911 49 BOMAG
2.4
ACEA1
E3-96/E5-02/E7-04/
E4-99/
E6-04 = 500 operating hours
API2
CG-4/CH-4/
CI-4 = 500 operating hours
!Caution
These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight and
for ambient temperatures higher than -10 °C.
When using fuels with a sulphur content of more
than 0.5% to 1% or under ambient temperatures
below -10 °C the oil change intervals specified in
the table must be halved. For fuels with a sulphur
content of more than 1% you should consult the
responsible service agency.
Fuels
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and en-
sure strict cleanliness when filling in. A higher sulphur
content has a negative effect on the oil change inter-
vals. Use only winter-grade diesel fuel under low am-
bient temperatures. The fuel level should always be
topped up in due time so that the fuel tank is never run
dry, as otherwise filter and injection lines need to be
bled.
When using fuels with a Cetan number < 49 poor
starting and white smoke can be expected, in particu-
lar in connection with low ambient temperatures.
The following fuel specifications are permitted: DIN/
EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS
2869: A1 and A2; ASTM D 975-78: 1-D and 2-D.
l DIN/EN 590
l BS 2869
l
ASTM D 975-78: 1-D and 2-D.
l Nato Codes: F-54, F-34, F44 and XF63
Winter fuel
Danger
!
Fire hazard!
Diesel fuels must never be mixed with gasoline.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At very
low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel.
1 Association des Constructeurs European d’Automobiles
2 American Petroleum Institute
41
2.4 Fuels and lubricants

In most cases a sufficient cold resistance can also be If the values of the analysis deviate, the water must be
achieved by adding flow enhancing fuel additives. treated accordingly.
Consult the engine manufacturer. l pH-value too low
Operation with rape seed oil methyl ester (RME Adding of caustic lye of soda or caustic potash so-
„Bio Diesel“) lution.
Due to the extreme quality differences of RMEW-fuels l Total hardness too high:
available on the market, which are caused by the non- Mixing with dehardenede water.
existence of a standardization, BOMAG does general- l Total hardness or carbonate hardness too low:
ly not approve any RME-fuels. If this is neglected the Mixing with harder water.
warranty will become null and void!
l Chlorides and/or sulphates too high:
However, if you still intend to operate the machine Mixing with dehardenede water.
with RME-fuels you should observe the following in-
formation: As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any cli-
l Reduced engine power (approx. 7%), higher fuel matic conditions.
consumption.
The proportion of cooling system protection agent
l The quality of RME-fuel should be in compliance must be between min. 35% and max. 45% to the wa-
with DIN draft 51606. ter.
l Avoid longer periods of standstill (formation of resin,
corrosion in injection system) ! Caution
l
RME-fuel can damage the paint finish of the ma- Do not mix different coolants and additives of any
chine. other kind.
l
Fuel dilution of engine oil, therefore shortening of oil
change intervals to half. Danger
!
l
Rubber parts, such as leak fuel return lines, seats Health hazard!
will be damaged in the long run and need to be re-
placed on a regular basis or should be replaced by The mixing of nitrite based anti-freeze agents with
parts made of fluorinated rubber. However, fluori- amine based agents results in the formation of
nated rubber is not resistant against normal diesel health affecting nitrosamines.
fuel.
l
If the fuel filter is clogged the filter change intervals Environment
must be shortened accordingly. Cooling system protection agents must be dis-
posed of environmentally.
Coolant, anti-freeze agent
The correct quality of water is highly important when Hydraulic oil
preparing coolant. Clear and clean water within the The hydraulic system is operated with hydraulic oil HV
boundaries of the following analysis values should 46 (ISO) with a kinematic viscosity of
generally be used. 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-
Water quality
cording to ISO 6743/3. The viscosity index (VI) should
Analysis values min. max. be at least 150 (observe information of manufacturer).
pH-value at 20 °C 6,5 8,5
Chloride ion content [mg/dm3] - 100 Bio-degradable hydraulic oil
Sulphate ion content [mg/dm3] - 100 On request the hydraulic system can also be filled with
Total hardness*1 [°dGH] ] 3 12 ester based biodegradable hydraulic oil (Panolin HLP
*1Proportion of carbonate hardness on the total hard- Synth. 46). The biologically quickly degradable hy-
ness min. 3 dGH draulic oil meets all demands of a mineral oil based
hydraulic oil according to DIN 51524.
Information concerning the water quality can be ob-
tained from the waterworks. In hydraulic systems filled with Panolin HLP Synth. 46
always use the same oil to top up. When changing
A test case for checking the water quality can be or- from mineral oil based hydraulic oil to an ester based
dered from the engine manufacturer. biologically degradable oil, you should consult the lu-
brication oil service of the oil manufacturer for details.
Check the filter more frequently after this change.

42 BOMAG 008 911 49

Fuels and lubricants 2.4
! Caution
Oil change bio-degradable hydraulic oil:
Perform regular oil analyses for content of water
and mineral oil.
Replace the hydraulic oil filter element every 500
operating hours.

Oil for drive axle

For the drive axle use only multi-purpose transmission
oil of API-class GL5 with viscosity class SAE 90.
The additives in this oil ensure low wear lubrication
under all operating conditions.

Lubrication grease
For lubrication use only EP-high pressure grease, lith-
ium saponified (penetration 2).

008 911 49 BOMAG 43

2.4 Fuels and lubricants

44 BOMAG 008 911 49

 3 Connection overview

008 911 49 BOMAG 45

3.1 Connection overview

Fig. 1 Travel pump

46 BOMAG 008 911 49

Connection overview
1 Control solenoid, high frequency
2 Control solenoid, low frequency
3 Multi-function valve 400 bar (boost check and
pressure relief valve), travel system
4 Connection, charge pressure to brake solenoid
valve, travel speed range selection and charge oil
supply for vibration pump
5 Multi-function valve 400 bar (boost check and
pressure relief valve), travel system
6 Setscrew, mechanical neutral position
7 Connection L, leak oil connection to vibration
pump
8 Lever, travel control
9 Pilot pressure test port
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 bar
12 Adjustment screw, low frequency
13 Connection L2, leak oil to tank
14 Pressure test port MB, high frequency
15 High pressure test port MA, low frequency
16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 Charge pump, internal
19 Connection L2, to drum drive motor (flushing)
20 Adjustment screw, high frequency
008 911 49 BOMAG
3.1
21 Connection D, charge pressure to filter
22 Multi function valve 345 bar (boost check and
pressure relief valve), vibration drive high frequen-
cy
23 Connection S, suction line charge pump from hy-
draulic oil tank
24 Multi function valve 345 bar (boost check and
pressure relief valve), vibration drive low frequen-
cy
25 Charge pressure relief valve, vibration pump
(blocked)
26 Connection E, charge oil from travel pump
27 Connection L1, leak oil connection to travel pump
28 Pressure test port MB, high pressure reverse
29 Charge oil from filter
30 Pressure test port MA, high pressure forward
31 High pressure port A, high pressure forward
32 Setscrew, mechanical neutral position, vibration
33 Leak oil connection D, leak oil from axle drive mo-
tor
34 Leak oil connection A, leak oil from travel pump
35 Leak oil connection G, leak oil from drum drive
motor
36 Leak oil connection F, leak oil from vibration motor
37 Radiator inlet
47
3.1 Connection overview

48 BOMAG 008 911 49

 4 Tests and adjustments

008 911 49 BOMAG 49

4.1 Special tools, tests and adjustments

4.1 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

50 BOMAG 008 911 49

Special tools, tests and adjustments 4.1
5. Digital rpm-meter for petrol engines

BOMAG part-no.: 059 711 12

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

BOMAG part-no.: 079 948 98

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

BOMAG part-no.: 057 668 06

Fig. 7
8. Hydraulic test case, large

BOMAG part-no.: 007 610 03

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

Fig. 8

008 911 49 BOMAG 51

4.1 Special tools, tests and adjustments

9. Hydraulic test case, small

BOMAG part-no.: 079 930 01

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

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

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

Fig. 11
12. Adapter for pressure test hose

BOMAG part-no.: 055 439 02

Fig. 12

52 BOMAG 008 911 49

Special tools, tests and adjustments 4.1
13. Gear pump testing device

BOMAG part-no.: 007 610 05

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

Fig. 14

008 911 49 BOMAG 53

4.2 Checking the rotation speeds

4.2 Checking the rotation speeds

Special tools
Vibration reed frequency meter, RPM-meter for
diesel engines.

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

Fig. 1

Check the engine speed

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

Nominal value idle speed:

Low idle speed, see technical data.
High idle speed, see technical data.
5. Switch the vibration on .

Nominal value nominal speed:

Fig. 2
See technical data.

Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting for the engine.

54 BOMAG 008 911 49

Checking the rotation speeds 4.2
Checking the exciter shaft speed
1. Switch the vibration on at max. engine speed.
2. Apply the brake.
3. Measure the speed of the vibrator shaft, rest the
tester on your thumb (Fig. 3).

Nominal value:
See technical data.

Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting in the vibration circuit.

Fig. 3

008 911 49 BOMAG 55

4.3 Checking / adjusting the neutral positions of the travel pump

4.3 Checking / adjusting the neutral posi-

tions of the travel pump
Special tools
Hydraulic test case

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

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

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

Fig. 3

56 BOMAG 008 911 49

Checking / adjusting the neutral positions of the travel pump 4.3
4. Connect 600 bar pressure gauges to high pres-
sure test ports MA and MB (Fig. 4).

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

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

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

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

Fig. 6
Evaluation of test

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

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

Fig. 7

008 911 49 BOMAG 57

4.4 Pressure tests in the travel circuit

4.4 Pressure tests in the travel circuit

Special tools
Hydraulic test case

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

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

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

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

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

58 BOMAG 008 911 49

Pressure tests in the travel circuit 4.4
Measurement with quickly operated travel le-
ver
6. Move the travel lever (Fig. 4) quickly forward,
read the pressure gauge.

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

Evaluation of test

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

008 911 49 BOMAG 59

4.5 Checking / adjusting the vibrator shaft speeds

4.5 Checking / adjusting the vibrator shaft

speeds
Special tools
Vibration reed frequency meter

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

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

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

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

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

Fig. 3

60 BOMAG 008 911 49

Pressure measurements in the vibration circuit 4.6
4.6 Pressure measurements in the vibra-
tion circuit
Special tools
Hydraulic test case

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

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

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

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

008 911 49 BOMAG 61

4.7 Check the leakage rate of the vibration motor

4.7 Check the leakage rate of the vibration

motor

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

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

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

Nominal value
max. 1.5 litre/min

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

62 BOMAG 008 911 49

Pressure test in steering circuit 4.8
4.8 Pressure test in steering circuit
Special tools
Hydraulic test case, gear pump testing equipment

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

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

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

Nominal value

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

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

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

Nominal value
see technical data for steering/charge pump.

Fig. 3

008 911 49 BOMAG 63

4.8 Pressure test in steering circuit

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

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

Nominal value
see technical data for steering/charge pump.

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

Fig. 5

64 BOMAG 008 911 49

 5 Flushing and bleeding

008 911 49 BOMAG 65

5.1 Special tools for flushing

5.1 Special tools for flushing

1. Filling and filtering unit with oil bag

BOMAG part-no.: 007 610 01

2. Filter element

BOMAG part-no.: 079 930 35

Fig. 1
3. Flushing filter (S connection)

BOMAG part-no.: 007 000 01

4. Filter element 1μ

BOMAG part-no.: 079 930 52

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

BOMAG part-no.: 055 509 19

6. Screw socket R1“ - 25S (2 pieces)

BOMAG part-no.: 055 400 52

Fig. 2
7. Flushing filter (L connection)

BOMAG part-no.: 079 390 29

8. Filter element

BOMAG part-no.: 079 390 14

9. Flushing hose 15L (2 pieces)

BOMAG part-no.: 055 510 09

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

BOMAG part-no.: 055 400 89

Fig. 3
11. SAE-flange 1“ - 20S

BOMAG part-no.: 058 142 60

12. O-ring

BOMAG part-no. 062 203 30

Fig. 4

66 BOMAG 008 911 49

Special tools for flushing 5.1
13. Flanged plate 1“ - 25S

BOMAG part-no.: 007 160 18

14. O-ring

BOMAG part-no. 062 202 22

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

BOMAG part-no.: 055 422 92

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

BOMAG part-no.: 055 422 98

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

BOMAG part-no.: 055 423 26

Fig. 8

008 911 49 BOMAG 67

5.1 Special tools for flushing

18. Connecting socket 15L

BOMAG part-no.: 055 426 55

Fig. 9
19. Connecting socket 18L

BOMAG part-no.: 055 426 06

Fig. 10
20. Connecting socket 16S

BOMAG part-no.: 055 459 43

Fig. 11
21. Connecting fitting 20S

BOMAG part-no.: 055 459 44

Fig. 12

68 BOMAG 008 911 49

Special tools for flushing 5.1
22. Connecting fitting 25S

BOMAG part-no.: 055 459 45

Fig. 13
23. Angular fitting 18L

BOMAG part-no.: 055 421 26

Fig. 14
24. Elbow fitting 16L

BOMAG part-no.: 055 421 36

Fig. 15
25. Elbow 20S

BOMAG part-no.: 055 421 37

Fig. 16

008 911 49 BOMAG 69

5.1 Special tools for flushing

26. Elbow 25S

BOMAG part-no.: 055 421 38

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

BOMAG part-no.: 493 301 01

Fig. 18
28. Connecting hose 15L

BOMAG part-no.: 055 510 09

Fig. 19

70 BOMAG 008 911 49

Flushing - general 5.2
5.2 Flushing - general Clean the hydraulic tank

Caution
!

Solid particles in the circuit will very quickly

cause damage to machine components.

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

Changing a component
Fig. 2
Caution
!

Always flush the complete oil circuit after !Caution

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

Fig. 3
Fig. 1

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

008 911 49 BOMAG 71

5.2 Flushing - general

Servicing the flushing filter kit

Fig. 4

l Replace the filter element of the flushing fil-

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

72 BOMAG 008 911 49

Flushing schematic travel circuit (distribution travel pump) 5.3

008 911 49 BOMAG 73

5.3 Flushing schematic travel circuit (distribution travel pump)

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

74 BOMAG 008 911 49

Flushing the travel circuit (travel pump distribution) 5.4
5.4 Flushing the travel circuit (travel
pump distribution)

Flushing the drum drive

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

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

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

Fig. 2

008 911 49 BOMAG 75

5.4 Flushing the travel circuit (travel pump distribution)

Bleeding the travel circuit

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

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

Fig. 4

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

Fig. 5

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

76 BOMAG 008 911 49

Flushing the travel circuit (travel pump distribution) 5.4
Flushing the drum drive motor

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

Fig. 7

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

Fig. 8

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

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

008 911 49 BOMAG 77

5.4 Flushing the travel circuit (travel pump distribution)

Flushing the axle drive

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

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

Fig. 11

Bleeding the travel circuit

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

Fig. 12

78 BOMAG 008 911 49

Flushing the travel circuit (travel pump distribution) 5.4
Flushing the hoses
19. Block drums and wheels with suitable chocks.

Fig. 13

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

Fig. 14

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

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

Fig. 16

008 911 49 BOMAG 79

5.4 Flushing the travel circuit (travel pump distribution)

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

Fig. 17

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

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

Bleeding the travel circuit

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

Keep circulating the tank content.

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

Fig. 19

80 BOMAG 008 911 49

Flushing schematic travel circuit (distribution axle motor) 5.5

008 911 49 BOMAG 81

5.5 Flushing schematic travel circuit (distribution axle motor)

82 BOMAG 008 911 49

Flushing schematic travel circuit (distribution axle motor) 5.5

008 911 49 BOMAG 83

5.5 Flushing schematic travel circuit (distribution axle motor)

84 BOMAG 008 911 49

Flushing schematic travel circuit (distribution axle motor) 5.5
1 Elbow union (tool) 13 High pressure hose (drum drive motor forward)
2 Connecting union (tool) 14 High pressure hose (B, axle motor reverse)
3 Drum drive motor 15 High pressure hose (A, axle motor forward)
4 Axle motor 16 High pressure hose (B, axle motor reverse)
5 Screw socket R1 - 25S (tool) 17 not used
6 not used 18 Flushing hose 25S - 20S (tool)
7 not used 19 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1μ (tool)
9 not used
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (drum drive motor reverse)

008 911 49 BOMAG 85

5.6 Flushing the travel circuit (axle motor distribution)

5.6 Flushing the travel circuit (axle motor

distribution)

Flushing the drum drive

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

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

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

Fig. 2

86 BOMAG 008 911 49

Flushing the travel circuit (axle motor distribution) 5.6
Bleeding the travel circuit

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

Fig. 3
Flushing the hoses

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

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

Fig. 5

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

008 911 49 BOMAG 87

5.6 Flushing the travel circuit (axle motor distribution)

Flushing the drum drive motor

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

Fig. 7

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

Fig. 8

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

Fig. 9

88 BOMAG 008 911 49

Flushing the travel circuit (axle motor distribution) 5.6
Flushing the axle motor
!Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
15. Jack up the rear of the machine, so that the
wheels can rotate freely.
16. Secure the drum with wheel chocks.
17. Pre-select the slow speed range.

Fig. 10

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

Fig. 11

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

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

Bleeding the travel circuit

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

Keep circulating the tank content.

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

008 911 49 BOMAG 89

5.6 Flushing the travel circuit (axle motor distribution)

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

Fig. 13

90 BOMAG 008 911 49

Flushing schematic for vibration drive
1 Elbow union (tool)
2 Connecting union (tool)
3 Vibration motor
4 Vibration pump
5 Screw socket R1 - 25S (tool)
6 Flushing hose 25S - 20S (tool)
008 911 49
5.7
7 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1μ (tool)
9 SAE flange (tool)
10 High pressure hose (B, high frequency)
11 High pressure hose (A, low frequency)
BOMAG 91
5.8 Flushing the vibration circuit

5.8 Flushing the vibration circuit

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

i Note
Observe the chapter "Flushing - General"

Installing the flushing filter

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

Fig. 2

92 BOMAG 008 911 49

Flushing the vibration circuit 5.8
Bleeding the vibration circuit

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

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

Fig. 4

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

Fig. 5

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

008 911 49 BOMAG 93

5.8 Flushing the vibration circuit

Flushing the vibration motor

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

Fig. 7

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

Fig. 8

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

Keep circulating the tank content.

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

94 BOMAG 008 911 49

Flushing the vibration circuit 5.8
Function test
17. Check the hydraulic oil level in the tank, fill up if
necessary.
18. Test drive.
19. Check all ports and connections for leak tightness
(visual inspection).

Fig. 10

008 911 49 BOMAG 95

5.9 Bleeding the travel circuit

5.9 Bleeding the travel circuit

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

! Danger
The engine should not start.

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

Fig. 2
7. Unlock the emergency stop switch

Fig. 3

96 BOMAG 008 911 49

Bleeding the travel circuit 5.9
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.

Fig. 4

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

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

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

008 911 49 BOMAG 97

5.10 Bleeding the vibration circuit

5.10 Bleeding the vibration circuit

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

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

Fig. 2
7. Unlock the emergency stop switch

Fig. 3

98 BOMAG 008 911 49

Bleeding the vibration circuit 5.10
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-
cedure, until the pressure gauge shows a con-
stant charge pressure.

Fig. 4

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

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

008 911 49 BOMAG 99

5.10 Bleeding the vibration circuit

100 BOMAG 008 911 49

 6 Fundamental electrics

008 911 49 BOMAG 101

6.1 Understanding circuit diagrams

6.1 Understanding circuit dia-
grams
Wiring diagrams are graphical representations of cir-
cuitry 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 sys-
tem. This plan provides the following information:
l Number and type of individual elements in the ex-
amined electric circuit, such as plug connectors,
fuses, switches, consumers, relays, ...
l The sequence in which current flows through the in-
dividual elements in the electric circuit.
l Connections between the examined, faulty electric
circuit and other circuits in the vehicle wiring sys-
tem.
l Pin assignment of plug-and-socket connections.
Structure:
l Table of contents
l Function groups
l List of components
Table of contents
The table of contents lists all function groups.

Fig. 6 Table of contents

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

102 BOMAG 008 911 49

Understanding circuit diagrams 6.1
Function groups l From top (plus potential) to bottom (minus poten-
On the individual pages the electric circuits are com- tial).
bined to function groups. l From left to right.
l From function group to function group.
Arrangement of current paths
l Via cross references for potentials and relays.
The individual current paths must be read as follows:

Fig. 7 Function groups Relay cross reference

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

008 911 49 BOMAG 103

6.1 Understanding circuit diagrams

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

Fig. 8 Current paths

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

Fig. 9 List of components

Component cross references

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

104 BOMAG 008 911 49

Understanding circuit diagrams
Graphic symbol
Graphic symbols are standardized representations for
electrical appliances. They serve the purpose of a
simplified 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
Commission). For Germany these symbols were in-
cluded in the DIN-Standard. The standardization
6.1
serves the purpose of global understanding and fault
free connection of appliances, especially in automo-
bile repairs.
Since the wiring diagram is intended to show only the
most essential aspects, the graphic symbol only
shows as much of the function, as is needed for easy
recognition and for the avoidance of mistakes.

Fig. 10 Graphic symbol

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

Fig. 11 Graphic symbol

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

008 911 49 BOMAG 105

6.2 Terminal designations

6.2 Terminal designations the individual connection terminals is determined by

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

Terminal designa- Meaning

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

2 Short circuit terminal (magneto ignition)

4 Ignition coil, ignition distributor high voltage

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

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

15a Output from dropping resistor to ignition coil and starter

17 Preheating starter switch, preheating

19 Preheating starter switch, starting

30 Battery plus direct

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

31 Battery minus direct or ground

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

32 Electric motors, return line

33 Electric motors, main connection

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

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

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

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

49 Input flasher relay

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

50 Starter, starter control

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

106 BOMAG 008 911 49

Terminal designations 6.2
Terminal designa- Meaning
tion
50c Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 1
Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 2
50d Start locking relay, input
50f Start locking relay, output
50g Start repetition relay, input
50h Start repetition relay, output

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

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

52 Trailer signals: further signals from trailer to towing vehicle

53 Wiper motor input (+)

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

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

55 Fog light

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

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

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

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

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

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

61 Generator control

71 Intermittent tone control unit, input

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

72 Alarm switch (flashing beacon)

008 911 49 BOMAG 107

6.2 Terminal designations

Terminal designa- Meaning

tion
75 Radio, cigarette lighter

76 Loudspeaker

77 Door valve control

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

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

82 Switch (maker), input

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

83 Switch (multi-position switch), input

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

84 Current relay, input drive and relay contact

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

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

86 Switching relay, input drive winding start

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

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

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

88 Relay contact for maker

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

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

108 BOMAG 008 911 49

Terminal designations 6.2
Terminal designa- Meaning
tion
DF2 Dynamo field 2 (generator excitation current)

U Three-phase generator, three-phase terminal

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

C Travel direction indicator (flasher relay) control light 1

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

008 911 49 BOMAG 109

6.3 Current and voltage

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

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

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

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

110 BOMAG 008 911 49

Current and voltage
Current
Electric current generally describes the directed
movement of charge carriers.
l The charge carriers may either be electrons or ions.
l Electric current can only flow if there is a sufficient
amount of free moving charge carriers.
l The higher the number of electrons flowing through
a conductor per second, the higher the amperage.
Current is measured with an ammeter.
Unit, Ampere
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).
008 911 49
6.3
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.
Pulsating direct current
Fig. 3 Pulsating direct current
Converting alternating current into a direct current sig-
nal by means of a rectifier results in an pulsating direct
current.
BOMAG 111
6.3 Current and voltage

Pulse width modulation (PWM)

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

Caution
!

Solenoid valves must not be interference sup-

pressed with suppressor diodes.

112 BOMAG 008 911 49

Current and voltage 6.3
Controller Area Network (CAN) Real-time critical, robust and low price communication
created by Bosch at the end of the eighties for auto- of control units, such as transmission and engine con-
mobile applications. trol, but also less time critical applications in the field
of convenience electronics, such as air conditioning.
Development objectives:

Fig. 5 CAN Characteristics of CAN

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

008 911 49 BOMAG 113

6.4 Resistance

6.4 Resistance
Resistance and voltage drop
While current flows through a conductor the current
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as 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.
Unnecessary resistances
Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.

Bad

Fig. 1 Various size resistors

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

Fig. 2 Spring clamps

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

Symbol, R

Unit, Ohm Ω

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

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

114 BOMAG 008 911 49

Resistance 6.4
Sometimes the flanks of flat plugs bend open. If these
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.

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

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

Fig. 4 Balistol oil

008 911 49 BOMAG 115

6.5 Series / parallel connection

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

Fig. 1 Series connection

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

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

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

Series connection of batteries

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

116 BOMAG 008 911 49

Series / parallel connection
Parallel connection
In parallel connection all resistances (consumers) are
connected between feed and return line.
l All resistances (consumers) are supplied with the
same voltage.
l Each of the resistances (consumers) draws as
much current as required.
6.5
l In parallel connection the plus pole of the first bat-
tery is connected with the plus pole of the second
battery and the minus pole of the first battery with
the minus pole of the second battery.
l Plus and minus poles have the voltage of the single
battery applied.
l The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.

Fig. 3 Parallel connection

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

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

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

Parallel connection of batteries

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

008 911 49 BOMAG 117

6.6 Ohm's law

6.6 Ohm's law 6.7 Electrical energy

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

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

118 BOMAG 008 911 49

Formula diagram 6.8
6.8 Formula diagram Example:
P = 150 Watt
Description:
U = 24 Volt
l Select the desired value from the inner circle.
Sought for = Current in Ampere
l Determine the formula variables in the quarter circle
l Calculate I = P : U = 150 W : 24 Volt = 6.25 Ampere

Fig. 1 Formula diagram

Resistance, R Ohm Ω

Voltage, U Volt

Current, I Ampere

Power, P Watt

008 911 49 BOMAG 119

6.9 Metrology

6.9 Metrology Multimeter

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

Fig. 1 Test lamp
! Caution
This type of tester must not be used for testing on
electronic components. The high power con-
sumption of the test lamp may destroy electronic
components in the control units.
Diode test lamp
This instrument is used for simple voltage measure-
ments. The test lamp consists of two test points. The
negative measuring cable is connected to ground and
the positive measuring cable to the corresponding
measuring location.
Fig. 1 Multimeter
In order to avoid damage:
l
the range selector switch must be correctly set for
the corresponding measurement.
l
the test cable must be plugged into the correct
socket.
l
the voltage type (AC/DC) must be set.
l
In case of direct voltage the correct polarity must be
assured.
l
the measuring range should be chosen higher at
the beginning of the test.
l In order to avoid any influence on the circuitry to be
measured, the internal resistance of the voltage
tester should be as high as possible.
Resistance and continuity measurement with mul-
timeter
The continuity tester of the multimeter can be used to
measure whether there is a connection between 2
measuring points. The following information should be
observed when measuring resistance and continuity:
l The component to be measured must not be con-
nected to the power supply during the measure-
ment.
l At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
l Polarity is of no significance.

Fig. 2 Diode test lamp

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

120 BOMAG 008 911 49

Metrology 6.9
Voltage and voltage drop measurement with mul- Clip-on measuring instrument
timeter
The clip-on measuring instrument can be used to
measure current, voltage and resistance.

Fig. 2 Voltage measurement

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

Current measurement with the multimeter

Fig. 1 Clip-on measuring instrument

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

Fig. 3 Current measurement

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

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

008 911 49 BOMAG 121

6.10 Diodes, relays, fuses

Magnet tester 6.10 Diodes, relays, fuses

Diodes

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. 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.

122 BOMAG 008 911 49

Diodes, relays, fuses 6.10
Diode logics and free-wheeling diode Light emitting diodes

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

Fig. 3 Diode circuitry

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

008 911 49 BOMAG 123

6.10 Diodes, relays, fuses

Relays 85 = Ground supply for coil

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

Fuses

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

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

Caution
!

Fuses must not be repaired or bridged.

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

Fig. 2 Relay circuitry

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

124 BOMAG 008 911 49

Batteries 6.11
6.11 Batteries Battery maintenance

Battery – accumulator
Fig. 1
In vehicles batteries are used to start the engine. The
ability to start the engine depends on the charge con-
dition of the batteries.
Lead collectors or accumulators are secondary ele-
ments, i.e they can be recharged after discharging
electric current.
The basic element of a lead accumulator is the cell. It
contains the plate blocks consisting of positive and
negative plates. These plates are separated from
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of
the cells.
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
a subsequent charging process.
In the worst case the accumulator can only be dis-
posed of after such an exhaustive discharge.
The following therefore applies for longer downtimes:
l Remove the battery and store it in a cool, dry and
frost protected room.
l Check the open circuit voltage on the battery at reg-
ular intervals (at least once every month).
l Recharge immediately if the open circuit voltage
has dropped to 12.25 Volt (no rapid charging).
i Note
The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.

Battery test in general

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

Testing batteries with screw plugs

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

008 911 49 BOMAG 125

6.11 Batteries

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

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

Acid density at 27 °C in kg/dm3

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

Fig. 4 Battery and generator tester

i Note
If the current consumption during charging is not 1/20
of the nominal capacity (example 100 Ah battery:
100Ah x 1/20 = 5 A) or full charging of the battery re-
sults in a final acid density of only 1.24 kg/dm3 or less,
the battery shows normal wear by aging. The battery
was insufficient charging or exhaustive discharge.
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%.

Fig. 3 Reading the acid level

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

Testing batteries without screw plugs

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

126 BOMAG 008 911 49

Batteries 6.11
Charge condition with hydrometer

Fig. 5 Charge condition

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

! Danger

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

low, the battery must no longer be charged.

008 911 49 BOMAG 127

6.12 Three-phase generator

6.12 Three-phase generator

General
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.

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

128 BOMAG 008 911 49

Three-phase generator 6.12
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.

Reverse current protection

The rectifier diodes also prevent discharging of the
battery via the stator windings. The current can only
flow from the generator to the battery.

Why does three-phase current need to be rectified

and how does this work?
There are a few components for which can either be
operated with alternating current or direct current, be-
cause they work independently from the current flow
direction.
This includes :
l Incandescent lamps
l Fluorescent lamps
l Glow lamps
l Electric heating elements.
There are also a few components that could be oper-
Fig. 7 Stator with 3 windings ated either with alternating current, direct current or
three-phase current, if the components were designed
accordingly.
This includes :
l
Electric motors
l
Relays
Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
es work with alternating or three-phase current.
This includes :
l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.

Fig. 8 3-phase current

The generator first of all produces three-phase volt-
age / three-phase current.
The wiring diagram (Fig. 8) shows the 3 windings in Y-
connection and the 6 associated rectifier diodes.
The diodes D1, D2, D3 are also referred to as minus
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

008 911 49 BOMAG 129

6.12 Three-phase generator

Charge control light Voltage regulator

It has by no means the function to show whether the A generator without regulator would just work light a
ignition is switched on or off. It has the function of in- bicycle dynamo. The power output would increase
dicating that the generator works correctly. Under nor- with rising speed. The voltage output would fluctuate
mal operating conditions the generator should work with the load. (In case of a bicycle dynamo the tail light
and the charge control light should be off. The charge bulb is overloaded when the head light does not con-
control lamp receives (+) from the battery at one pole. sume any power). The function of the regulator is the
The other pole is connected to (D+), i.e. the (+) carbon provision of a uniform vehicle voltage, almost com-
of the generator. If the generator is working correctly, pletely independent from speed and load of the gen-
(+) is attached to both connections on the charge con- erator.
trol lamp. Since there is no difference in voltage, no
current can flow, the lamp does not light up. If the gen-
erator does not work, current flows via the (+) carbon
through the armature winding, via the (-) carbon to
ground and from there back to the battery. The electric
circuit is closed, battery voltage is applied to the
charge control lamp and the lamp lights up. Since the
generator does not work when the engine is not run-
ning, the charge control lamp is not connected directly
to the battery, but via the ignition switch. When the ig-
nition is off, the charge control lamp is dead.

Fig. 9 Regulator with diode plate and rectifier diodes

In most cases voltage regulators (Fig. 9) with carbon
brushes form a compact component. The voltage reg-
ulator is maintenance free and the wear of carbon
brushes is only so little, that they hardly ever need to
be replaced during the lifetime of a machine.
The regulator has the following function:
l
To maintain the vehicle voltage under any operating
conditions below 14.4 V.
l
To match the regulator voltage to the temperature.
l
Smooth rising of generator current when switching
loads (convenience function to avoid jerking of the
engine).

130 BOMAG 008 911 49

Three-phase generator 6.12
Checking the generator
First one must check whether the generator is actually
defective.
l This can be easily found out by checking whether
the charge control light in the dashboard lights up. If
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula-
tor, the wiring or the V-belt.
l When the engine is at rest, the charge control light
must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the volt-
age supply within certain limits.
l Cable connections on the generator OK? Fig. 10 Rotor
l V-belt OK? l
Remove the regulator with carbon brush.
l Generator ground (engine ground) OK? l
Contact the rotor slip ring with the tester points.
l Pre-excitation from vehicle electronics OK? l
The resistance should be between 3 and 6 OHM Ω.
Only if all criteria mentioned above are OK, the fault l
The rotor coils should not have continuity to ground.
must be in the generator itself. In this case it must be
Checking the stator
replaced or the following trouble shooting procedure
must be performed.

Measuring the charge current

l
All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l
The generator ground connection must be OK.
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 consumers.

Checking the rotor

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

Fig. 11 Stator

i Note
The stator coils can only be measured in disassem-
bled state.
l Measure the resistance of all three coils.
l The coils should not have contact among each oth-
er.

008 911 49 BOMAG 131

6.12 Three-phase generator

Checking the regulator voltage with the generator l Perform the measurement at raised engine speed.
tester l The voltage (B+) should adjust itself at 13 to 14 Volt.
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. 12
The generator test assesses the regulator voltage and
the ripple factor of the generator voltage.
l
All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l
The generator ground connection must be OK.
l
The battery should be in good condition – the idle
speed voltage of the battery should be at least 12.6
Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.

Checking the regulator voltage with the multime-

ter

Fig. 13
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l The generator ground connection must be OK.
l The battery should be in good condition – the idle
speed voltage of the battery should be at least 12.6
Volt.
l If possible switch off all consumers.

132 BOMAG 008 911 49

Three-phase generator 6.12
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. 15
E.g minus controlled regulator
i Note One connects the regulator (Fig. 15) 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. 16

Fig. 17
Fig. 14
The illustrations (Fig. 16) and (Fig. 17) show two dif-
l If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).

008 911 49 BOMAG 133

6.12 Three-phase generator

Replacing the carbon brushes

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

134 BOMAG 008 911 49

Electric starter
6.13 Electric starter
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:
l to accelerate the combustion engine to start speed
with lowest possible current consumption.
6.13
l establish the gear connection between starter and
combustion engine.
l to maintain this connection.
l to switch on the starter current.
After starting the engine:
l to return the starter pinion to initial position.
l to switch off the starter current.

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

008 911 49 BOMAG 135

6.13 Electric starter

Function of pre-engaged-drive starting motor

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

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

136 BOMAG 008 911 49

Electric starter 6.13
Trouble shooting "Starter" Testing and measuring the electric starter
The most frequent fault is definitely a fully discharged
battery. i Note
If the starter rotates too slowly, either the brushes The highest current flows when the starter is blocked!
are partly worn off, or parts of the exciter or armature (Short circuit current in starter). This is the case when
winding is shorted. In some cases oxidized electric the pinion is engaged and the starter has the duty to
contacts or a soiled ground connection causing ex- accelerate the flywheel to starting speed.
tremely high voltage losses in the overall starter sys-
tem are the cause of problems. Function test with starter installed
If the starter only emits a clicking sound,- either
l Initiate the starting process and measure the volt-
the magnetic switch is defect / soiled (dismantle and age on the pickup solenoid switch (50a). At least
clean))- the main contacts on the magnetic switch are 10.8 Volt should be applied.
worn off / soiled (scrape off carefully with a file and l When operating the starter switch the magnetic
clean)- the starter motor is defective / soiled (remove switch must engage in the flywheel ring gear (no-
armature and clean), cover cleaned, moveable parts ticeable clicking sound) and release the starting
with grease. current to the starter. On most magnetic switches
the voltage can be measured with the multimeter. If
Frequently a jammed return mechanism is the reason
this does not happen even though voltage is ap-
for a starter failure.
plied, replace the magnetic switch.
Occasionally worn contacts are found on the magnetic
return switch Function tests with disassembled starter
Defects on the actual starter motor including pinion
and carbon brushes are very rare. !Caution
With a trouble shooting chart the faults in the starter Before removing the starter you must disconnect
system can be narrowed down. The starter system the ground cable from the minus pole of the bat-
can only work when many conditions are fulfilled at tery while the ignition is switched off.
the same time. l Check the wear on the carbon brushes and their
l
Immobilizer deactivated? contact pressure.
l
Ignition switch OK? l Check the collector, it must not have electrical con-
l
Travel lever in correct position? tact with the rotor shaft.
l
Emergency stop not actuated? l Check the drive pinion for excessive wear.
l
Battery sufficiently charged? l The return mechanism should not be tight, if neces-
l
Battery poles OK? sary grease amply with silicon grease (Bosch PZ 2
V3) or a comparable grease.
l
Main battery fuse OK?
l Measure the resistance of the magnetic switch main
l
Main battery switch closed?
contact in disengaged condition. Maximum value
l
Main starter cable (terminal 30) OK? 0.2 OHM Ω.
l
Starter control cable (terminal 50) OK, voltage
drop?
l
Ground cable OK?
l Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l
the experience of the specialist
l
the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.

008 911 49 BOMAG 137

6.14 Telemecanique switch

6.14 Telemecanique switch

Example of terminal designations

Fig. 1 Terminal designations

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

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

138 BOMAG 008 911 49

Telemecanique switch 6.14
Disassembly

Fig. 2 Disassembly
l Lift up the interlock (5).

Fig. 4 Pulling out the front element

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

008 911 49 BOMAG 139

6.14 Telemecanique switch

Assembly

Fig. 5 Assembly
l Insert the front element (3) into the bore in the con-
trol panel.

Fig. 7 Assemble the switch block

l Clip on the switch block (4).

Fig. 6 Observe the marks.

i Note
Hook in the switch block at the bottom first (Fig. 7).
l Clip the fastening adapter (6) onto the front element
(3).

i Note
Watch the marls on front element (Fig. 6) and fasten-
ing flange.
l
Tighten the screw (1) with a tightening torque of 0.6
Nm.

140 BOMAG 008 911 49

Inductive proximity switches 6.15
6.15 Inductive proximity switches NPN circuitry

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

Working principle

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

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

Fig. 9 PNP circuitry

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

008 911 49 BOMAG 141

6.16 Angle sensor with current output

6.16 Angle sensor with current out-

put

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

142 BOMAG 008 911 49

Plug connectors
Fig. 2 Connection diagram
The angle sensor has 3 electric connections (Fig. 2).
Ub, supply voltage (+ 8.5 Volt)
Gnd, ground
Out, output current 4-20 mA.
l at -35° = 4 mA output current
l
at 0° = 12 mA output current
l at +35° = 20 mA output current.
008 911 49
6.17
6.17 Plug connectors
Duties and requirements
Electric plug connectors must provide a reliable con-
nection between different system components and
thus ensure the safe function of the systems under
any operating condition. There design ensures that
they will withstand the applied loads throughout the
lifetime of the machine.
Examples for these loads are:
l Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l Dampness
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.
BOMAG 143
6.18 Deutsch plug, series DT and DTM

6.18 Deutsch plug, series DT and DT Series

DTM

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

Fig. 1 DT plug connection

Fig. 3 Crimp connections

Fig. 2 DT Series
Caution
!

Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Fig. 3 Sectional drawing
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
l
Perform a pull test on each lead, each of the termi-
nals and connections must withstand a pulling force
of 45 N without any difficulties.

144 BOMAG 008 911 49

Deutsch plug, series DT and DTM 6.18
Installing DT contacts

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

Caution
!

Perform a pull test on each lead, each of the termi-

nals and connections must withstand a pulling
force of 45 N without any difficulties.

i Note
Use the same method when assembling the socket.

008 911 49 BOMAG 145

6.18 Deutsch plug, series DT and DTM

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.

146 BOMAG 008 911 49

Deutsch plug, series DT and DTM 6.18
DTM Series

Fig. 1 DTM plug connection

Fig. 2 DTM Series

Fig. 3 Sectional drawing

008 911 49 BOMAG 147

6.18 Deutsch plug, series DT and DTM

Installing DTM contacts

Fig. 4
l
Insert the contacts through the rubber grommet until
they click into place.
l
Insert the orange wedge, until it clicks into place.

Caution
!

Perform a pull test on each lead, each of the termi-

nals and connections must withstand a pulling
force of 45 N without any difficulties.

i Note
Use the same method when assembling the socket.

148 BOMAG 008 911 49

Deutsch plug, series DT and DTM 6.18
Disassembling DTM contacts

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

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

008 911 49 BOMAG 149

6.19 Plugs and terminals in spring clamping technology

6.19 Plugs and terminals in spring

clamping technology

General

Fig. 1
Spring clamp technology (Fig. 1) for quick, vibration
resistant and maintenance-free connection of all con-
ventional copper conductors (single, multiple or fine
stranded) with or without wire and ferrule.

! Caution
The spring clamp technology is not suitable for
extra fine conductors. Extra fine conductors can
be easily pulled out of the spring clamp!

150 BOMAG 008 911 49

Plugs and terminals in spring clamping technology 6.19
Connecting terminal for quick repairs BOMAG part-no.: 057 565 72

Fig. 1 That's how it works

The connecting clamp clamps up to 3 or 5 stripped
fine conductors of 0.08 qmm bis 4 mm², single or mul-
tiple 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 termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.

Fig. 2 Connecting clamp

008 911 49 BOMAG 151

6.19 Plugs and terminals in spring clamping technology

Series clamp

Fig. 1 That's how it works

That's how it works

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

!Caution
Perform a pull test on each lead, each of the termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.

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

Fig. 2 Test adapter

152 BOMAG 008 911 49

Plugs and terminals in spring clamping technology
X-COM System
The X-COM-SYSTEM, a synthesis of plug connector
and series clamp, has grown up to a construction kit
6.19
for universal system wiring, ever since it was intro-
duced in 1997. All the familiar series clamping func-
tions have thus become pluggable.

X-COM plug clamp

Fig. 1 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 termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.

Measuring signals
Fig. 3 X-COM plug plugged onto the series clamp

Fig. 2 X-COM plug with measuring cable

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

008 911 49 BOMAG 153

6.19 Plugs and terminals in spring clamping technology

154 BOMAG 008 911 49

 7 Special tools, electrics

008 911 49 BOMAG 155

7.1 Special tools, electrics

7.1 Special tools, electrics

Measuring equipment
14. Electric test case

BOMAG part-no.: 057 505 70

Fig. 4
15. Multimeter

BOMAG part-no.: 057 509 91

Fig. 5
16. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.

BOMAG part-no.: 079 900 53

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

BOMAG part-no.: 079 900 54

Fig. 6
18. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.

BOMAG part-no.: 079 900 51

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

BOMAG part-no.: 079 900 52

Fig. 7

156 BOMAG 008 911 49

Special tools, electrics 7.1
20. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 0.5 m.

BOMAG part-no.: 079 900 58

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

BOMAG part-no.: 079 900 59

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

BOMAG part-no.: 079 900 60

23. Measuring and connecting lines with 4mm plug,
Fig. 8 high flexible design, red, length 0.5 m.

BOMAG part-no.: 079 900 55

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

BOMAG part-no.: 079 900 56

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

BOMAG part-no.: 079 900 57

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

BOMAG part-no.: 079 900 63

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

BOMAG part-no.: 079 900 64

28. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 300 mm.
Fig. 9
BOMAG part-no.: 079 900 61
29. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 600 mm.

BOMAG part-no.: 079 900 62

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

BOMAG part-no.: 079 900 65

Fig. 10

008 911 49 BOMAG 157

7.1 Special tools, electrics

31. Magnetic coil tester

BOMAG part-no.: 057 555 54

Fig. 11
32. Clip-on measuring instrument

BOMAG part-no.: 079 900 50

Fig. 12
33. Battery - generator tester

BOMAG part-no.: 079 900 91

Fig. 13
Spring clamps (Wago or Weidmüller)
34. Cranked screwdriver (Fig. 14) to open spring
clamps (Fig. 15).

BOMAG part-no.: 972 024 68

Fig. 14

158 BOMAG 008 911 49

Special tools, electrics 7.1
35. Testing adapter to measure the signals from the
series spring clamps (Wago).

BOMAG part-no.: 057 564 26

Fig. 15
Deutsch contacts
36. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).

BOMAG part-no.: 079 900 84

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

Fig. 17
38. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
AWG 8 = 10,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section

BOMAG part-no.: 079 900 69

Fig. 18

008 911 49 BOMAG 159

7.1 Special tools, electrics

39. Disassembly tool for Deutsch contacts of series

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

Fig. 19
ITT contacts
40. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 80

Fig. 20
41. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 81

Fig. 21
42. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 82

Fig. 22

160 BOMAG 008 911 49

Special tools, electrics 7.1
Schaltbau contacts
43. Disassembly tool for Schaltbau contacts of series
M1, M2.

BOMAG part-no.: 057 509 95

Fig. 23
44. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm2.

BOMAG part-no.: 057 509 94

Fig. 24
FCI Burndy contacts
45. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO

BOMAG part-no.: 079 900 00

Fig. 25
AMP contacts
46. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).

BOMAG part-no.: 079 900 35

Fig. 26

008 911 49 BOMAG 161

7.1 Special tools, electrics

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

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

BOMAG part-no.: 079 900 48

Fig. 27
48. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).

BOMAG part-no.: 079 900 23

Fig. 28
49. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 14 - 10.

BOMAG part-no.: 079 900 88

Fig. 29
50. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 16 - 14
and AWG 18.

BOMAG part-no.: 079 900 89

Fig. 30

162 BOMAG 008 911 49

Special tools, electrics 7.1
51. Disassembly tool for AMP-contacts of series CIR-
CULAR-CONNECTOR.
1.5 mm2, BOMAG part-no.: 079 900 74
2,5 mm2, BOMAG part-no.: 079 900 75
Spare sleeve 1.5 mm2, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm2, BOMAG part-no.: 079
900 77

Fig. 31
Universal tools
52. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 - 1.0 mm2.

BOMAG part-no.: 972 038 47

Fig. 32
53. Precision pressing pliers for non-insulated flat
male and female connectors0.5 - 6,0 mm2.

BOMAG part-no.: 079 900 70

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

BOMAG part-no.: 057 503 83

Fig. 34

008 911 49 BOMAG 163

7.1 Special tools, electrics

55. Voltage measurement adapter for Deutsch plugs,

8-piece (2 to 12 pole).

BOMAG part-no.: 079 900 68

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

BOMAG part-no.: 079 900 83

Fig. 36

164 BOMAG 008 911 49

 8 Electronic modules

008 911 49 BOMAG 165

166 BOMAG 008 911 49
 8.1 Seat contact module

008 911 49 BOMAG 167

8.1 Seat contact module

Seat contact switch

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

The following applies in general:

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

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

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

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

In addition to the seat monitoring system all

monitoring functions are implemented by the

Module UPM2

168 BOMAG 008 911 49

Seat contact module 8.1

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

Stay-Alive LED

Programmierstecker

Spannungs- Status-
versorgung Leuc htdioden
1

4
3

5
2

7
8
9

14
15
6

10

13
12
11

Vibrationstaster
Versorgungsspannung (+UB)

Sitzkontaktschalter
Versorgungsspannung (+UB)

Vibration
Haltewicklung Abstellmagnet

Masseanschluß

Generator / D+ Signal
Anzugswicklung Abstellmagnet
Bremsventil
Warnsummer

Masseanschluß

Öldruck
Fahrhebel

Fig. 1: Module

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

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

PIN Potential with LED on Potential with LED off

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

008 911 49 BOMAG 169

8.1 Seat contact module

Emergency operation

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

Description of function

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

Sw itching on the ignition

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

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

Starting the engine

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

170 BOMAG 008 911 49

Seat contact module 8.1

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

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

Engine has stopped

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

008 911 49 BOMAG 171

8.1 Seat contact module

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

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

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

172 BOMAG 008 911 49

Seat contact module 8.1

0 Hardware description

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

Input Behaviour Comment

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

0.1 Pin assignment of inputs

Signal name Module Signal at input

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

0.2 Pin assignment of outputs

Signal name Module Signal at output

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

008 911 49 BOMAG 173

8.1 Seat contact module

174 BOMAG 008 911 49

 9 Speedometer Module

008 911 49 BOMAG 175

9.1 Speedometer module

9.1 Speedometer module

Fig. 1 Speedometer module

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

Manual testing of the speedometer

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

176 BOMAG 008 911 49

Speedometer module 9.1

Pin-no. module Pin name Description

Test E_ANZEIGENTEST Input HIGH active: Activate manual display test

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

OUT - Display - Output: Ground connection for speedometer

OUT + Display + Output: Output voltage for speedometer

GND (2X) Ground Input: Module ground connection

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

Teaching the module

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

Caution
!

BW24RH, BW27RH, C550H and C560H = travel 18

meters.
All other machines = travel 15 meters.

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

The module has now learned the pulses of the

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

008 911 49 BOMAG 177

9.1 Speedometer module

178 BOMAG 008 911 49

 10 Service Training

008 911 49 BOMAG 179

180 BOMAG 008 911 49
 10.1 Electrics BEM (BOMAG Evib-meter)

008 911 49 BOMAG 181

10.1 Electrics BEM (BOMAG Evib-meter)

BOMAG Evib-meter (BEM)

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

182 BOMAG 008 911 49

Electrics BEM (BOMAG Evib-meter) 10.1

Service Training
Electrics
MESX

Version 3.01

Status: 01.04.2005 Page 1 of 55

Author: T.Löw / TE
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Table of contents
1 Document alteration list.....................................................................................................................3
2 Proof of software change MESX .......................................................................................................4
3 Proof of software change BOP..........................................................................................................5
4 Known faults ......................................................................................................................................6
5 How to proceed when replacing components? .................................................................................7
5.1 How to proceed when replacing an ESX control? .......................................................................7
5.2 How to proceed when replacing a rear axle sensor? ..................................................................7
5.3 Which components can be replaced without a subsequent adjustment procedure? ..................7
5.4 List of machine types ...................................................................................................................8
6 Possible adjustments on machines without BOP ..............................................................................9
6.1 Description of the Display Module ...............................................................................................9
6.2 Input of code numbers.................................................................................................................9
6.3 Changing the machine type (only via display module)...............................................................10
6.4 Inverting the direction signal (only via display module)..............................................................11
6.5 Changing the bit rate (only with display module) .......................................................................12
7 Adjustment/display possibilities on machines with BOP .................................................................13
7.1 Adjusting the machine type (BOP).............................................................................................13
7.2 Inverting the direction signal via the BOP control terminal ........................................................15
7.3 Accessing the diagnostics menu ...............................................................................................17
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof)................ 19
7.3.2 Extended diagnose BVC machines.......................................................................................... 20
7.4 Changing the printout language.................................................................................................21
7.5 Setting the machine serial number ............................................................................................23
7.6 Teaching distance pulses ..........................................................................................................25
7.7 Activating the amplitude limitation (only BVC machines)...........................................................27
7.8 Changing the display mode (metric/imperial) ............................................................................29
8 Possible settings on the BCM05mobile...........................................................................................31
8.1 Reading the software version ....................................................................................................31
8.2 Changing the language..............................................................................................................31
8.3 Changing the unit system (metric/imperial) ...............................................................................31
9 Block diagram BEM.........................................................................................................................33
10 Block diagram BTMplus / VARIOCONTROL.............................................................................34
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile ..............................................35
12 Description of the Signals on the ESX-Control..........................................................................36
13 Fault codes of the ESX control ..................................................................................................41
13.1 Overview ...............................................................................................................................41
13.2 Description of fault reactions .................................................................................................42
13.3 Detailed description of fault codes and their possible causes..............................................43
14 Input codes for ESX control (only via display module on BEM).................................................47
14.1 Travel system ........................................................................................................................47
14.2 Vibration ................................................................................................................................48
14.3 Light.......................................................................................................................................48
14.4 Acceleration transducer.........................................................................................................49
14.5 Diesel engine.........................................................................................................................49
14.6 Setting the machine type.......................................................................................................50
14.7 Parameter change.................................................................................................................51
15 Terminology in connection with ESX .........................................................................................52

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1 Document alteration list

Version Date Description of changes resp.

0.00 27.04.2004 Creation of version 1 Löw
1.00 05.05.2004 Î Block diagrams added Löw
Î Description of display module extended
Î "Proof of software change" added
1.01 23.07.2004 Î Description of BOP display pages added. Löw
2.00 31.08.04 Î Input code 4602 replaced by code 4606 Löw
Î Machine type BW219D added
3.00 15.10.2004 Î Item "How to proceed when replacing components?" added Löw
Î Description for ESX Pin 0:35 added
Î Description fault code 4601 and 4606 corrected
Î Description Software Version 3.00 added
3.01 16.11.2004 Î Description Code 7534 from version 3.00 added Löw,
Î Description Software change V3.01 added Horch
Î Description Code 7573 from version 3.01 added
Î Description of menus "Amplitude limitation" and "Imperial
display" added
Î Description Software Version up to 3.03 added
Î Terminal designation MESX canged from X0 to X44
Î Description of codes 7502, 7511, 7512, 7532, 7541, 7542,
7550, 7551, 7552, 7562, 7571, 7572, 7576 from version 3.03
added
Î Proof of "Software change" changed to "Software MESX"
Î Item "Proof of software change BOP" added
Î Item "Adjustment possibilities on BCM05mobile" added
Î Block diagram BTMplus / VARIOCONTROL and
BCM05mobile added
Î Serial numbers added to list of machine types

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2 Proof of software change MESX

Version Date Description of changes resp.

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

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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 Part-No. 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 Î Amplitude bar graph in imperial display mode 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 adjustment,

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

Therefore set the machine type in the first step! see "5.4 List of
machine types", or "7.1 Adjusting the machine type"

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 6.4.

5.3 Which components can be replaced without a subsequent

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

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

recommended.

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5.4 List of machine types

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

The following machine types can be adjusted:

Machine type First serial number Last serial number Code Available from
version
177 D 101 582 20 1001 XXX XXX XX XXXX 7500 1.00
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7502 3.03
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7503 1.00

179 DH 101 582 24 1001 XXX XXX XX XXXX 7511 3.03

179 PDH 101 582 25 1001 XXX XXX XX XXXX 7512 3.03
XXX XXX XX XXXX
211 D 101 582 40 1001 XXX XXX XX XXXX 7520 1.03
101 582 41 1001

213 D 101 582 50 1001 XXX XXX XX XXXX 7530 1.03

213 DH 101 582 51 1001 XXX XXX XX XXXX 7531 1.03
213 PDH 101 582 52 1001 XXX XXX XX XXXX 7532 3.03
213 BVC 101 582 53 1001 XXX XXX XX XXXX 7533 1.02
213 BVC Platten 101 582 54 1001 XXX XXX XX XXXX 7534 3.00
213 BVC DI 101 582 53 1001 XXX XXX XX XXXX 7535 1.05

214 DH 101 582 58 1001 XXX XXX XX XXXX 7541 3.03

214 PDH 101 582 59 1001 XXX XXX XX XXXX 7542 3.03

216 D 101 582 62 1001 XXX XXX XX XXXX 7550 3.03

216 DH 101 582 60 1001 XXX XXX XX XXXX 7551 3.03
216 PDH 101 582 61 1001 XXX XXX XX XXXX 7552 3.03

219 D 101 582 72 1001 XXX XXX XX XXXX 7560 2.00

219 DH 101 582 70 1001 XXX XXX XX XXXX 7561 1.05
219 PDH 101 582 71 1001 XXX XXX XX XXXX 7562 3.03

226 DH 101 582 80 1001 XXX XXX XX XXXX 7571 3.03

101 582 83 1001
226 PDH 101 582 81 1001 XXX XXX XX XXXX 7572 3.03
101 582 84 1001
226 BVC 101 582 82 1001 XXX XXX XX XXXX 7573 3.01
101 582 85 1001
226 BVC DI 101 582 82 1001 XXX XXX XX XXXX 7575 1.04
101 582 85 1001
226 BVC RC 101 582 82 1001 XXX XXX XX XXXX 7576 3.03
101 582 85 1001

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6 Possible adjustments on machines without BOP

6.1 Description of the Display Module

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

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

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

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

057 667 72
15/54

illustration).

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.

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

New controls are delivered with a default machine type setting 7 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 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 "14").

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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)

Adjusting the machine type requires the following sequence:

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

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

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

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

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

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

• Switch the ignition off and on again.

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

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

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

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

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

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

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

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

• Press "ESC" to leave the page.

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

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7.3 Accessing the diagnostics menu

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

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

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

• Press "ESC" to leave the page.

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

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7.3.1 Extended diagnostics on machines with circular exciter (BTMplus,

BTMprof)

4.23 V Ubv: actual voltage front acceleration transducer

4.24 V Ubh: actual voltage rear acceleration transducer

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

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

Direction: Status MESX input travel direction (LED on = 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: actual voltage of exciter position potentiometer

4.23 V Ubv: actual voltage front acceleration transducer

4.24 V Ubh: actual voltage rear acceleration transducer

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

Direction: Status MESX input travel direction (LED on = 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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7.4 Changing the printout language

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

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

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

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

• Press "ESC" to leave the page.

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7.5 Setting the machine serial number

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

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

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

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

• Press "ESC" to leave the page.

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7.6 Teaching distance pulses

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

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

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

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

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7.7 Activating the amplitude limitation (only BVC machines)

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

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

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

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

• Press "ESC" to leave the page.

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7.8 Changing the display mode (metric/imperial)

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

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

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

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

• Press "ESC" to leave the page.

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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 unter the name
BOMAG.

8.2 Changing the language

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 and select
the bottom switch "Service".

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

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 and select
the bottom switch "Service".

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

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

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 Service Training MESX Block diagram

008 911 49
9 Block diagram BEM
Electrics BEM (BOMAG Evib-meter)

BOMAG
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10 Block diagram BTMplus / VARIOCONTROL

BOMAG
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11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile
Electrics BEM (BOMAG Evib-meter)

BOMAG
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12 Description of the Signals on the ESX-Control

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

ESX terminal Signal description Nominal values (voltage / current)

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

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

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

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

X44:6

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

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

Analogue input / voltage input 0..8.5 V
X44:8

X44:9 Input exciter position front Position of front exciter (measured against AGND)
Analogue input / voltage input 0..8.5 V Bottom stop ) approx. 2.2 V
Neutral position ) approx. 4.25 V
Top stop ) approx. 6.6 V

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008 911 49
ESX terminal Signal description Nominal values (voltage / current)
X44:10

X44:11

X44:12

X44:13

X44:14

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

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

X44:16 Input button "START" (option) Push button pressed ) 12 V

Digital input active high Push button not pressed ) 2V
X44:17 Input button "STOP" (option) Push button pressed ) 12 V
Digital input active high Push button not pressed ) 2V
X44:18 Input button "PRINT" (option) Push button pressed ) 12 V
Digital input active high Push button not pressed 2V

BOMAG
)
X44:19 Input button "CLEAR" (option) Push button pressed ) 12 V
Digital input active high Push 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, travel speed range switch, etc. Permissible range: approx. 7,65..9,35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override condition (emergency operation).
X44:24

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ESX terminal Signal description Nominal values (voltage / current)

X44:25

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

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

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

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

Analogue input / voltage input 0..8.5 V
X44:30 Input acceleration transducer VH/VR15g Acceleration signal (measured against AGND)

BOMAG
Open circuit voltage (vibration off): ) 4,2..4,3 V
Analogue input / voltage input 0..8.5 V
X44:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)

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

Analogue input / voltage input 0..8.5 V
X44:32

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

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

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008 911 49
ESX terminal Signal description Nominal values (voltage / current)
X44:36

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

Digital input active high Engine not running ) 0V
X44:38 Input vibration 2 On Vibration on: ) >6V
Digital input active high Vibration off: )approx.0 V
X44:39

X44:40

X44:41
Electrics BEM (BOMAG Evib-meter)

X44:42

X44:43

X44:44

BOMAG
X44:45

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

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

X44:49

X44:50

X44:51

X44:52

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ESX terminal Signal description Nominal values (voltage / current)

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

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

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

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

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

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

X44:61

BOMAG
X44:62

X44:63

X44:64

X44:65 Mouse port Baby Boards approx. 0 V

X44:66 Mouse port Baby Boards approx. 0 V

X44:67 Mouse port Baby Boards approx. 0 V

X44:68 Mouse port Baby Boards approx. 0 V

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Service Training Fault codes of the ESX control

13 Fault codes of the ESX control

13.1 Overview

Fault code Fault description

4501 - Position controller (exciter potentiometer, valves)
4650
41 0 - Acceleration transducer
40
8 60
20 - Internal software errors
8250

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13.2 Description of fault reactions

Fault reaction Description of fault reaction

1 Warning.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
2 Function affected, the faulty function is replaced by an emergency function.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
3 Partial function faulty, the partial function cannot be overridden by an emergency function.
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
4 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective

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

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

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13.3 Detailed description of fault codes and their possible causes

Fault Fault description Possible cause Terminal Input Fault

code on ESX code for reaction
diagnose
450 Input exciter potentiometer front -{}-) Wire breakage in current path X44:09 5
1 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
450 Input exciter potentiometer front ) Current path connected to +12 V / +8,5 V X44:09 5
2 The voltage applied to the input is above the
Electrics BEM (BOMAG Evib-meter)

) Potentiometer not connected to ground

specified range (see signal description). ) Potentiometer defective

BOMAG
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Fault Fault description Possible cause Terminal Input Fault

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

452 Output proportional solenoid front ) Current path is interrupted X44:46 2

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

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

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

452 Output proportional solenoid front ) Current path is interrupted X44:47 2

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

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008 911 49
Fault Fault description Possible cause Terminal Input Fault
code on ESX code for reaction
diagnose
453 Position controller positive limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
1 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

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

460 Input acceleration transducer 1 ) Current path has no connection to +12 V / +8,5 V X44:29, 4601 2
1 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
460 Input acceleration transducer 1 ) Current path connected to +12 V / +8,5 V X44:29, 4601 2
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

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

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

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Fault Fault description Possible cause Terminal Input Fault

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

BOMAG
Ct0 Display module has no connection to ESX- ) Wire breakage in CAN bus lines X44:26 - -
control. ) Short circuit between CAN bus lines X44:27
) One or both CAN bus line(s) has (have) connection to 12V or
ground
) Incorrect bit rate in display module (nominal value: 125 kBit)

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008 911 49
14 Input codes for ESX control (only via display module on BEM)

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 "transducer 0 0 0 0 ) Neutral position
for travel direction". 000I ) Reverse travel detected
Electrics BEM (BOMAG Evib-meter)

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

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

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

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14.2 Vibration

Input code Description of display function Display values

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

14.3 Light

Input code Description of display function Display values

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

BOMAG
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008 911 49
14.4 Acceleration transducer

Input code Description of display function Display values

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

14.5 Diesel engine

Input code Description of display function Display values

Electrics BEM (BOMAG Evib-meter)

5000 Input MD+ 0000 ) Engine OFF

Show status of diesel engine. 0001 ) Engine ON

BOMAG
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14.6 Setting the machine type

Input code Description of display function Display values

7000 Shows the adjusted machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7010 Switches on function „Set machine type“ see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7011 Confirms entered machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7500..75 Preselect machine type see adjustment instructions (page Fehler! Textmarke nicht
99 definiert.)!

BOMAG
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008 911 49
14.7 Parameter change

Input code Description of display function Display values

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

BOMAG
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Service Training MESX

15 Terminology in connection with ESX

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

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

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

Terminal, cable lug

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

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Short circuit to ground

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

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

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

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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

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

Marking Closed loop control Control

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

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Current and voltage measurement

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

Override / emergency operation

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

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

PWM – digital output

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

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Service Training 10.2

Service Training

Single Drum Roller

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

008 911 49 BOMAG 241

10.2 Service Training

Service Training
Table of contents

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

BW 211 / 213 / 216 D-4

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

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

BW 211 / 213 / 216 D-4

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10.2

Travel circuit
from brake valve

M4 M5

from speed
ø 0.8
range valve
M4 M3 L

BW 216 D-4 / Deutz 1013 EC

2 A

BW 211 / 213 D-4 / Deutz 2012C

ø 0.81
ø 0.6
6

ø 0.6
4 8

BOMAG
T3
25 bar 9
3
1

M2
B

Charge pressure to vibration pump

Charge pressure from hydraulic oil filter

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

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

-E1-
Service Training

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008 911 49
Service Training

M4 M3
A
2 M1

6 11

BW 216 D-4 / Deutz 1013 EC

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

B M2

7 10

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

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

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

• travel pump with control and safety elements,

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

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

• axle drive motor,

• charge pump (also for vibration circuit),

• hydraulic oil filter (in charge circuit),

• hydraulic oil cooler with thermostat

• hydraulic lines.

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

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

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

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

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

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

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

246 BOMAG 008 911 49

Service Training 10.2

Service Training
Travel pump

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

M4 M5

2
A from/to
Travel motor

25 bar 4
3
1

from/to
Travel motor
B
Charge pressure to vibration pump

Charge pressure from hydraulic oil filter

Fig. 3: Hydraulic diagram of travel pump

1 Pump drive 3 Charge pressure relief valve

2 Servo control 4 Multi-function valves

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 247

10.2 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. 4: Travel pump

1 Control lever 5 Cylinder block

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

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

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

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

Note:
These machines are equipped with two charge pumps.

BW 211 / 213 D-4 / Deutz 2012C

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

248 BOMAG 008 911 49

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Service Training
Cross-sectional view of travel pump

2
4
5
1 3

9
10
8
11

Fig. 5: Cross-sectional view of travel pump

1 Retainer for swash plate 7 Swash plate bearing

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

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 249

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Service Training
View of the rotating group

4 3
5

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

250 BOMAG 008 911 49

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Service Training
Description of function

2 3 4 5 6
1

8 6 7

Fig. 7: Function of travel pump

1 Drive shaft 5 Cylinder block

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

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 251

10.2 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 211 / 213 D-4 / Deutz 2012C

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

252 BOMAG 008 911 49

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Service Training
Tandem pump, connections and adjustment points

32

Thermostat
housing

Fig. 8: Connections and adjustment points

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 253

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

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

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

37 cooler inlet

BW 211 / 213 D-4 / Deutz 2012C

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

254 BOMAG 008 911 49

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Service Training
servo control

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

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

Control piston

Sliding block

Servo arm

Fig. 9: Control piston

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

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 255

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Service Training
• when shutting the engine down,

• if the external control cable comes loose,

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

BW 211 / 213 D-4 / Deutz 2012C

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

256 BOMAG 008 911 49

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Service Training
Multi-function valves

High pressure limitation

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

1 2

3
A

6 5

B
4

Fig. 10: Multi-function valves

1 to the control 6 Drive shaft

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 257

10.2 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. 11: Multi-function valve, details

1 Reducing fitting 7 Check valve

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

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

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

258 BOMAG 008 911 49

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Service Training
Charge pressure relief valve

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

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

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

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

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 259

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Service Training
Flushing valve

Fig. 12 Cross-section of flushing valve

1 Flushing spool
2 Flushing pressure relief valve

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

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

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

Axle drive motor,

BW 211 / 213 D-4 / Deutz 2012C

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

260 BOMAG 008 911 49

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

5 7 8

6
9

11
10
4
2

Fig. 13: Axle drive motor,

1 Control piston 7 Cylinder block

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

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 261

10.2 Service Training

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

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

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

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

Function

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

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

262 BOMAG 008 911 49

Service Training 10.2

Service Training
Rear axle

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

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

Fig. 14: Manual releasing of rear axle brakes

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

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

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

Attention!

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 263

10.2 Service Training

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

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

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

2 3

4
1

43090070

8 7 6 5

Fig. 15: Drum drive motor

1 Drive shaft with output flange

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

BW 211 / 213 D-4 / Deutz 2012C

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

264 BOMAG 008 911 49

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Service Training
The housing consists of:

• bearing section (drive shaft bearings),

• torque section (cam race) and

• oil distributor.

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

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

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

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

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

2
3

Fig. 16: Function of the radial piston motor

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 265

10.2 Service Training

Service Training
Piston position 1:

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

Piston position 2:

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

Piston position 3:

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

Piston position 4:

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

Piston position 5:

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

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

266 BOMAG 008 911 49

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Service Training
Releasing the brake in the radial piston motor manually

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

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

• Remove the plug 1 (Fig. 17).

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 267

10.2 Service Training

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

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

2
3 4
1

10 8
9

Fig. 18: Reduction gear CR 31

1 Travel motor 6 Sun gear

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

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

BW 211 / 213 D-4 / Deutz 2012C

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

268 BOMAG 008 911 49

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Service Training
Brake control

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

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

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

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

Manual releasing of the brake in the drum drive reduction gear

Brake releasing device

in operation position

Brake releasing device in

position “brake manually
released”

Fig. 19 Manual brake releasing device

BW 211 / 213 D-4 / Deutz 2012C

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

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Service Training

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

• Turn both screws (Fig. 20) for releasing the brake in the drum drive reduction gear evenly in
clockwise direction, until the drum can be turned freely.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 27 -

270 BOMAG 008 911 49

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Service Training
Travel circuit: BW 211 / 213 D-4 Drum drive with radial piston motor

1
4

6 1

n
ctio 1 Travel pump
i r e
e ld 2 Vibration pump
av 3 Travel lever
Tr 4 Hydraulic oil filter
High pressure 5 Rear axle
Low pressure 6 Axle drive motor
7 Drum drive motor
Charge pressure
8 Hydraulic oil tank
Leak oil (case pressure)

Fig. 21: BW 211 / 213 D-4, travel circuit, routing of hoses

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 28 -

008 911 49 BOMAG 271

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Service Training
Travel circuit: BW 216 D-4 Drum drive with travel motor with reduction
gear

2
9

3
8

4
7 5

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

Fig. 22: Travel circuit with 51 C 110 and CR 31

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 29 -

272 BOMAG 008 911 49

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Service Training
Brake control: BW 211 / 213 D-4 with radial piston motor

Brake valve

Leak oil from drum drive motor to brake valve

Brake releasing pressure
Charge pressure
Leak oil from brake valve to hydraulic oil tank

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 30 -

008 911 49 BOMAG 273

10.2 Service Training

Service Training
Brake circuit Brake control: BW 216 D-4 Travel motor with reduction gear

Brake valve

Charge pressure
Brake releasing pressure
Leak oil

Fig. 23: Brake circuit

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 31 -

274 BOMAG 008 911 49

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Service Training

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 32 -

008 911 49 BOMAG 275

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Service Training
Travel drive, components and test points

Travel pump: left hand side

2
1

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

diagram
1 Test port, forward 10, MD max. 426 bar
2 High pressure port, forward 10, A

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 33 -

276 BOMAG 008 911 49

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Service Training
Travel pump: right hand side

3
1

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

diagram
1 Test port, reverse 10, MC max. 426 bar
2 High pressure port, reverse 10, B
3 Travel control (travel control cable)

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 34 -

008 911 49 BOMAG 277

10.2 Service Training

Service Training
Front travel motor with radial piston motor for BW 211 / 213 D-4

2 1

5
4
6
3

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

diagram
1 High pressure port, forward 12, L
2 High pressure port, reverse 12, R
3 Brake 12 open, 26 bar
pressureless
closed
4 Cross-flushing of travel pump T1 12
5 Cross-flushing outlet to tank 12, 1
6 Travel speed range selector 12, Y Motor Qmax,
depressurized
Motor Qmin,
26 bar

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 35 -

278 BOMAG 008 911 49

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Service Training
Rear travel motor: Axle motor

1
4
3 2

6
5
7

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

diagram
1 Solenoid for speed range selector Y31 14 Motor Qmax---
valve depressurized,
Motor Qmin---
26 bar
2 Flushing valve 14
3 High pressure port, drum drive 14, A
motor forward
4 High pressure port, drum drive 14, B
motor reverse
5 High pressure from travel pump 14, A
forward
6 High pressure from travel pump 14, B
reverse
7 Qmin- setscrew 14

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 36 -

008 911 49 BOMAG 279

10.2 Service Training

Service Training
BW 216 D-4 Travel motor with reduction gear (drum drive motor)

5
7
6

2 1

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

diagram
1 Pressure travel forward 16 - A
2 Pressure travel reverse 16 - B
3 Flushing valve 16
4 Solenoid for speed range selector Y 30 16 Motor Qmax,
valve depressurized
Motor Qmin,
26 bar
5 Qmin- setscrew 16
6 Leak oil port 16
7 Brake port on gearbox 16

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 37 -

280 BOMAG 008 911 49

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Service Training
BW 211 / 213 D-4 Brake and travel speed range selection

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

diagram
1 Speed range selector valve for front Y 31 08, a2 Motor Qmax,
travel motor (Poclain) depressurized
Motor Qmin,
26 bar
2 Brake valve Y 04 08, a1 open, 12V closed,
de-energized

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 38 -

008 911 49 BOMAG 281

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Service Training
BW 216 D-4 Brake valve

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

diagram
1 Brake valve Y 04 08, open, 12V closed,
de-energized

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 39 -

282 BOMAG 008 911 49

Service Training 10.2

Service Training
Travel lever console with rotary switch for speed range selection

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 40 -

008 911 49 BOMAG 283

10.2 Service Training

Service Training
Travel lever

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

diagram
1 Initiator for backup alarm B14 0 / 12V, normally
closed
2 Initiator for brake B13 Normally closed,
opened in braking
position
0/12V

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 41 -

284 BOMAG 008 911 49

Service Training 10.2

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

Procedure:

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

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

Machine travels with travel lever in 'Neutral'

Machine does not drive (forw. and reverse)
Machine drives to one direction only

Max. travel speed not reached

TROUBLE SHOOTING TRAVEL

Hydraulic oil overheating

SYSTEM
BW 211 / 213 / 216 D-4
SYMPTOMS

POSSIBLE CAUSES
Brake valve (electric/mechanical/hydraulic) 1
Brake in axle/drum drive motor (mechanical/hydraulic) 2 2 3
Travel speed range switch position /defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/ travel pump high pressure limitation
3 2 3 3
dirty/out of adjustment/defective
Adjustment of travel cable 1 2
Travel pump mechanical neutral 3 3
Travel pump(s) defective 3 3 2
Axle drive motor control valve (electric / mechanical / hydraulic) 1 2
Flushing valve axle drive motor seized 3
Travel motor(s) defective 3 3
Hydraulic oil cooler soiled (internally/externally) 1
Thermostat (hydraulics) soiled/jammed/defective 2
Kupplung Dieselmotor-Pumpe 2
Dieselmotor 1

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013 EC - E 42 -

008 911 49 BOMAG 285

10.2 Service Training

Service Training
Vibration system
The vibration system of the single drum rollers of generation D-4 works with two frequencies and two
amplitudes. This enables perfect adaptation of the machine to various types of soil and different
applications.

The vibration drive is a closed hydraulic circuit. The circuit consists of:

• the vibration pump,

• the vibration motor and

• the pressure resistant connecting hoses

from charge pump via to release the brake

Travel pump
Charge oil
Vibration pump
D M3 E

L2 N

Block

M1

M2

S
B
2
1
M4

M5

Fig. 1: Vibration circuit

1 Vibration pump
2 Vibration motor

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F1-

286 BOMAG 008 911 49

Service Training 10.2

Service Training
Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly
driven by the diesel engine.

When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral
position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to
one of the two control piston sides. The swash plate inside the pump will swash to the corresponding
side and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the
vibrator shaft inside the drum.

When altering the position of the swash plate through the neutral position to the opposite side, the oil
flow will change its direction and the vibration motor will change its sense of rotation.

Since the end stops for the swash plate are set to different swashing angles to both directions, the angle
for the piston stroke is also different to both sides. This angle influences the length of the piston stroke
and thereby the actual displacement of the pump.

• Large angle = high displacement = high vibrator shaft speed (frequency)

• Small angle = low displacement = slow vibrator shaft speed (frequency)

The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending
on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic
weights.

This results in the following constellations:

• Basic weight + change-over weight = high amplitude

• Basic weight - change-over weight = low amplitude

In order to achieve effective compaction results the vibration system is designed in such a way, that high
amplitude is coupled with low frequency and low amplitude with high frequency.

Fig. 2:

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F2-

008 911 49 BOMAG 287

10.2 Service Training

Service Training
Vibration pump

Similar to the travel pump the vibration pump is also a swash plate operated axial piston pump with
variable displacement for operation in a closed circuit.

The displacement of the pump is proportional to the engine speed and the chosen displacement.

When actuating the swash plate out of neutral position the flow quantity to the chosen direction will
increase from ”0” to the maximum value. When altering the position of the swash plate through the
neutral position to the opposite side, the oil flow will change its direction and the vibration motor will
change its sense of rotation. All valves and safety elements for operation in a closed circuit are
integrated in the pump.

from charge pump via Releasing the brake

Travel pump
Charge oil
Vibration pump
D M3 E

1 Vibration pump
L2 N 2 Charge pump
3 High pressure limitation
Block
4 4/3-way solenoid valve
A

M1

M2

S
B

M4

M5

Fig. 3: Hydraulic diagram vibration pump

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F3-

288 BOMAG 008 911 49

Service Training 10.2

Service Training
Function

1 2

5 4 3

Fig. 4 Cross-section of vibration pump

1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F4-

008 911 49 BOMAG 289

10.2 Service Training

Service Training

1
2
5

4 3

Fig. 5 Cross-section of vibration pump

1 Control
2 Servo piston
3 Friction free swash plate bearing
4 Attachment plate
5 Spool valve

The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.

The slipper pads rest against the sliding surface of the swash plate and are at the same time held on
the sliding surface by a retaining device.

During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F5-

290 BOMAG 008 911 49

Service Training 10.2

Service Training
During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into
the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he
closed circuit.

Control

The electro-hydraulic displacement control (remote control) converts the electric input signal to a load
controlling output signal. Since the pump is not equipped with a proportional control, but a 12 Volt
solenoid valve, the pump is always actuated to one of the two end stop positions.

Charge pumps

These machines are equipped with two charge pumps.

One of the pumps is an external gear pump, which is directly driven by the auxiliary output of the engine
and serves also as steering pump.

The second pump is an internal gear pump and is located in the end cover of the vibration pump.

The oil flow generated by the charge pumps is joined together with the return flow from the steering
valve before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and
vibration pump.

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F6-

008 911 49 BOMAG 291

10.2 Service Training

Service Training
High pressure relief valves

As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.

Fig. 6 Pressure relief valve

1 From the charge pump

2 Closed circuit
3 High pressure relief valve with
integrated boost check valve

Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 371 bar
(pressure difference between high and low pressure side = 345 bar + charge pressure = 26 bar).

The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit. The function of these valves has already been described in the chapter "travel
system".

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F7-

292 BOMAG 008 911 49

Service Training 10.2

Service Training
Vibration motor

The vibration motor is a Bosch-Rexroth (Hydromatik) axial piston motor of series A10FM 45 with fixed
displacement in bent axle design. Since the motor can be subjected to pressure from both sides, it is
most suitable for the use in closed hydraulic circuits.

The output speed of the motor depends on the oil quantity supplied by the vibration pump.

2 3
4 5
1

8 7
10 9

Fig. 7 Cross-section of vibration motor

1 Flushing valve block

2 Flushing valve
3 Working pistons with slipper pads
4 Roller bearing for output shaft
5 Radial seal
6 Output shaft
7 swash plate
8 Retaining plate
9 Pre-tensioning spring
10 Flushing pressure relief valve

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F8-

008 911 49 BOMAG 293

10.2 Service Training

Service Training
The output torque raises with increasing pressure difference between low and high pressure side in the
closed circuit.

Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.

When switching the vibration on the motor must first start to move the resting vibration shaft. This
resistance causes a hydraulic starting pressure, which is limited to 345 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).

• Hard ground = High operating pressure

• Loose ground = Low operating pressure

A MA

3 1

B MB

Fig. 8 Circuit diagram of vibration motor

1 Vibration motor
2 Flushing valve
3 Flushing pressure relief valve

BW 211 / 213 D-4 / Deutz 2012C

BW 216 D-4 / Deutz 1013EC -F9-

294 BOMAG 008 911 49

Service Training 10.2

Service Training
The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a
pressure difference will appear between the two sides of the closed circuit. The higher pressure moves
the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low
pressure side.

1
A

Fig. 9 Flushing valve

1 Flushing spool
2 Flushing pressure relief valve

The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.

This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 295

10.2 Service Training

Service Training
Drum

4
14

5 9

7 13
6
10
3 8 11

12

Fig. 10 Cross-section of drum

1 Drum shell 8 Change-over weight

2 Vibration bearing 9 Coupling vibr.-motor – vibrator shaft
3 Basic weight 10 Travel bearing
4 Vibrator housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Vibrator shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing

BW 211 / 213 D-4 / Deutz 2012C

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

296 BOMAG 008 911 49

Service Training 10.2

Service Training
Vibration system: Components and test ports

Vibration pump

1
2

5 6 3
4

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

diagram
1 Pressure test port, charge pressure MA 26 bar
2 Differential pressure switch, charge 07 ^p 3.5 bar
pressure
3 High pressure port, low MF
amplitude
4 High pressure port, high ME
amplitude
5 Solenoid valve, low amplitude Y08 12V / 3.33A
6 Solenoid valve, high amplitude Y07 12V / 3.33A

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 297

10.2 Service Training

Service Training
Vibration pump

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

diagram
1 Pressure test port, vibration MF max. 371 bar
pressure low amplitude
2 Pressure test port, vibration ME max. 371 bar
pressure high amplitude

BW 211 / 213 D-4 / Deutz 2012C

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

298 BOMAG 008 911 49

Service Training 10.2

Service Training
Vibration motor

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

diagram
1 High pressure port, low amplitude 16
2 High pressure port, low amplitude 16
3 Leak oil and flushing oil port 16 approx. 10 l/min,
incl. flushing
quantity

BW 211 / 213 D-4 / Deutz 2012C

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

008 911 49 BOMAG 299

10.2 Service Training

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

Procedure:

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

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

No vibration (charge pressure OK)

Vibration only with one amplitude
Exciter shaft speed too low
TROUBLE SHOOTING
VIBRATION
BW 211 / 213 / 216 D-4
SYMPTOMS

POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1
Vibration push button (on/off) 1
Electrics defective / wiring 2 2
Pump control (electrical / hydraulic) 1 1
Pressure override / high pressure relief valves in vibration pump
2
soiled/out of adjustment/ defective
Charge pump / charge pressure relief valve
2
soiled/ defective
Vibration pump frequency adjustment 2
Vibration pump defective 2 2
Coupling between diesel engine and travel pump defective
Exciter shaft bearings defective 3
Vibration motor coupling defective 2
Vibration motor defective 2 1
Diesel engine 1

BW 211 / 213 D-4 / Deutz 2012C

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

300 BOMAG 008 911 49

 11 Engine

008 911 49 BOMAG 301

11.1 Diesel engine

11.1 Diesel engine The engines are characterized by the following posi-
tive features:
l short and compact design
Description
l low noise level
Single drum rollers of series BW211/213 D/PD-4 and
BW211/213 D/PD-40 are powered by Deutz diesel en-
l almost vibration free operation
gines type TCD 2013 L04 2V with intercooling. The in- l low fuel consumption
tercooler reduces the thermal load on the engine, the l low exhaust emissions
exhaust temperature and the fuel consumption and l high power reserves and
thus enables a higher power output.
l excellent access to all service locations.

Fig. 1 Engine compartment The cylinders must be successively numbered, start-

ing with 1 at the flywheel (Fig. 2).
Cylinder arrangement
Sense of rotation
Viewed on power take-off side.
Turning to the left, anti-clockwise.

Engine side
Viewed on power take-off side.
Left = Exhaust side
Right = Operation side

Fig. 2 Numbering of cylinders

302 BOMAG 008 911 49

Diesel engine 11.1
Operation side

Fig. 3 Operation side 15Possible installation of hydraulic pump or compres-

1 Lubrication oil filling neck sor (optional)
2 Charge air line 16Fuel filter
3 Coolant inlet 17Engine shut-down solenoid
4 Ventilation line to compensation tank 18Crankcase ventilation valve
5 Fan hub 19Cover
6 Fuel lift pump 20Charge air pipe
7 Ribbed V-belt 21Injection pump
8 Idler pulley 22Control cell (ATL pressure control)
9 Coolant pump
10Lubrication oil drain plug
11Replaceable lubrication oil filter
12Lubrication oil sump
13Lubrication oil cooler
14Generator

008 911 49 BOMAG 303

11.1 Diesel engine

Exhaust side

Fig. 4 Exhaust side

1 Exhaust turbo charger
2 Transport device
3 Speed controller
4 Flywheel or (transmission connection SAE)
5 Engine mounts
6 Lubrication oil return line from exhaust gas turbo
charger
7 Relay (starter)
8 Lubrication oil filling neck (optional)
9 Coolant inlet
10Exhaust manifold

304 BOMAG 008 911 49

Diesel engine 11.1
Lubrication oil circuit

Fig. 5 Lubrication oil circuit 12 Plunger with rocker arm pulse lubrication
1 Lubrication oil sump 13 Push rod, lubrication oil supply for rocker arm lubri-
2 Lubrication oil suction line cation
3 Lubrication oil pump 14 Rocker arm
3.1 Pressure relief valve 15 Return line to lubrication oil sump
4 Lubrication oil cooler 16 Lubrication oil line to exhaust turbo charger
4.1 Return flow check valve (only on 2012) 17Exhaust turbo charger
4.2 Bypass valve 18 Return line from compressor / hydraulic pump to
crankcase
4.3 Lubrication oil filter bypass valve
19 Compressor or hydraulic pump
4.4Pressure control valve
20 Oil line to crankshaft and camshaft, compressor /
5 Lubrication oil filter
hydraulic pump
6 Main lubrication oil lines
21 Return flow from exhaust turbo charger
6a Internally switched exhaust gas recirculation
7 Crankshaft bearing
8 Conrod bearing
9 Camshaft bearing
10 Line to spray nozzle
11 Piston cooling nozzle with pressure retaining valve

008 911 49 BOMAG 305

11.1 Diesel engine

Description
The oil inside the combustion engine has the function
of lubricating and cooling all drive components, re-
moving impurities and neutralizing chemically effec-
tive combustion products, transferring forces and
damping vibrations.. The oil is only able to fulfil this
function, if sufficient quantities are transported to the
critical points in the engine and if its properties are
adapted to the prevailing requirements by corre-
sponding manufacturing processes and refining (addi-
tives).
(Fig. 5) shows pressure circulation lubrication in com-
bination with splash and oil mist lubrication. Here oil is
transported under pressure to all bearing locations by
the oil pump (3), while sliding surfaces are splash or
oil mist lubricated. After flowing through the bearing
locations and along sliding surfaces the oil is collected
in the oil sump (1) under the drive, where the oil is
cooled, defoamed by calming and stored.
The oil filter (5) removes solid foreign particles from
the engine oil (combustion residues, metal abrasion,
dust) and thus maintains the function of the lubrication
oil during the maintenance intervals.

306 BOMAG 008 911 49

Diesel engine 11.1
Fuel diagram

Fig. 6 Fuel supply 13Fuel tank

1 Water separator sensor connection 14Manual fuel pump
2 Flow to fuel lift pump 15Fuel pre-filter
3 Fuel lift pump 16Water separator
4 Connecting line pump - main filter 17Fuel pre-heating connection (option)
5 Main fuel filter 18Fuel pre-heating (R79) 200 Watt (option)
6 Connecting line between main filter and flow to in- 19Water separator sensor (B124)
jection pumps
7 Injection pump
8 High pressure line
9 Injector
10Check valve
11
12Return flow to tank

008 911 49 BOMAG 307

11.1 Diesel engine

Coolant diagram components surrounding the combustion chamber,

In order to avoid thermal overloads, burning of lubrica- like cylinders, cylinder head, valves and possibly also
tion oil on piston sliding surfaces and uncontrolled the pistons, must be cooled intensively.
burns caused by high component temperatures, the

Fig. 7 Coolant diagram

1 Coolant outlet on radiator
2 Thermostat
3 Coolant - supply to radiator
4 Coolant pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder liner / head cooling
8 Coolant flow to heater
9 Cabin heater (optional)
10Coolant to thermostat
11Conection for cabin heater
12Compensation line
13Ventilation line to compensation tank
14Coolant outlet to radiator
15Compensation tank
16Compensation line to heat exchanger

308 BOMAG 008 911 49

Diesel engine 11.1
Description Heating
The coolant pump 4 (Fig. 7) draws coolant through the Water-cooled DEUTZ diesel engines utilize the cool-
hose lines (3) directly out of the radiator and forces it ant to heat the driver's cab. For this purpose the en-
first of all through the lubrication oil cooler (5), which gine coolant is guided directly to the heat exchanger
is integrated in the engine. The coolant then enters (9) and the heat is directly dissipated into the environ-
into the engine, flows up along the cylinders into the ment (direct heating).
cylinder head and to the thermostat (2) at the coolant
outlet (14). Form their the coolant is returned through
the corresponding lines to the radiator inlet. When the
engine is cold the coolant is pumped in a short circuit
through the engine, until the response temperature of
the thermostat (start of opening) is reached. The wa-
ter pump draws cold coolant out of the radiator, as re-
quired to replenish the hot out flowing coolant.
The coolant is a mixture of water and anti-freeze
agent. The anti-freeze agent increases the boiling
temperature of the mixture and thus enables temper-
atures of up to 120° C at an overpressure of up to 1.4
bar.
The coolant compensation tank (15) enables reliable
gas separation, thus avoiding cavitation in the cooling
system, which mainly occurs in the suction side of the
pump. The air volume inside the compensation must
be so high, that quick build-up of pressure in case of
heating and expansion of coolant is assured and any
escape of coolant during after-boiling is avoided.
The radiator dissipates the waste heat generated in
the engine into the into the environment.
Part of the combustion heat is transferred to the lubri-
cation oil. The lubrication oil cooler (5) serves the
function of cooling the lubrication oil.

008 911 49 BOMAG 309

11.2 Fuel filter and check valve

11.2 Fuel filter and check valve
Fuel pre-filter
Description
The quality of the fuel filter and the compliance with
the specified service intervals are decisive for the life-
time of the fuel injection system. The heart of the fuel
pre-filter is made of hydrophobic special paper, which
is spirally wound in form of a bag in order to offer the
largest possible filtering area under the prevailing spa-
tial conditions and thus to achieve a high lifetime in
combination with a high dirt retaining capacity.

Fig. 8 Fuel pre-filter 6 Water separator sensor connection (B124)

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

310 BOMAG 008 911 49

Fuel filter and check valve 11.2
Function Main fuel filter
The fuel lift pump draws the fuel through this filter.
Description
Any water contained in the fuel deposits on the dirt
side of the filter paper and separates from the fuel in
form of large drops on the clean side of the filter (coa-
lescence effect).
Water is heavier than diesel fuel, it settles as a differ-
ent colour fluid on the bottom.
Once the water level reaches the height of the warn-
ing connections (sensor B124), the warning lamp in
the monitoring board (A15) will come on.

Fuel pre-heating (option)

In diesel engines the pre-heating of the fuel prevents
malfunctions caused by the formation of jelly (paraffin
separation) in the fuel under low temperatures.
The integrated heating is a starting aid for cold weath-
er applications. The heating is delivered with an auto-
matic thermostat to start the heating when the fuel
temperature drops below 7°C. The generated heat
works directly under the filter element and melts the
wax crystals that have formed, so that the fuel can
flow through the filter element without restriction. The
heating automatically shuts down at a fuel tempera-
ture of 24°C. The 200W heating is supplied with 12V
D.C-current.
The heater is activated when operating the ignition
switch; this should take place at least 5 minutes be-
fore starting the engine.
Fig. 9 Main fuel filter
! Caution
The main fuel filter is subjected to the approx. 10
bar fuel pre-pressure from the fuel lift pump. This
pressure value is considerably higher than on oth-
er engines. You should therefore only use original
filter elements (Fig. 9) at this point. Similar looking
filters with identical dimensions are not necessar-
ily pressure proof!
A filter, with insufficient pressure resistance, will
be destroyed and disintegrate by this high pres-
sure This will cause severe damage in the injec-
tion system!

008 911 49 BOMAG 311

11.2
Check valve
Description
Fig. 10 Flow direction
According to our experience, it is not always assured
that only clean fuel will be used. Fuel tanks are fre-
quently filled without suitable precautions against con-
tamination or fuel filters are inappropriately serviced.
Many damage analyses on injection pumps and injec-
tion valves have revealed that most of these compo-
nents had failed due to premature wear. Wear on
injection pump plunger and injection valve needle seat
is caused by contaminated fuel. Modern exhaust opti-
mized diesel engines with high pressure injection sys-
tems strictly require clean fuel to be able to work
reliably over their entire lifetime. If the throttle resist-
ances of pre-cleaner/main filter caused by contami-
nated fuel are so high that the fuel pump is no longer
able to ensure a sufficient fuel supply, the injection
pumps will draw the required fuel through the leak fuel
return line from the tank without filtration. The engine
is no longer able to provide its full power, operation of
construction equipment or other machines, however,
may still be possible to a limited extent. After short
time operation under such conditions the injection
system components may already be pre-damaged.
Fig. 11 Check valve
312 BOMAG
Fuel filter and check valve
Work in the low pressure system
Cleanliness
Service and repair work in the low pressure system,
including main fuel filter changes, are only permitted
under absolutely clean environmental conditions, be-
cause even smallest dirt particles entering into the
high pressure fuel system will cause considerable
damage.
Air pollution, like dirt, dust, moisture etc. must be
strictly avoided.
Before starting work in the fuel system (including filter
changes) the engine must be thoroughly cleaned and
dried (steam cleaning equipment). Engine compart-
ments in which dirt deposits may come loose, must be
covered with new and clean foil.
When working in the open you may need to apply pro-
tective measures against dust entering because of
wind.
! Danger
For diesel fuel the ignition temperature, i.e. the
temperature at which fuel will ignite when coming
into contact with air, is approx. 220°C, but may de-
viate strongly because of impurities.
Fuel conducting components and lines therefore
are a source of danger inside the engine compart-
ment, because leaks may lead to fire resulting in
considerably damage to material and persons.
Perform
A power drop or poor starting of the engine is mainly
caused by leaks in the fuel system. If you suspect a fil-
ter problem, you should check whether bleeding
screw and drain valve are tightly closed and the filter
element is flush with the sight glass. Check the filter
connections for leaks and the lines for clogging or po-
rous points.
008 911 49
Check, clean the water separator 11.3
11.3 Check, clean the water separa- 11.4 Change the fuel pre-filter car-
tor tridge

Danger
! Danger
!

Danger of injury! Fire hazard!

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

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

Fig. 13
l
Unscrew the fuel filter cartridge (Fig. 13) using an
appropriate filter wrench.
l
Clean the sealing face on the filter carrier from any
dirt.

Fig. 12
l
Slacken the drain plug (Fig. 12) for a few turns and
catch running out fuel / water.
l Tighten the drain plug again and check for leaks, if
necessary replace the seal ring.

Fig. 14
l Unscrew the water separator from the filter car-
tridge (Fig. 14).

008 911 49 BOMAG 313

11.5 Change the fuel filter cartridge

11.5 Change the fuel filter cartridge

! Danger

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

Fig. 15
l Apply a thin coat of oil to the rubber seal of the water
separator 1 (Fig. 15).
l Screw the water separator on by hand (2), until the
seal contacts.
l Tighten the water separator for another half turn (3).
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
l Tighten the filter element for another half turn (6). Fig. 17

l Check the filter cartridge for leaks after a short test

l
Loosen and unscrew the fuel filter cartridge (Fig.
run. 17) using an appropriate filter wrench.
l
Clean the sealing face on the filter carrier from any
dirt.
i Note
Air in the fuel system causes irregular running of the
engine, a drop in engine power, stalls the engine and
makes starting impossible.
Therefore bleed the fuel system after changing the
fuel prefilter.

Fig. 16
l Slacken the bleeding screw (Fig. 16) on the fuel
pre-filter for 2 to 3 turns.
l Operate the hand pump manually, until fuel flows
out of the slackened bleeding screw (Fig. 16) with-
out air bubbles.
l Then tighten the bleeding screw while pumping.
Fig. 18
l Slightly oil the rubber seal (Fig. 18) on the new filter
cartridge.
l Fill the filter cartridge with clean diesel fuel.
l Turn the new filter cartridge on by hand, until the
seal contacts.
l Tighten the filter element for another half turn.
l Check the filter cartridge for leaks after a short test
run.

314 BOMAG 008 911 49

Oil pressure switch and low oil pressure circuitry
11.6 Oil pressure switch and low oil
pressure circuitry
The oil pressure switch (B06) is mounted to the en-
gine oil filter. After starting it reports when a safe op-
erating pressure has been reached and causes the
warning light in the monitoring board (A15) to light, if
the engine oil pressure drops below approx. 0.8 bar.
11.6
In case of too low engine oil pressure with the engine
running, the monitoring board (A15, terminal 9) will
send a time delayed (10 sec.) 12 V signal to relay K22
(terminal 86). The relay interrupts the electric power
supply to the solenoid valve (Y13) and the diesel en-
gine is shut down.

Fig. 1
1 Oil pressure switch

Pos. Designation in Designation Technical data

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

008 911 49 BOMAG 315

11.7 Changing engine oil and oil filter cartridges

11.7 Changing engine oil and oil fil-

ter cartridges

Caution
!

The oil change at 500 operating hours refers to the

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

Danger
!
Fig. 3
Danger of scalding! l Thoroughly clean the outside of both filter cartridges
When draining off hot oil. (Fig. 3).
By hot oil when unscrewing the engine oil filter. l Unscrew both filter cartridges using an appropriate
filter wrench.
Environment
Catch running out oil and dispose of environmen- i Note
tally together with the engine oil filter cartridge. The filter cartridges are fitted with a valve that pre-
vents engine oil from running out during removal and
installation.
l Clean the sealing face on the filter carrier from any
dirt.
l
Slightly oil the rubber seal on the new filter cartridg-
es.

Fig. 2
l Unscrew the drain plug (Fig. 2) and catch running
out oil.
l
Turn the drain plug tightly back in.

Fig. 4
l Turn the new filter cartridges (Fig. 4) on by hand,
until the seal contacts.
l Tighten the filter cartridges for another half turn.

316 BOMAG 008 911 49

Changing engine oil and oil filter cartridges 11.7

Fig. 5
l Fill in new engine oil (Fig. 5).

For quality and quantity of oil refer to the table of

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

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

008 911 49 BOMAG 317

11.8 Coolant temperature switch

11.8 Coolant temperature switch

Fig. 1 Coolant temperature switch

Pos. Designation in Designation Technical data

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

318 BOMAG 008 911 49

Disassembling and assembling the coolant temperature switch
11.9 Disassembling and assem-
bling the coolant temperature
switch
Removal
l Turn the battery disconnecting switch to position
"OFF".
l Open the lid on the coolant reservoir.
! Danger
Danger of scalding!
Do not remove the cap from the compensation
tank when the engine is still hot.
Fig. 2 Temperature switch
l Press in the locking wire and disconnect the plug
(Fig. 2).
l Lay a cloth around the temperature switch and
catch running out coolant.
Environment
Dispose of escaping coolant environmentally
l Unscrew the temperature switch.
Fig. 3 Coolant temperature switch
l
Remove and dispose of the seal (Fig. 3).
008 911 49
11.9
Installation
l Clean thread and seat for switch.
l Install the temperature switch with Loctite 577 and
a new seal, tightening torque 20 Nm.
l Push the plug back on (plug interlock clicks into
place).
l Check the plug interlock by lightly pulling on the wir-
ing loom.
l
Fill in coolant up to the “MAX” mark .
For quality of coolant refer to the chapter 5.2, fuels
and lubricants.
l Run the engine up to operating temperature.
i Note
Check the area around the coolant temperature sen-
sor for leaks.
l Let the engine cool down and check the coolant lev-
el again, top up if necessary.
BOMAG 319
11.10 Removing and installing the thermostat

11.10Removing and installing the

thermostat
l Open the lid on the coolant reservoir.

Danger
!

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

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

Fig. 6
l Clean the sealing surfaces (Fig. 6).
l Fit a new seal (1) to the thermostat.

Fig. 4
l Disconnect the coolant hoses.
l Remove the outlet socket 1 (Fig. 4).

Fig. 7
l Install the coolant thermostat (Fig. 7).

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

Fig. 5
l
Remove the thermostat (Fig. 5).

320 BOMAG 008 911 49

Checking the thermostat in disassembled state 11.11
11.11Checking the thermostat in
disassembled state
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. 8
l Assemble the outlet socket 1 (Fig. 8).
l Tightening torque: 30 Nm.
l Install the coolant hoses again.
l Fill in coolant up to the “MAX” mark .

For quality of coolant refer to the chapter 5.2, fuels

and lubricants.
l
Run the engine up to operating temperature.
Fig. 1
i Note l Measure and write down the measurement "a" on
Check for leaks around the thermostat. the thermostat (Fig. 4).
l
Let the engine cool down and check the coolant lev-
el again, top up if necessary. i Note
"a" = beginning of stroke at approx. 83 ± 2°C (T1)
"b" = end of stroke at approx. 95 °C (T2)

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

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

008 911 49 BOMAG 321

11.12 Change the coolant

The temperature increase should not exceed 1°C/ 11.12Change the coolant
min, as otherwise the start of opening will be delayed
accordingly.
! Danger

Danger of scalding!
Change the coolant only when the engine is cold.

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

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. 4
The stroke at the given temperature (T2) should be
min. 8 mm. l
Set the cock valve for the cabin heater to position
"warm".

Fig. 5
l Unscrew the plug, let the coolant run out and catch
it.
l Screw the plug back in once all coolant has run out.

322 BOMAG 008 911 49

Change the coolant 11.12

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

For quality of coolant refer to the chapter 5.2, fuels

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

008 911 49 BOMAG 323

11.13 Three-phase generator

11.13Three-phase generator

Fig. 1 Generator

Pos. Designation in Designation Technical data

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

Description disconnect the generator while the engine is run-

The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.
i Note
The generator is maintenance free. Function tests and
repair work must only be performed in authorized
workshops.
! Caution
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.

324 BOMAG 008 911 49

Checking / replacing the ribbed V-belt 11.14
The generator can only be operated with the bat- 11.14Checking / replacing the
tery connected. Under special conditions emer-
gency operation without battery is permitted, the ribbed V-belt
lifetime of the generator is in such cases especial-
ly limited. Danger
!
Plus and minus cables must be disconnected dur- Danger of injury!
ing rapid charging of the battery or electric weld-
ing on the vehicle. Work on the V-belt must only be performed with
the engine shut down.
When cleaning the generator with a steam or wa-
ter jet make sure not to direct the steam or water
jet directly on or into the generator openings or Checking the wear limit of the ribbed V-
ball bearings. After cleaning the generator should belt
be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.

Fig. 2
l Check the distance between the tongue of the
moveable tensioner arm and the fixed tensioner
housing (Fig. 2).
l If measurement "a" is smaller than 3 mm, replace
the ribbed V-belt.

Changing the ribbed V-belt

Fig. 3
l Unscrew the fastening screws (Fig. 3) and slide the
fan forward.

008 911 49 BOMAG 325

11.14 Checking / replacing the ribbed V-belt

Fig. 4
l
Release the idler pulley (Fig. 4) in direction of arrow
until the ribbed V-belt is free.
l
Pull the ribbed V-belt first to the smallest pulley.
l Install the new ribbed V-belt.
l
Release the idler pulley against the direction of ar-
row until the V-belt is tensioned.
l Measure the V-belt tension, tighten if necessary.

i Note
Retighten the new fan V-belt after a running time of 20
minutes.

326 BOMAG 008 911 49

Boost fuel solenoid valve
11.15Boost fuel solenoid valve
During the starting process the solenoid valve is sup-
plied with 12 Volt.
This injection adaptation serves the purpose of com-
pensating for condensation and leakage losses and
11.15
for rising the engine torque during the acceleration
phase after starting. For this compensation and to as-
sure starting of the cold engine additional fuel needs
to be injected at the time of starting and accelerating.

Fig. 5
1 Boost fuel solenoid valve

Pos. Designation in Designation Technical data

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

008 911 49 BOMAG 327

11.16 Engine shut-down solenoid

11.16Engine shut-down solenoid
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the monitoring board in case of too low oil
pressure (terminal 9).

Fig. 6

Pos. Designation in Designation Technical data

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

328 BOMAG 008 911 49

Air filter, differential pressure switch
11.17Air filter, differential pressure
switch
The air filter retains the dust contained in the intake air
and keeps it away from the engine in order to avoid
engine wear.
On paved roads the dust content in the air is 1 mg/m 3 take hose energizes the control light in the monitoring
on average, on sealed roads or construction sites the
dust content can rise up to 40 mg/m3.
Dry air filters with integrated dust separator are char-
acterized by a good filtering effect (irrespective of en-
gine speed and inclination) and thus enable long
lasting and low wear engine operation.
11.17
The air filter has the additional function of damping the
air intake noise. This damping is achieved by the de-
sign of the air filter in from of a reflection silencer
based on the principle of a Helmholz resonator, damp-
ing the intake noise by its resonance frequency.
The differential pressure switch 1 (Fig. 1) in the air in-
board (A15) when the pressure difference between at-
mospheric pressure and intake pressure exceeds >
50 mbar. This indicates that the air filter does not allow
sufficient air flow to the combustion chamber.

Fig. 7
1 Differential pressure switch

Pos. Designation in Designation Technical data

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

!Caution
Combustion air lines between filter and engine
("clean air lines") must be absolutely leak tight
and withstand mechanical loads caused by en-
gine vibrations and pressure pulsation.

008 911 49 BOMAG 329

11.18 Service the combustion air filter

11.18Service the combustion air fil-

ter

! Caution
Perform cleaning, maintenance and repair work
only with the engine shut down. Do not start the
engine after removing the filter element.
Do not use gasoline or hot fluids to clean the filter
element.
After cleaning the filter element must be inspected
for damage using a torch.
Fig. 9
Air filter elements with damaged paper bellows or
seal lips must be replaced in any case. l Open the engine hood (Fig. 9) completely and se-
cure it.
The main filter element must be replaced after 3
times cleaning, but at the latest after one year, ir-
respective of the operating hours. Removing the main filter element
Each cleaning interval must be marked with a
cross on the cover of the filter element.
Cleaning does not make sense if the air filter ele-
ment is covered with a sooty deposit. Use a new
filter element.
Incorrectly handled filter elements may become
ineffective because of damage (e.g.: cracks) and
cause engine damage.

Fig. 10
l Loosen both locking hooks (Fig. 10) on the housing
cover and take the cover off.

Fig. 8
Maintenance of the dry air filter is due when control
light “c” (Fig. 8) in the instrument cluster lights perma-
nently when the engine is running, but at the latest af-
ter one year.

i Note
Once the air filter service indicator lights up, work may Fig. 11
be continued until the end of the day.
l Pull out the main filter element (Fig. 11) with light
turning movements.

330 BOMAG 008 911 49

Service the combustion air filter 11.18
Cleaning the main filter element Caution
!

Do not continue to run the machine with a dam-

!Caution aged main filter element. If in doubt use a new
If necessary, the main filter element may be main filter element.
cleaned up to five times. It must be renewed at the
latest after a maximum utilization period of two Cleaning the dust bowl
years.
The number of cleaning intervals of the main filter
element can be marked on the safety element with
a ball pen or a felt pen.
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!
Additional cleaning intervals between two filter Fig. 14
services signalized by the fault monitoring board
are not necessary.
l
Pull the internal part (Fig. 14) out and remove the
dust from the cover.
l
Reinsert the inner part.

!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-
Fig. 12 ment is automatically forced in the correct position.
l Blow the filter cartridge out from inside to outside
with dry compressed air (max. 5 bar) (Fig. 12), until Changing the safety filter element
all dust has been removed.
Caution
!

The safety filter element must not be cleaned and

Fig. 13
l Examine the filter cartridge with a torch for cracks
and holes in the paper bellows (Fig. 13).
should not be used again after it has been re-
moved.
Break the seal only to replace the safety filter ele-
ment.
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.

008 911 49 BOMAG 331

11.19 Heating flange on engine

11.19Heating flange on engine

Fig. 15
l Pull the safety element (Fig. 15) out by slight turning
movements. Fig. 1 Heating flange

l Push in a new safety filter element.
l Reassemble main filter element and cover.
Caution
! The heating power is approx. 2000 Watt.
Make sure that the cover locks engage correctly.
The heating flange is a component with an electrically
operated heating wire and high energy density used to
heat up the intake air in case of very low ambient tem-
peratures.
The heating power improves the cold starting charac-
teristics and the exhaust emissions (white smoke) of
the diesel engine.
A differentiation is made between preheating, to as-
sure the cold start ability of the engine, and subse-
quent heating.

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

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

332 BOMAG 008 911 49

Heating flange on engine 11.19
the engine must be avoided and trouble shooting
should be performed instead.
Several successive starting attempts can cause
overheating of the heating flange .

Fig. 2
1 Heating control unit (A13)
2 Heating relay (K14)

Fig. 3 Coolant temperature sensor

1 Temperature sensor (B113) for heating flange
control (A13)
2 Coolant temperature switch (B30)

008 911 49 BOMAG 333

11.19 Heating flange on engine

Pos. Designation in Designation Technical data

circuit diagram
(Fig. 1) R19 Heating flange With a coolant temperature of -30°C
the preheating time will be max. 52
seconds, with +5°C the minimum
time will be 38 seconds.
With a coolant temperature of -30°C
the after-heating time will be max.
180 seconds, with +25°C the mini-
mum time will be 35 seconds.
12 Volt
approx. 2000 Watt
approx. 167 A
approx. 0.07 Ohm

2 (Fig. 2)) A13 Heating control unit 12 Volt

3 (Fig. 2) K14 Heating relay 12 Volt

1 (Fig. 3) B113 Temperature sensor for heating approx. 2 Ohm at 20°C

flange control (A13)
2 (Fig. 3) B30 Coolant temperature switch Contact switches at approx. 110° C
to ground

Fig. 4 Heating flange function diagram

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

334 BOMAG 008 911 49

Checking the heating flange control 11.20
11.20Checking the heating flange After the engine has started the after heating time
must continue for 35 to 180 seconds. This after-heat-
control ing time is not indicated by the control light (K) .

Fig. 1 Monitoring board (A15)

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

Sensor failure: Either short circuit or cable break-

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

Heating flange failure: Either short circuit or cable

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

i Note
The heating flange only becomes active at a coolant
temperature below 25°C. When the plug of the tem-
perature sensor is pulled off (simulated sensor fail-
ure), a coolant temperature of 0° C is assumed.
l
Start the heating process.

Depending on the coolant temperature the control

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

Rated current: 165 Amp +- 10 Amp.

i Note
The relay must remain energized for another approx.
15 seconds, after the control light has gone out.

008 911 49 BOMAG 335

11.21 Electric throttle control

11.21Electric throttle control

Fig. 1 Engine solenoid ings. The engine solenoid is equipped with a limit
switch (2), which is mechanically connected with the
Throttle control solenoid Y120
governor rod (1) on the diesel engine. This switch
bridges the holding winding until the end position of
the governor rod is reached (high engine speed)
This bridging has the effect, that the "aux"-terminal
has the same potential as the "+"-terminal. If the
bridge is open, the "aux"-terminal has almost the
same potential as the "-" terminal, because of the low
resistance of the pick-up winding and the high resist-
ance of the holding winding.

Fig. 2 Electric circuit of solenoid

The throttle control solenoid 5 (Fig. 2)) is equipped
with a pick-up winding (4) and a holding winding (3),
both switched in series. The holding winding has a
much higher resistance than the pick-up winding. The
"aux"-connection is connected between the two wind-

336 BOMAG 008 911 49

Crankcase - disassembling and assembling the ventilation 11.22
Adjusting the solenoid 11.22Crankcase - disassembling
and assembling the ventila-
tion valve
Disassembly

Fig. 3
The throttle control switch (S120) is used to change
from "MIN" to "MAX" idle speed and vice versa.
l
Switch on the ignition.
Fig. 1
l Turn the rotary switch (Fig. 3) to position "MAX".
l
Loosen spring clamp 1 (Fig. 1) with special spring
clamp pliers..
l Pull off the ventilation hose (2).
l Unscrew screws (3).
l
Remove the crankcase ventilation.

Fig. 4

i Note
When switching on, the solenoid plunger is pulled
against the stop. The limit switch then switches the
pick-up and holding winding in series. The current flow
is reduced from approx. 70 A to approx. 3.5 A. Fig. 2
l
Measure the gap between stop screw 1 (Fig. 4) and l Check the components visually (Fig. 2).
throttle lever (2).

Caution
!

The gap should be min. 0.1 mm and max. 0.5 mm.

If the gap is too small, the limit switch in the sole-
noid may not be able to operate.
In case of a too wide gap the engine will not reach
its maximum speed.

008 911 49 BOMAG 337

11.22 Crankcase - disassembling and assembling the ventilation

Assembly

Fig. 5
l Connect the ventilation hose.
l Position the spring clamp with the special spring
clamp pliers.

Fig. 3
l Clean the sealing face on the crankcase ventilation.
l Clean the valve cover.
l Assemble a new gasket 1 (Fig. 3).

Fig. 4
l
Attach the crankcase ventilation (Fig. 4).
l Tighten the screws with 20 ± 2 Nm.

338 BOMAG 008 911 49

Disassembling and assembling the starter 11.23
11.23Disassembling and assem- Assembling the starter
bling the starter
Disassembling the starter

Fig. 1 Fig. 3
l Remove the heat shield (Fig. 1). l
Insert the starter into place (Fig. 3)
l Tighten the screws (arrows) with 60 Nm.
l Connect the cable connections.
l
Connect the negative battery terminal.

Fig. 2
Fig. 4
l Disconnect the negative battery terminal.
l Assemble the heat shield (Fig. 4).
l Disconnect the cable connections.
l Unscrew the screws (arrows) (Fig. 2).
l Remove the starter.
l Check the components visually.

008 911 49 BOMAG 339

11.24 Engine monitoring

11.24Engine monitoring

Fig. 1
1 Monitoring board (A15)

Pos. Designation Control light Warning buzz- Shut-down Shut-down

er time (engine) time (engine) 2
10 sec. min.
a Control light, overheating of en- flashes X X
gine
b Engine oil pressure control light flashes X X
c Control light for engine air filter lights
d Charge control light lights
i Control light, water in diesel fil- lights X X
ter
j Control light, coolant provision flashes X X

340 BOMAG 008 911 49

Engine monitoring 11.24
Checking the engine monitoring system
i Note
The following control lights and shut-down functions Control light i (Fig. 1) lights up. An audible warning will
can be checked with the engine running: sound and the engine is shut down after 2 minutes.
Air filter l
Push the plug back together, the plug interlock
clicks into place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.

Engine oil pressure

Fig. 2 Differential pressure switch

l Press on the locking wire and pull the plug off the
differential pressure switch (Fig. 2).
l Bridge both contacts on the plug of the wiring loom.
Fig. 4 Oil pressure switch
i Note l
Press on the locking wire and pull off the plug 1 (Fig.
Control light c (Fig. 1) lights up. No audible will sound 4).
and the engine will not be shut down. l Apply the contact to engine ground.
l
Push the plug back on, the plug interlock clicks into
place.
i Note
l Check the plug interlock by lightly pulling on the wir- The control light b (Fig. 1) flashes. An audible warning
ing loom. will sound and the engine is shut down after 10 sec-
onds.
Water separator
l Push the plug back on, the plug interlock clicks into
place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.

Fig. 3 Sensor water separator

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

008 911 49 BOMAG 341

11.24 Engine monitoring

Engine overheating l Push the plug back together, the plug interlock
clicks into place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.

Emergency stop switch

Fig. 5 Coolant temperature switch

l Press on the locking wire (Fig. 5) and pull off the
plug.
l Bridge both contacts on the plug of the wiring loom. Fig. 7 Emergency stop switch
l
Press the emergency stop switch (Fig. 7). The en-
i Note gine should stop immediately.
The control light a (Fig. 1) flashes. An audible warning
will sound and the engine is shut down after 2 min-
utes.
l
Push the plug back on, the plug interlock clicks into
place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.

Coolant provision

Fig. 6 Coolant temperature switch

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

i Note
Control light j (Fig. 1) lights up. An audible warning will
sound and the engine is shut down after 2 minutes.

342 BOMAG 008 911 49

Adjusting the valve clearance 11.25
11.25Adjusting 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.
Fig. 9
l Remove the valve covers.
l Crank the engine, until the valves on cylinder 1
overlap.
l The individual cylinder positions can be taken from
the section "valve adjustment schematic".

Adjusting the valve clearance

Fig. 10
l Attach the rotation angle disc 3 (Fig. 10) and the
spanner socket (4) to the valve adjustment screw 2
(Fig. 9).
l Fix the magnet (5) of the rotation angle disc.
l Turn the rotation angle disc clockwise against the
stop (rocker arm no clearance) and set the scale to
Fig. 8
zero.
l Loosen counter nut 1 (Fig. 8). l
Turn the rotation angle disc clockwise, until the
specified angle is reached.
Intake valve IN = 90° (0,4 mm)
Exhaust valves EX= 150° (0,6 mm)
l
Hold the rotation angle disc tight, so that it does not
turn, and tighten counter nut 1 (Fig. 8).
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.

008 911 49 BOMAG 343

11.25 Adjusting the valve clearance

Intake valve clearance adjustment in case
of exhaust gas recirculation
l Turn the rotation angle disc 3 (Fig. 12) anti-clock-
wise, until the specified angle is reached (90°).
l Hold the rotation angle disc tight, so that it does not
turn, and tighten counter nut 6 (Fig. 11).
l Repeat the adjustment procedure on each intake
valve.

Valve adjustment schematic

l
Firing order 1-3-4-2

Valves Cylinder
overlapping 1 3 4 2
adjustment 4 2 1 3

Fig. 11 Overlapping of valves:

l Loosen counter nut 6 (Fig. 11). 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. 12

Fig. 13
l Attach the rotation angle disc 3 (Fig. 12) with the
special spanner (8) to the valve setscrew 7 (Fig. 13)
on the intake valve.
l Fix the magnet 5 (Fig. 12) of the rotation angle disc.
l Turn the rotation angle disc 3 (Fig. 12) clockwise
against the stop (rocker arm no clearance) and set
the scale to zero.

344 BOMAG 008 911 49

Adjusting the control piston play 11.26
11.26Adjusting the control piston l Hold the rotation angle disc tight, so that it does not
turn, and tighten counter nut 1 (Fig. 14).
play l Repeat this adjustmennt procedure on each control
piston according to the crankshaft position.
Caution
! l Assemble the cylinder head cover with a new gas-
This work must be performed after adjusting the ket.
valve clearance.
l Crank the engine, until the valves on cylinder 1 Adjustment schematic
overlap. l
Firing order 1-3-4-2
l The cylinders to be adjusted can be taken from the
section "Adjustment Schematic".
Valves Cylinder
Adjusting the control piston play overlapping 1 3 4 2
adjustment 4 2 1 3

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. 14
l
Loosen counter nut 1 (Fig. 14).

Fig. 15
l Plug rotation angle disc and socket onto the set-
screw 2 (Fig. 15).
l Fix the magnet of the rotation angle disc.
l Turn the rotation angle disc clockwise against the
stop (rocker arm no clearance) and set the scale to
zero.
l
Turn the rotation angle disc anti-clockwise, until the
specified angle is reached.

008 911 49 BOMAG 345

11.27 Checking the compression

11.27Checking the compression

l Adjust the valve clearance.
l Remove the injector.

Fig. 3
l
If necessary connect the adapter to the connecting
piece.

Fig. 1
l
Insert the connecting piece (Fig. 1).

i Note
Use seal ring for injector.

Fig. 4
l Connect the compression tester to the connecting
piece (Fig. 4).
l Crank the engine with the starter.

Fig. 2
l Attach clamping claw 1 (Fig. 2).
l Tighten screw (2) hand-tight.

i Note
When mounting the connecting piece to cylinders 1 to
5, the clamping claw must be attached together with
the connecting piece (Fig. 3).

346 BOMAG 008 911 49

Checking the compression 11.27

Fig. 7
l
Unscrew fastening screw 2 (Fig. 7).
l
Remove clamping claw (1).
Fig. 5

i Note
The measured compression (Fig. 5) depends on the
starter speed during the measuring process and the
altitude of the engine location. Limit values can there-
fore not be specified exactly. It is recommended to
use the compression measurement to compare the
cylinders of an engine among each other. Should a
deviation of more than 15% be measured, the affected
cylinders should be dismantled to examine the cause.

Fig. 8
l Remove the connecting piece (Fig. 8).
l Remove the seal.
l Install the injector.

Fig. 6
l Disconnect the compression tester (Fig. 6).

008 911 49 BOMAG 347

11.28 Engine

11.28Engine

Faults Possible cause Remedy

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

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

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

Fuel lines leaking Check all line connections for leakages

and tighten the fittings.

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

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

tive

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

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

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

Injection lines leaking Check the lines for leakages

Turbo charger defective Have examined by a specialist

Dry air filter dirty clean, replace if necessary

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

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

Exhaust gas turbo-charger defective Have examined by a specialist

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

Incorrect valve clearance Adjust the valve clearance

348 BOMAG 008 911 49

Engine 11.28
Faults Possible cause Remedy

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

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

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

correctly adjusted

Cooling air flow restricted Clean the cooling air duct

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

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

Dry air filter dirty clean, change if necessary

Exhaust gas turbo-charger defective Have examined by a specialist

Charge air hose leaking Check fastening and connections

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

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

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

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

008 911 49 BOMAG 349

11.29 Special tools, Deutz engine (TCD 2013 2V)

11.29Special tools, Deutz engine

(TCD 2013 2V)


TCD 2013 2V Standard tools

8002
Pressure pump
Checking cooling system for leak-tightness

© 35409-2

8005
Compression pressure tester
for diesel engines
10 - 40 bar

© 35410-3

8011
Hose clip pliers
e. g. fuel return pipe

© 39426-1

350 BOMAG 008 911 49

Special tools, Deutz engine (TCD 2013 2V) 11.29

Standard tools TCD 2013 2V

8024
Assembly pliers
Removing valve stem gaskets

© 37509-2

8035
Socket wrench insert
reinforced, size 22
removing and installing main bearing

© 37504-2

8113
Socket wrench insert
Torx - E 14

© 43022-0

008 911 49 BOMAG 351

11.29 Special tools, Deutz engine (TCD 2013 2V)

352 BOMAG 008 911 49

Special tools, Deutz engine (TCD 2013 2V) 11.29

Standard tools TCD 2013 2V

8190
Rotation angle disc
with magnet
Setting valve clearance

© 43528-0

8191
Screwdriver insert
for slotted screw
Valve clearance setting

© 43060-0

8192
Bowl wrench
Fuel pre-filter (type: Racor)

© 43193-1

008 911 49 BOMAG 353

11.29 Special tools, Deutz engine (TCD 2013 2V)


TCD 2013 2V Standard tools

8193
Screwdriver insert
with pressed in hexagonal pin (5 mm), 
1/2 inch, long version
(in conjunction with rotation angle disc 8190)

© 43183-0

8194
Screwdriver insert
with hexagon socket (size 4 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)

© 43183-0

8195
Multi-toothed screwdriver set
260 mm long
remove and install air compressor

© 43195-0

354 BOMAG 008 911 49

Special tools, Deutz engine (TCD 2013 2V) 11.29

Standard tools TCD 2013 2V

8196
Open end wrench adapter
Size 13, 
for torque wrench
Tightening of lock nut of the valve clearance setting
screw

© 43019-0

8198
Pricker
Removing rotary shaft lip seal

© 43206-0

8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)

© 44309-0

008 911 49 BOMAG 355

11.29 Special tools, Deutz engine (TCD 2013 2V)


TCD 2013 2V Standard tools

9017
Assembly lever
Example: Removing and installing the valves

© 37511-2

9090
Spring band pliers
320 mm
tighten spring band clamp

© 35420-3

356 BOMAG 008 911 49

Special tools, Deutz engine (TCD 2013 2V) 11.29


TCD 2013 2V Special tools

100 190
Connector
(in conjunction with compression pressure tester 8005)

© 42524-1

100 320
Turning gear
flywheel side

© 35422-1

100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper

© 35423-1

008 911 49 BOMAG 357

11.29 Special tools, Deutz engine (TCD 2013 2V)

Special tools TCD 2013 2V

100 400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm

© 35424-1

100 410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm

© 43205-0

100 750
Measuring device
Measuring bar with two shims
(in conjunction with 100400 and 100410)
Checking valve lag dimension
Checking piston projection

© 39402-1

358 BOMAG 008 911 49

Special tools, Deutz engine (TCD 2013 2V) 11.29


TCD 2013 2V Special tools

103 050
Socket wrench insert
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)

© 43023-0

103 220
Special pliers
for removing the roller tappet

© 43010-0

110 500
Special wrench
Size 17
Removing and installing high-pressure lines

© 35436-1

008 911 49 BOMAG 359

11.29 Special tools, Deutz engine (TCD 2013 2V)

Special tools TCD 2013 2V

110 640
Lever tool
Remove injector

© 43941-0

110 700
Socket wrench insert
long
Installing and removing pressure sensors
(rail pressure, oil pressure, fuel pressure)

© 43198-2

110 900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three
assembly sleeves with guide:
- High pressure pump (Ø 36), 110 902
- Injector, 2V motor (Ø 16), 110 903
- Injector, 4V motor (Ø 23), 110 904
Removing and installing O-rings

© 43208-0

360 BOMAG 008 911 49

Special tools, Deutz engine (TCD 2013 2V) 11.29


TCD 2013 2V Special tools

120 430
Assembly tool
Removing and installing the glow plugs

© 43020-0

120 680
Puller
(in conjunction with slide hammer 150 800)
Removing fixed injector sealing ring

© 35437-1

120 900
Support bracket
pivoting
Clamping cylinder head

© 35438-3

008 911 49 BOMAG 361

11.29 Special tools, Deutz engine (TCD 2013 2V)

Special tools TCD 2013 2V

120 910
Base plate
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)

© 35439-3

121 330
Assembly lever
Removing and installing the valves

© 43185-0

121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket

© 43210-0

362 BOMAG 008 911 49

Special tools, Deutz engine (TCD 2013 2V) 11.29


TCD 2013 2V Special tools

130 300
Universal piston ring pliers
Removing and installing the piston rings

© 43021-0

130 420
Trapezoidal groove wear gauge
Piston diameter 108 mm

© 36461-2

130 640
Piston ring compressor
Piston diameter 108 mm

© 39408-1

008 911 49 BOMAG 363

11.29 Special tools, Deutz engine (TCD 2013 2V)

Special tools TCD 2013 2V

142 810
Assembly tool
Installing crankshaft sealing ring
(flywheel side)

© 35446-1

142 820
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)

© 35445-1

150 170
Puller, universal
Comprising traverse, support and threaded rod
(in conjunction with disc 150 171)
Removing cylinder liner

© 43207-0

364 BOMAG 008 911 49

Special tools, Deutz engine (TCD 2013 2V) 11.29


TCD 2013 2V Special tools

150 171
Plate
(in conjunction with puller 150 170)
for liner diameter: 108 mm
Removing cylinder liner

© 43204-0

150 180
Liner holder
(Set comprises 7 holders)
Turning crankshaft with cylinder head removed

© 43181-0

150 190
Assembly lever
Lever with bolts 
(in conjunction with disc 150 191)
Installing cylinder liner

© 43209-2

008 911 49 BOMAG 365

11.29 Special tools, Deutz engine (TCD 2013 2V)

366 BOMAG 008 911 49

Special tools, Deutz engine (TCD 2013 2V) 11.29


TCD 2013 2V Special tools

170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

© 43663-0

6066
Assembly block
Engine clamping, double-sided

© 35451-2

6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided

© 35452-1

008 911 49 BOMAG 367

11.29 Special tools, Deutz engine (TCD 2013 2V)

Special tools TCD 2013 2V

6068
Engine lifting device
Version for commercial vehicles with worm gear, ulti-
mate load (2t), 3-point suspension, spindle clamp,
traverse, chains and hooks

© 43184-0

6692
Slotted nut wrench
Cable plug

© 43199-0

368 BOMAG 008 911 49

 12 Air conditioning system

008 911 49 BOMAG 369

12.1 Physical basics

12.1 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.

370 BOMAG 008 911 49

Physical basics 12.1
Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
l Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
l Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
l Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.

Fig. 4 Pressure - Temperature Diagram

In the pressure - temperature diagram for the refriger-
ant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direc-
tion of the arrow.
The characters A, B, C, D stand for:
Fig. 3 Steam pressure curve A - compression
Steam pressure curve for refrigerant R134a B- condensation
The steam pressure curve is a means for explaining C- relaxation
the operation principle of an air conditioning system. D- evaporation.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a.
The diagram for example shows, that R134a is liquid
at 0°C and a pressure of 5 bar, but becomes gaseous
at 40°C and 5 bar.
For better understanding one must also be aware of
the following:
1. A gas heats up when being compressed (e.g. air
pump, turbo charger, ...).
2. When relieving gas it will cool down (e.g. white frost
forms on the valve when relieving air pressure from a
car tire).
3. Condensing gas dissipates a lot of heat energy.

008 911 49 BOMAG 371

12.1 Physical basics

Excerpt from the wet steam table 1 R134a

1 This table is used for the determination of evaporation and con-
densation temperature.
Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar
reading Pe in bar) P in bar)
-20 0,33 1,33
-10 1,01 2,01
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72

372 BOMAG 008 911 49

Refrigerant R134a
12.2 Refrigerant R134a
General
The evaporation and condensation process is the
method commonly used in mobile air conditioning sys-
tems. The system in this case works with a substance
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
under a steam pressure of 1 bar.
Although the refrigerant circuit is a hermetically closed
loop, the system loses approx. 100g of refrigerant
over the course of 1 year by diffusion through hoses,
pipes and seals, even though the system is free of
leaks. If too much refrigerant is lost the cooling power
of the system will drop.
Physical data of the refrigerant R134a
Chemical formula:
CH2F-CF3 or CF3-CH2F
Chemical designation:
Tetrafluoroethane
Boiling point at 1 bar:
- 26.5 °C
Solidification point:
-101.6 °C
Critical temperature:
100,6 °C
Critical pressure:
40.56 bar (absolute)
Critical point:
Critical point (critical temperature and critical pres-
sure) means that above this point there is no separat-
ing interface between liquid and gas. Above its critical
point any substance is gaseous. At temperatures be-
low the critical point all refrigerant types in pressure
containers have a liquid and a gaseous phase, i.e. a
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.
008 911 49 BOMAG
12.2
Characteristics of the refrigerant R134a:
Refrigerant R134a is currently available under the fol-
lowing trade marks.
H-FKW 134a
SUVA 134a
KLEA 134a
Colour:
Refrigerant in form of vapour or liquid is colourless as
water. The gas is invisible. Only the bordering layer
between gas and liquid is visible. (Fluid level in rising
pipe of filling cylinder or bubbles in inspection glass).
In the inspection glass the liquid refrigerant R134a
may appear coloured (milky). This turbidity results
from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Steam pressure:
In an incompletely filled, closed container, vaporous
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-
sure and is frequently referred to as steam pressure.
The steam pressure is independent from the temper-
ature.
Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
ation oils, e.g. PAG-oils (polyalkylene glycol oils).
Behaviour with metals:
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
compounds, leads to aggressiveness against certain
metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical temperature / critical pressure:
Up to a gas pressure of 39.5 bar overpressure (this
corresponds with a temperature of 101 °C) the refrig-
erant R134a remains chemically stable, above this
temperature the refrigerant decomposes (see com-
bustibility).
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
373
12.3
liquid container has absorbed approx. 8 gr. of water,
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle
of the expansion valve and turns to ice. The air condi-
tioning system stops cooling. Water destroys the air
conditioning system, because under high pressures
and temperatures and in connection with other con-
taminants it forms acids.
Inflammability:
Refrigerant is not inflammable. On the contrary, it has
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul-
traviolet light also cracks refrigerant (caused by
electric welding). This results in toxic fission products,
these must not be inhaled. However, irritation of the
mucous membranes is an early and in-time warning.
Filling factor:
In a container there must be a steam space above the
liquid space. The liquid expands with increasing tem-
perature. The steam filled space becomes smaller.
From a certain time on the container will be filled with
just liquid. After this only a minor temperature in-
crease is enough to generate very high pressures in
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
avoid overfilling of a container the pressure gas direc-
tive clearly specifies how many kilograms of refriger-
ant may be filled into the container per litre volume.
Multiplied with the internal volume this "filling factor"
determines the permissible filling capacity For refrig-
erants used in motor vehicles it is 1.15 kg/l.
Environmental aspects
The contribution of R134a to the greenhouse effect is
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.
374 BOMAG
Compressor oil / refrigeration oil
12.3 Compressor oil / refrigeration
oil
The compressor oil lubricates the movable parts in the
compressor, seals e.g. the gap between piston and
cylinder inside the compressor to prevent refrigerant
loss and prevents other seals in the system from dry-
ing up.
Part of the compressor oil dissolves in the refrigerant
until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
agent circulates through the system.
Compressor oil (the oil quantity should be 10 % of the
refrigerant weight) mixes with the refrigerant and cir-
culates permanently through the system.
In connection with R134a- air conditioning systems
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
from this, the materials in the R134a air conditioning
system may be attacked when the mixture is flowing
through the refrigerant circuit under high pressure and
at high temperatures or if the lubrication film in the
compressor tears off. The use of non-permitted oils
can cause damage to the air conditioning system, you
should therefore only used the approved oils.
Properties of compressor oil / refrigeration oil:
The most important properties are high solvency in
connection with refrigerants, good lubrication charac-
teristics, that they are free of acids and their low water
content. For this purpose only certain oils can be
used. PAG-oils suitable for use with refrigerant R134a
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
moisture and acids, becomes dark, viscous and ag-
gressive against metals.
008 911 49
Working principle of the air conditioning system
12.4 Working principle of the air
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en-
vironment. Everybody knows the effect: if a sweating
body is exposed to wind it will cool down, because
heat is extracted. For this purpose a refrigerant circu-
lates in a closed circuit inside the vehicle. This refrig-
erant thereby continuously changes its physical state
between liquid and gaseous.
Fig. 1 Principle sketch of an air conditioning system
An engine driven compressor (1) draws in gaseous re-
frigerant from the evaporator (5) and compresses it.
During this process the temperature of the refrigerant
increases tremendously.
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front
of the vehicle radiator, so that a sufficient air flow is as-
sured. In the condenser (2) the gas is cooled down
and consequently liquefied.
In the dryer / liquid container (3) the refrigerant is then
collected and freed of moisture and contaminants.
The expansion valve (4) regulates the flow rate from
the dryer / liquid container (3) back to the evaporator
(5) and the circuit starts again.
008 911 49 BOMAG
12.4
12.5 Monitoring devices
Pressure switch
The pressure switch (8) is used as monitoring feature
for too high and too low pressures. The switching con-
tacts (4 and 5) effect the magnetic clutch of the com-
pressor via a relay (6).
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)
is set to approx. 1.5 bar to avoid icing. The switch on
pressure is 0.5 to 2 bar higher than the shut-off pres-
sure (depending on system, see description of com-
ponents.)
Thermostat
A frost protection thermostat (3) protects the evapora-
tor against icing. Similar to the pressure switch, the
thermostat activates or deactivates the magnetic
clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
tween the fins of the evaporator or attached to the
evaporator outlet (suction side). With fixed tempera-
ture controls the control switches the compressor off
at about 1 °C and back on again at about 2.5°C to 5.5
°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.
375
12.6 Description of components

Monitoring chain 12.6 Description of components

Compressor

Fig. 2 Monitoring chain consisting of:

l 1 Switch
l 2 Fuse
l 3 Thermostat
l 4 Low pressure switch contact Fig. 1
l 5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
l
6 Relay
the function of the system. Coupling and decoupling is
l
7 Connection for magnetic clutch accomplished by an electromagnetically controlled
l
8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.

Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)

! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil / refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.

Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.

376 BOMAG 008 911 49

Description of components 12.6
Reason of oil loss Amount of oil lost Condenser
Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve

! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1
To avoid excessive oil in the A/C-system and thus The condenser is located in front of the the radiator for
a poor cooling effect, the oil level in the A/C-sys- the machine. It emits heat energy from the system into
tem must be adjusted accordingly. the surrounding air and liquefies the gaseous refriger-
The quantity depends on the amount of oil that ant.
may have been lost in connection with the possi-
ble replacement of other components.
i Note
The compressor oil quantity must be 10% of the The fins must be free of dirt and damage.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re- ! Caution
quires a compressor oil / refrigerant oil filling of
100 gr. When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
Procedure: changing the components, must be replaced with
Drain and measure the compressor oil from the fresh oil.
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.

i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.

008 911 49 BOMAG 377

12.6
Dryer / filter / fluid container / inspection
glass
Fig. 1
Dryer / filter
The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve.
Moisture that has entered during assembly of the re-
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.
i Note
Since the absorbing capacity of this filter/dryer is lim-
ited, it must be changed within certain service inter-
vals. We recommend to replace it 1 x per years,
before the start of the season.
! Caution
The filter/dryer must generally be replaced when-
ever opening the refrigerant circuit, because
moisture will enter in such a case.
This requires emptying the air conditioning sys-
tem!
Installation position:
The arrow marks on the filter/dryer must point in
flow direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!
378 BOMAG
Description of components
Safety valve
Fig. 2
The fluid container is equipped with a safety valve.
Response pressure 32 +/- 4 bar
Tightening torque 10 - 15 Nm
Inspection glass
Fig. 3
During operation the refrigerant must flow through the
inspection glass without air bubbles. In most cases
the presence of air bubbles is a sign for a too low re-
frigerant level in the system. Apart from this, the refrig-
erant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
down to a level, at which gaseous refrigerant could
flow through the rising tube to the inspection glass.
This results in abnormally high temperatures in and on
the fluid lines (between refrigerant container and ex-
pansion valve), as well as very high pressures in the
pressure side.
However, incorrect evacuation or filling may also be
the reason for air entering into the system and since
air cannot be condensed, one will not be able to get
rid of these bubbles by topping up refrigerant. In this
case the air conditioning system needs to be evacuat-
ed and refilled.
008 911 49
Description of components
i Note
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.
! Danger
In case of mechanical damage or corrosion on
this pressure container this collector unit must be
replaced, to avoid bursting and further damage.
008 911 49
12.6
Expansion valve
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.+
BOMAG 379
12.6 Description of components

Evaporator Defroster thermostat

Fig. 1 Fig. 1

The evaporator is mounted inside the HKL-module in
the cabin. It consists of a heat exchanger (inside air -
refrigerant), with refrigerant flowing to a pipe system
with cooling flanges.
As with the condenser, correct operation of all fans
and cleanliness of the fins must be assured.
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator,
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt.
A condensation water filter is mounted in the air flow
after the evaporator. This filter has the function to col-
lect the water that has condensed from the air in the
evaporator block and to discharge this water into the
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
The feeler of a defroster thermostat to switch off the
magnetic clutch in case of icing up or to switch the
clutch back on after defrosting, is mounted on the
evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
should be checked during maintenance.
Switching point on: + 1°C (± 1°C)
Switching point off: + 5,5°C (± 1°C)
i Note
It is very important that the feeler is mounted down-
stream of the evaporator, but before the pressure sen-
sor, in countercurrent direction, with full length and
insulated against the outside temperature.

! Caution
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.

380 BOMAG 008 911 49

Description of components 12.6
Pressure switch Pipes and hoses
Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
Fig. 1
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure Recommended tightening torques for O-ring
side, the pressure switch will switch of the magnetic sealed fittings
clutch of the compressor, thus to avoid destruction of
system components by excessive pressure or draw- Thread Spanner width Torque
ing in external gases and foreign matter as a result of 5/8“ 17 or 19 13,6 - 20,3 Nm
too low pressure. 3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
Working pressure:
1 1/16“ 32 40,7 - 47,5 Nm
Low pressure off: 1,5 ±0,5 bar M30X2 36 105,0 - 115,0
Low pressure on: 3.5 bar Nm
M36X2 41 165,0 - 175,0
Overpressure off: 25,0 ±1,5 bar
Nm
Overpressure on: 18,0 ±1,5 bar
Bending radii for air conditioning hoses

Hose type Nominal width Bending radius

GH 134 NW8 min. 50 mm
GH 134 NW10 min. 65 mm
GH 134 NW12 min. 75 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm

008 911 49 BOMAG 381

12.7 Checking the compressor oil level

12.7 Checking the compressor oil

level

Checking the compressor oil level / refrig-

eration oil level

!Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404).
l Run the compressor for 10 minutes at engine idle
speed.
l In order to avoid any compressor oil losses you
should slowly drain all refrigerant from the air condi- Fig. 2
tioning system. l Turn the nut that hold the armature clockwise with a
socket wrench, until the counterweight is correctly
positioned.

i Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
l Insert the oil dipstick.
l Pull out the dipstick and count the notches covered
by oil.
l Drain off oil or fill up as specified in the table.

Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
Fig. 1
Fastening angle (de- Oil dipstick in incre-
l Measure the fastening angle (Fig. 1) of the com- gree) ments
pressor (oil plug at top) 0 5-7
l
Remove the oil filler plug. 10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
l
Screw the oil filler plug back in.

! Caution
The contact area must be clean and should be free
of damage.
Use a new O-ring.
Tightening torque 15 to 25 Nm
l Refill the air conditioning system.

382 BOMAG 008 911 49

Checking the magnetic clutch 12.8
12.8 Checking the magnetic clutch i Note
l Measure the voltage. The gap should be 0.4 to 0.8 mm.
l
Take off the drive V-belt and rotate the V-belt pulley
by hand while the magnetic clutch is disengaged.
i Note
Nominal value = vehicle voltage
l
Check the magnetic coil locking ring for secure fit.
i Note
In case of excessive flatness faults or deviations the
l
Check the current consumption. magnetic clutch needs to be replaced.

Cross-section of magnetic clutch

Fig. 3 shows a cross-section of the magnetic clutch. If
the coil (7) is not supplied with operating voltage,
there is no contact between the front plate of the
clutch (1) and the V-belt pulley (2). A spring presses
the front plate away from the belt pulley. The V-belt
pulley rotates with the bearing (3) in idle speed, the
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is
generated and pulls the front plate of the clutch. Both
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works.

Fig. 1

i Note
Nominal value approx. 3.5 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.

Fig. 3 Cross-section of magnetic clutch

Fig. 2 Measuring the air gap

l
Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).

008 911 49 BOMAG 383

12.9 Inspection and maintenance work

12.9 Inspection and maintenance 12.10Checking, replacing the refrig-

work erant compressor V-belt1
l Visual inspection of the complete system for dam-
age. Danger
!
l Check the compressor mounting bracket on the ve- Danger of injury!
hicle engine for tight fit and damage.
Work on the V-belt must only be performed with
l Check the condition, alignment and tightness of the the engine shut down.
V-belt.
Wear safety goggles.
l
Check the routing of refrigerant hoses and cables in
the area of the vehicle engine and transmission, as
Check the V-belt
well as on the chassis for chafing and rectify any de-
tected faults. Ensure sufficient clearance to hot
parts, such as the exhaust; install a protective
shield, if necessary.
l Check the routing of hoses and hoses on the at-
tachment box or in the cabin.
l Check all hose and screw fittings for leaks.
l Check the fastening of the condenser unit.
l
Clean the condenser fins, replace the condenser
block if damaged fins are found.
l
Check the fastening of the evaporator unit.
l
Check the function of evaporator and condenser
fans. Fig. 4
l
Check the electric control panel. If discolorations on l
Inspect the entire circumference of the V-belt (Fig.
conductors are found, these should be replaced 4) visually for damage and cracks. Replace dam-
and possibly also the corresponding relays. aged or cracked V-belts.
l
Switch on the cooling system and check the refrig- l Check with thumb pressure whether the V-belt can
erant level. be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
l
Filter/dryer and filter/dryer/fluid container combina-
essary.
tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by Tighten the V-belt.
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
l Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
out air temperature - The temperature difference
should be at least 8-10 K.
l
Measuring the pressure in the refrigerant circuit

Fig. 5
l
Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).

1 Optional equipment

384 BOMAG 008 911 49

Service the air conditioning
Press the compressor in direction of arrow, until the
l
correct V-belt tension is reached.
l Retighten all fastening screws.
Changing the V-belt
l Slightly slacken the fastening screws 1, 2 and 3.
l Press the compressor against the direction of arrow
completely against the engine.
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
Caution
!
Check the V-belt tension after a running time of 30
minutes.
008 911 49
12.11
12.11Service the air conditioning1
Cleaning 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.
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.
Danger
!
Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 6
l Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
l
Clean the condenser fins on front and back with
compressed air or cold water .
Checking the refrigerant level
l
Start the engine.
1 Optional equipment
BOMAG 385
12.11 Service the air conditioning

Fig. 7 Fig. 9
l Switch the air conditioning (Fig. 7) on. l Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
at the top.

i Note
The refrigerant level is correct.

Fig. 8
l Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 8) in the blue section.
l
Open the air outlet nozzles.
l
Check, whether the outflowing air is noticeably cool-
er. Fig. 10
l
If the white float (Fig. 10) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
i Note
the service department.
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on. i Note
l Open the hood. The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.

386 BOMAG 008 911 49

Service the air conditioning 12.11
Checking the moisture level of the drying
agent

Fig. 12
l Check the drier/collector unit (Fig. 12) for mechani-
cal damage or rust.
Fig. 11
l Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
orange = drying agent o.k.
colorless = moisture level of drying agent too high.
l Inform the service department. Replace drier/col-
lector unit, check air conditioning system.

Caution
!

Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.

Checking the condition of the drier/col-

lector unit

!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
with this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.

! Danger

Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.

008 911 49 BOMAG 387

12.12
12.12Drying and evacuation
Evacuation of air conditioning systems using R-type
refrigerants not only has the purpose of emptying the
system of all air before filling in refrigerant, but also to
verify the leak tightness over a longer lifetime in the
achieved vacuum. However, the most important factor
in this work step is the drying of the system.
Any water residues in the refrigerant circuit will com-
bine with the refrigerant, which will lead to the previ-
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration
system.
The refrigerant compressor is not suitable for the pur-
pose of evacuation, because it is not able to achieve
a sufficient final vacuum and, apart from this, may be
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
It is common practice to evacuate the refrigeration
system to a final vacuum of 1 Torr, i.e. 1.33 mbar.
An exact time for evacuation and drying cannot be
predicted. It can only be determined by means of a
vacuum meter. However, if there is no vacuum meter
at hand it is generally better to evacuate 1 hour longer
than 1 hour too less.
Function drying:
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced,
water will already evaporate, e.g. under a pressure of
10 mbar, at an ambient temperature of almost 7°C,
but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in
the system, the evacuation process is supported by
the co-called vacuum breaking (filling the circuit with
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.
388 BOMAG
Drying and evacuation
12.13Emptying in case of repair
For repair work the air conditioning systems must very
often be emptied of all refrigerant.
Especially with expensive refrigerants and larger
amounts of oil it may be necessary to keep the refrig-
erant for later use.
For later use these refrigerants must be drawn out
with suitable equipment and intermediately stored in
collecting containers.
Environment
Contaminated refrigerant must be disposed of en-
vironmentally
Releasing refrigerant into the atmosphere is pro-
hibited (see restrictive injunction concerning
CFC, day of enforcement 01. 08. 1991, § 8)
! Danger
For draining refrigeration systems you should not
simply use any delivery containers, but only ap-
propriate pressure bottles, which must be special-
ly marked and should comply with the pressure
gas directive.
When transferring refrigerant you must make sure
that the bottle does not contain more than the per-
mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
In order to reduce the evacuation period in case of
short repairs, you may fill the refrigerant circuit with
approx. 0.5 bar nitrogen when opening. This ensures
that nitrogen will flow out of the refrigerant circuit while
it is open and no air or moisture can enter. However,
the necessity for vacuum generation and a dryer
change remains.
008 911 49
Leak test 12.14
12.14Leak test

! Caution
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.

Leak test with electronic leak tester

Fig. 1 Electronic leak tester

Small leaks with only very low amounts of refrigerant
escaping can be detected, e.g. with an electronic leak
tester. Such equipment is able to detect leaks of less
than 5 gr. per year.
The leak tester used must be specially designed for
the refrigerant composition in the air conditioning sys-
tem. For example, leak detectors for refrigerant R12
are not suitable for R134a, because the refrigerant
R134a is free of chlorine atoms, meaning that this leak
detector will not respond.

Leak test with soap bubbles

Fig. 2 Soap bubble test

Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.

008 911 49 BOMAG 389

12.15 Filling instructions

12.15Filling instructions

Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).

! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.

i Note
White frost on the suction line is no measure for as-
sessing the filling.

390 BOMAG 008 911 49

Filling instructions 12.15

Fig. 1 10 Filter dryer

1 High pressure - gaseous 11 Fluid container
2 High pressure - liquid 12 Condenser
3 Low pressure - gaseous 13 Manual shut-off valve (not used)
4 Compressor 14 Pressure switch with high and low pressure con-
5 Compressor pressure switch (not used) tacts
6 not used 15 Defroster thermostat
7 Evaporator 16 Vacuum meter
8 Expansion valve 17 Low pressure gauge
9 Inspection glass 18 High pressure gauge

008 911 49 BOMAG 391

12.15
19 Pressure reducing valve
20 Vacuum pump
21 Nitrogen bottle
22 Refrigerant bottle
23 Pressure gauge bar
Filling instructions
1 Connect the service adapter with the blue hand
wheel in the suction side.
2 Connect the service adapter with the red hand
wheel in the pressure side (the hand wheels on
the service adapters must be fully backed out - left
hand stop)
3 Connect the blue suction hose below the blue
hand wheel on the pressure gauge bar to the blue
service adapter.
4 Connect the red pressure hose below the red
hand wheel on the pressure gauge bar to the red
service adapter.
5 Connect the yellow hose below the yellow hand
wheel on the manometer bar to the 2-stage vacu-
um pump.
6 Connect the last hose below the black hand wheel
on the nitrogen bottle via the pressure reducing
valve.
7 Check on the pressure gauge bar that all hand
wheels are closed.
8 Turn the hand wheels on both service adapter
clockwise. This opens the valves (right hand
stop).
9 Open the valve on the nitrogen bottle (only via
pressure reducer); pressure approx. 20 bar.
10 Open the black and red hand wheels on the pres-
sure gauge bar and fill nitrogen into the system,
until a pressure of approx. 3.5 to 5.0 bar is indicat-
ed on the suction side.
11 Then open the blue hand wheel and raise the
pressure in the suction side (max. 10 bar). Check
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
392 BOMAG
Filling instructions
16 Switch off the vacuum pump, watch the pressure
gauges to see whether the vacuum is maintained.
17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
gauge bar. Fill refrigerant into the system, until a
pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
es).
18 Close the red hand wheel.
19 Perform a leak test with the electronic leak detec-
tor.
20 Start the engine and switch on the system.
21 Open the blue hand wheel and continue filling in
refrigerant until the inspection glass is free or air
bubbles (in fluid container/dryer combinations the
white pearl should float in the upper third of the in-
spection glass). Then close the refrigerant bottle.
22 Close the blue hand wheel on the pressure gauge
bar.
23 Preparing the test run: -Close windows and doors
-Fan on full speed stage -Mount measuring feel-
ers to air discharge and air intake.
24 Run the system for approx. 20 minutes with medi-
um engine speed.
25 The temperature difference between air discharge
and air intake should be (depending on type of air
condition) 8-10°C. The ambient temperature
thereby is approx. 20°C. (These data are only ref-
erence values, which may be influenced by possi-
ble insolation)
26 Switch off system and engine and check for leaks
again.
27 Turn out (left hand stop) and remove the hand
wheels on both service adapters.
28 Fit all valves with dust caps.
29 Perform a leak test.
30 Mark the system with the corresponding type
plates and information decals, such as type of oil
and refrigerant.
008 911 49
Trouble shooting in refrigerant circuit, basic principles 12.16
12.16Trouble shooting in refriger-
ant circuit, basic principles

Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
l Expert knowledge
l technical equipment

Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
l
Service station
Filling the system with refrigerant causes an excess
l
Pressure gauge pressure of Pe = 3 bar.
l
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
l
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
l
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
l
Container for old oil
l
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
l
Hoses
l Scales
l Suction station
l Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.

Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.

Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)

008 911 49 BOMAG 393

12.16 Trouble shooting in refrigerant circuit, basic principles
Pressure gauge with saturation temperature scale
Fig. 3 Absolute pressure gauge
Temperature scales on the pressure gauges always
refer to the absolute pressures Pabs. Please note that
it is not possible to measure a temperature directly
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper-
ature is assigned to the measured pressure.
If the refrigerant is fluid, the temperature is below the
saturation temperature.
If the refrigerant is gaseous, the temperature is above
the saturation temperature.
Pressure gauges must indicate 0 bar when not con-
nected to the system.
Low pressure gauges have a blue, high pressure
gauges a red border.
Thermometer
Normally digital thermometers with surface or contact
feelers are used. Especially for high temperature dif-
ferences excellent heat insulation of the measuring lo-
cation is of utmost importance. The sparing use of a
heat conducting paste is highly recommended. If the
measuring location is soiled, it needs to be cleaned
and probably treated with a fine emery cloth. Only the
temperature of the feeler is measured. Due to missing
heat insulation and insulating oxide layers on the line,
temperature differences of a few degrees Kelvin be-
tween the measured and the actual values may arise.
Overheating
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are
not compressible and must therefore not enter into the
compression chamber of the compressor.
394 BOMAG
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
is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
ates within a range between 4 and 12 Kelvin. The in-
fluence of the ambient air on the suction line causes
an additional overheating effect.
Overheating is calculated as follows:
Δ to2h = to2h - to
Δ to2h, overheating at evaporator outlet in K
to2h, temperature at evaporator outlet in °C
to, evaporation temperature in °C
„h“ represents "overheated"
Supercooling
It is the function of the expansion valve to reduce the
refrigerant to a lower pressure level (evaporation
pressure) after it has been liquefied. For an optimal
function of the valve pure fluid must be applied to its
inlet port.
The refrigerant must "squeeze" (literally speaking)
through a throttle gap inside the expansion valve.
When comparing a certain mass of refrigerant in fluid
and in vaporous state (with constant pressure), the
vaporous refrigerant requires a much higher volume.
That's why the vaporous refrigerant needs a much
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
If the refrigeration system is operated with the "expan-
sion valve inlet" condition directly on the boiling curve,
slightest fluctuations in operating condition may cause
008 911 49
Trouble shooting in refrigerant circuit, basic principles 12.16
a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.

Common supercooling values

In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.

Supercooling is calculated as follows:

Δ tc2u = tc - tc2u
Δ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"

008 911 49 BOMAG 395

12.16 Trouble shooting in refrigerant circuit, basic principles

Fig. 1 Refrigerant circuit with t, h- diagram

1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion

396 BOMAG 008 911 49

Trouble shooting, refrigerant circuit diagram 12.17
12.17Trouble shooting, refrigerant
circuit diagram

Fig. 1 Refrigerant circuit diagram 13 Compressor

1 Cold air 14 Condenser
2 Evaporator 15 Cooling air
3 Thermostat 16 Pressure gauge, low pressure
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air

008 911 49 BOMAG 397

12.18 Trouble shooting procedure

12.18Trouble shooting procedure l Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
l The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
l Ambient temperature above 15 °C.
about the system design, the installed components l The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:

Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.

i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.

Test prerequisites
l Cooler and condenser are clean, clean if neces-
sary.
l The ribbed belt for compressor and generator is
correctly tightened.
l All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
l The engine has operating temperature.

398 BOMAG 008 911 49

Trouble shooting procedure
Fig. 2 Flow diagram with measuring points
l C, condenser measuring points
l E, expansion valve measuring points
l O, evaporator measuring points
l V, compressor measuring points
The flow diagram contains "Minimum Requirements"
which must be fulfilled to be able to check the system
or perform trouble shooting.
Temperature and pressure at the evaporator outlet
can be used to derive the overheating of the evapora-
tor. Overheating is a clear indicator for the evaporator
filling level. In case of excessive overheating the re-
frigerant quantity fed into the evaporator is too low, in
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is
caused by the expansion element or by insufficient fill-
ing. A differentiation is only possible if there is a clear
indicator for the refrigerant filling quantity.
Pressure and temperature at the condenser outlet can
be used to derive the supercooling. This can be used
008 911 49 BOMAG
12.18
Measuring points and measurements
to assess the filling quantity. In systems with fluid con-
tainer the inspection glass is most suitable to check
the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
The hot gas temperature can be used to check wheth-
er the compressor runs in the permissible operating
range.
Example: Measurement of overheating
l a) Which measuring equipment is required ?
l b) Where to measure with which size ?
l c) A pressure gauge connected to the evaporator
indicates "Peo2 = 1.7 bar". How high is the evapora-
tor pressure "Po" ?
l
d) How high is the evaporator temperature "to" ?
l e) A thermal sensor attached to the evaporator out-
let measures the temperature "to2h = +3 °C". How
high is the overheating „Δto2h“ ?
l
f) Evaluation of the measured overheating.
399
12.18 Trouble shooting procedure

Solution: be a defect in the expansion valve or problems in the

l a) Pressure gauge, thermometer, steam table oil recirculation.
l b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
l c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
l
d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
l e) Δto2h = to2h - to, „Overheating at evaporator out-
Ambient temperature in °C Excess pressure in bar
let = evaporator outlet temperature - evaporation
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
l f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
l a) Which measuring equipment is required ?
l
b) Where to measure with which size ?
l
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
l
d) How high is the condensing temperature "tc" ?
l
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "Δtc2u" ?
l
f) Evaluation of the measured supercooling.

Solution:
l
a) Pressure gauge, thermometer, steam table
l
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
l c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
l d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
l e) Δtc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
l f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.

Typical faults and possible causes

Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist. r Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also

400 BOMAG 008 911 49

Trouble shooting procedure 12.18
Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X

008 911 49 BOMAG 401

12.18 Trouble shooting procedure

Suction pressure too low (1), high pressure too

low to normal (2)

Fig. 3

Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspec- Check for leaks, refill
tion glass, high overheating, hoar-
frost on evaporator
Evaporator fins or air filter soiled Cooling power too low clean
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vac- Replace the valve
uum, because the valve has closed
Screen or nozzle in expansion valve high overheating clean
clogged
Filter dryer clogged Bubbles in inspection glass, high Change filter dryer
overheating, filter dryer cold
Heat power too low Frequent low pressure shut off, Check the control
thawing thermostat / rotary thermo-
stat switching too frequently

402 BOMAG 008 911 49

Trouble shooting procedure 12.18
Suction pressure normal (1), high pressure too
high (2)

Fig. 4

Cause Possible effect Remedy

Condenser dirty high hot gas temperature, low cool- clean
ing power
Condenser fan failed high hot gas temperature, high pres- repair
sure shut down
overfilled high hot gas temperature, low su- Correct the filling capacity
percooling, low cooling power
Leak gas (air) high hot gas temperature, low renew filling
measured supercooling, low cooling
power
Restriction between compressor and high hot gas temperature, low cool- Check lines and valves
condenser ing power

008 911 49 BOMAG 403

12.18 Trouble shooting procedure

Suction pressure too high (1), high pressure too

low to normal (2)

Fig. 5

Cause Possible effect Remedy

Compressor defective Cooling power too low Replace the compressor

404 BOMAG 008 911 49

Trouble shooting procedure 12.18
Suction pressure too high (1), high pressure too
high (2)

Fig. 6

Cause Possible effect Remedy

Expansion valve defective overheating too low, wet operation Replace the valve
of compressor

008 911 49 BOMAG 405

12.18 Trouble shooting procedure

Other faults

Symptom Cause Possible effect Remedy

Hot gas temperature too Lack of refrigeration oil increased compressor Refill refrigeration oil
high, the hot gas line be- wear
comes so hot that it cannot
be touched long with a
hand
Compressor does not start Pressure switch or any oth- System stopped Check the control units,
er safety feature has trig- check cause for switching
gered, electrical fault, and rectify
cylinder filled with liquid re-
frigerant
Compressor switches con- Switching difference too Cycling of compressor, in- Check the control units,
tinuously small, triggering of a creased wear, too low cool- check cause for switching
switching element (over- ing power and rectify
pressure switch, low pres-
sure switch), lack of
refrigerant, fan defective,
overfilled
Excessive overheating Expansion valve deadjust- low cooling power, hot gas Replace the expansion
ed or screen blocked, lack temperatures too high valve, clean the screen, fill
of refrigerant in refrigerant, leak test
Hoarfrost on inlet side of incorrectly working expan- too low infeed of refrigerant Check the expansion
evaporator sion valve, lack of refriger- into the evaporator valve, check the refrigerant
ant filling
Evaporator fully covered Load problem, too low air low cooling power of sys- Clean the evaporator,
with hoarfrost flow volume tem check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, low cooling power Eliminate the pressure
shows condensation filter dryer clogged drop, replace the filter dryer
Exceptionally cold pres- "Wet intake" of the com- low cooling power, exces- Clean the compressor, re-
sure lines pressor due to insufficient sive wear of compressor place if necessary, replace
overheating of evaporator the expansion valve if nec-
essary

Noise in system

Faults Possible cause Remedy

V-belt loose or excessively worn
Magnetic clutch loud
Refrigerant compressor is loud
Fan is loud, fan motor excessively
worn
Whistling and rattling noise in opera- V-belt pulley and bearing worn
tion, noticeable unevenness when
turning by hand
Rattling noise or vibration of high
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud
Hissing noise in evaporator housing, refrigerant level in system too low
on expansion valve, turbidity in in-
spection glass or ball does not float
V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch runs until high pres- Repair or replace the magnetic
sure builds up, then the clutch starts clutch
to slip
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
Replace the fan motor
Replace the bearing, check V-belt
pulley for wear
System overfilled Draw out refrigerant
excessive moisture in system Replace the dryer
Perform a leak test, fill up the system

406 BOMAG 008 911 49

Trouble shooting procedure 12.18
Inspection glass

Faults Possible cause Remedy

Steam bubbles in inspection glass
Discolouration of inspection glass
(black from inside)
Moisture indicator changes to pink
Ball floats at bottom
No supercooling before expansion
valve, lack of refrigerant in system,
pressure loss in system, supercool-
ing caused by excessively soiled fil-
ter dryer
Lubricant destroyed by excessive
operating temperatures
Moisture level of drying agent too
high
lack of refrigerant
Fill up the system, replace the filter
dryer, perform a leak test
Replace the refrigeration oil, exam-
ine the temperature increase
Replace the filter dryer
Fill the system

Monitoring devices

Faults Possible cause Remedy

The high pressure contact has
switched off the magnetic clutch
The low pressure contact has
switched off the magnetic clutch
The thermostat has switched off the Ambient temperature below 1°C, Check the thermostat switching
magnetic clutch
System pressure exceeded, con- Clean the condenser, replace the
denser excessively soiled, condens- expansion valve, check the con-
er fan defective, expansion valve denser fan
defective
System pressure fallen short of, re- Clean the evaporator, replace the
frigerant level too low, expansion expansion valve, check the evapora-
valve defective, evaporator fan de- tor fan
fective, heat load too low, ambient
temperature below 1.5 °C
expansion valve defective, thermo- point, replace the expansion valve,
stat defective, air flow volume too clean the evaporator, check the
low evaporator fan

008 911 49 BOMAG 407

12.19 Steam table for R134a

Tempera- Pres- Density spec. volume spec. enthalpy Evapora-

ture sure tion heat
of the fluid of the of the fluid of the of the fluid of the
steam steam steam

408 BOMAG 008 911 49

Steam table for R134a 12.19

008 911 49 BOMAG 409

12.19 Steam table for R134a

410 BOMAG 008 911 49

Steam table for R134a 12.19

008 911 49 BOMAG 411

12.19 Steam table for R134a

412 BOMAG 008 911 49

 12.20Heating control / air conditioning control

008 911 49 BOMAG 413

12.20 Heating control / air conditioning control

414 BOMAG 008 911 49

Heating control / air conditioning control 12.20

008 911 49 BOMAG 415

12.20 Heating control / air conditioning control

416 BOMAG 008 911 49

Heating control / air conditioning control 12.20

008 911 49 BOMAG 417

12.20 Heating control / air conditioning control

418 BOMAG 008 911 49

 13 Replacing the cab window panes

008 911 49 BOMAG 419

13.1 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

420 BOMAG 008 911 49

Special tools 13.2
13.2 Special tools
1. Locking handle for fastening element

BOMAG part-no.: 055 705 84

Fig. 1
2. Suction lifter

commercial

Fig. 2

008 911 49 BOMAG 421

13.3 Auxiliary materials

13.3 Auxiliary materials

Safety gloves
3. Cutter

Commercial

Fig. 1
4. Window glass bonding agent

BOMAG part-no.: 009 780 34

Fig. 2
5. Activator

BOMAG part-no.: 009 780 33

Fig. 3

422 BOMAG 008 911 49

Auxiliary materials 13.3
6. Silicone sealant

BOMAG part-no.: 009 700 36

Fig. 4

008 911 49 BOMAG 423

13.4 Removing and installing the window pane

13.4 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

424 BOMAG 008 911 49

Removing and installing the window pane 13.4
6. Turn the fixing and spacer washer hand-tight onto
the thread of the fastening element (Fig. 4).

i Note
Do not overtighten the thread.

Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).

i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.

Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.

Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).

i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.

Fig. 7

008 911 49 BOMAG 425

13.4 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

426 BOMAG 008 911 49

Removing and installing the window pane 13.4
19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).

Fig. 12
20. Treat the inside joint (Fig. 13)

Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.

i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.

Fig. 14

008 911 49 BOMAG 427

13.4 Removing and installing the window pane

428 BOMAG 008 911 49

 14 Drum

008 911 49 BOMAG 429

14.1 Special tools, drum, single drum rollers

14.1 Special tools, drum, single drum roll-

ers
1. Disassembly device for side plate

BOMAG part-no.: 007 211 55

Fig. 1
2. Assembly device for side plate

BOMAG part-no.: 971 079 21

Fig. 2
3. Assembly device for coupling hub and flanged
hub

Fig. 3

430 BOMAG 008 911 49

Special tools, drum, single drum rollers 14.1
4. Pressing plate for cylinder roller bearing

Fig. 4
5. Pressing plate for travel bearing

Fig. 5
6. Pressing bushing for radial seal

Fig. 6
7. Lifting device for exciter unit

BOMAG part-no.: 007 215 08

Fig. 7

008 911 49 BOMAG 431

14.2 Repair overview for drum

432 BOMAG 008 911 49

Repair overview for drum 14.2
1 Drum 13 Flanged hub
2 Cylinder roller bearing 14 Vibrator shaft
3 Coupling 15 Coupling
4 Vibration motor 16 Vibrator shaft
5 Rear shell 17 Change-over weight
6 Grooved ball bearing 18 Cylinder roller bearing
7 Spacer block 19 Basic weight
8 Rectangular rubber buffer 20 Flanged housing
9 Side plate 21 Flange
10 Spacer ring 22 Cylinder roller bearing
11 Grooved ball bearing 23 Rear shell
12 Mechanical seal

008 911 49 BOMAG 433

14.2 Repair overview for drum

434 BOMAG 008 911 49

Repair overview for drum 14.2

008 911 49 BOMAG 435

14.2 Repair overview for drum

436 BOMAG 008 911 49

Repair overview for drum 14.2

008 911 49 BOMAG 437

14.2 Repair overview for drum

438 BOMAG 008 911 49

Repair overview for drum 14.2

008 911 49 BOMAG 439

14.3 Removing and installing the drum

14.3 Removing and installing the drum

i Note
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (Fig. 1).

Fig. 1

i Note
However, the drum can also be removed without
having to disassemble the side plate, if it is lifted
up and out of the frame (Fig. 2).

Fig. 2
Removing the drum

i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.

Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
1. Mark the hydraulic hoses (Fig. 3)on the travel mo-
tor and disconnect them from the ports.
2. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 3

440 BOMAG 008 911 49

Removing and installing the drum 14.3
3. Mark the hydraulic hoses on the vibration motor
(Fig. 4) and disconnect them from the ports.
4. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 4

! Danger
Danger of squashing! Do not stand or step
under loads being loaded.
Always secure the machine against unintend-
ed rolling!
5. Unscrew bolts 1 (Fig. 5) and nuts and remove the
front scraper (2).
6. Unscrew bolts 3 and nuts and remove the front
scraper (4).

Fig. 5
7. Support the front cross-member safely with suita-
ble trestles or wooden blocks (Fig. 6).

Fig. 6
8. Support the rear cross-member safely with suita-
ble trestles or wooden blocks (Fig. 7).

Fig. 7

008 911 49 BOMAG 441

14.3 Removing and installing the drum

9. Disassemble bracket 1 (Fig. 8) for the hydraulic

hoses.

Fig. 8
10. Fasten the lifting gear to the side plate on the vi-
bration motor side.
11. Unscrew bolts 1 (Fig. 9) from the spacer blocks
on vibration and travel motors.

Fig. 9

!Danger
Danger of squashing! Do not stand or step
under loads being loaded.
12. Force out plug 1 (Fig. 10) and unscrew the bolts
(2) from the front and rear cross-members.
13. Take off the side plate.

Fig. 10
14. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 11).

!Danger
Danger of squashing! Do not stand or step
under loads being loaded.

Fig. 11

442 BOMAG 008 911 49

Removing and installing the drum 14.3
15. Check all rubber buffers (Fig. 12), replace if nec-
essary (see corresponding chapter).

Fig. 12
16. Check rectangular rubber buffers (Fig. 13), re-
place if necessary.

Fig. 13

Installing the drum

! Danger

Danger of squashing!
Do not stand or step under loads being load-
ed.
1. Place the drum into the frame and align it parallel
to the frame (Fig. 14).

Fig. 14
2. Attach the side plate, insert the bolts 2 (Fig. 15)
into rear and front cross-members and tighten
with 463 Nm.

i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
3. Close the screw holes with plugs (1).

Fig. 15

008 911 49 BOMAG 443

14.3 Removing and installing the drum

4. Fasten the spacer blocks on travel and vibration

motor sides with bolts 1 (Fig. 16) and nuts to the
side plates.

Fig. 16
5. Connect hydraulic hoses to the connections on
travel motor and vibration motor according to the
marking (Fig. 17).

Fig. 17
6. Fasten bracket 1 (Fig. 18) for the hydraulic hoses.

Fig. 18
7. Assemble the front scraper 2 (Fig. 19), fasten
with bolts (1), washers and nuts.
8. Assemble the rear scraper (4), fasten with bolts
(3), washers and nuts.

i Note
9. Observe the adjustment measurement 30-35 mm

Fig. 19

444 BOMAG 008 911 49

Removing and installing the drum 14.3
! Caution
Before resuming operation of the machine:
Bleed the hydraulic system and check for
function and leaks.
Adjust the pretension of the rubber buffers.
10. Measure distance „X“ between spacer piece 1
(Fig. 20) and side plate.
11. Calculate the thickness of the compensation
plates.

Nominal value:

Fig. 20
Distance "X" + 2 mm
12. Turn one screw (3) into the welded nut (2) at top
and bottom and open a sufficient gap to insert the
compensation plates.
13. Insert the compensation plates 4 (Fig. 21). Insert
screws (1), slide on washers (3), turn on and
tighten nuts (2).
14. Unscrew the screws from the welded nuts.

Fig. 21

008 911 49 BOMAG 445

14.4 Repairing the drum

14.4 Repairing the drum

Removing the travel motor

! Danger
Danger of squashing!
Do not stand or step under suspended loads.
1. Attach the lifting tackle to the travel motor.
2. Unscrew all nuts (Fig. 3) from the rubber buffers.
3. Take the drive disc with the travel motor off the
rubber buffers.

Fig. 1
4. Unscrew the nuts, pull out the screws and re-
move the support legs (Fig. 4).

Fig. 2
5. Attach the lifting tackle to the travel motor (Fig. 3).

! Danger
Danger of squashing!
Do not stand or step under suspended loads.

Fig. 3

446 BOMAG 008 911 49

Repairing the drum 14.4
6. Unscrew the bolts (Fig. 4) and separate the travel
motor from the drive disc.

! Caution
Flush the hydraulic system if dirt or chips are
found in the travel motor.

Fig. 4

Disassembling the exciter unit (travel

motor side)
1. Unscrew both socket head cap screws from the
flange (Fig. 5).

Fig. 5
2. Mount bracket 1 (Fig. 10) for the lifting device to
the flange.
3. Unscrew screws (2) from the flange.

i Note
Do not unscrew the thin drawn screws.

Fig. 6

008 911 49 BOMAG 447

14.4 Repairing the drum

4. Slide the lifting device over the bracket.

5. Force the exciter unit off with two forcing screws
(Fig. 7).

Fig. 7

! Danger
Danger of squashing!
Do not stand or step under suspended loads.
6. Pull the exciter unit out of the drum (Fig. 8).
7. Take the coupling element off the coupling half.

Fig. 8

Disassembling the exciter unit (travel

motor side)
1. Unscrew fastening screws 1 (Fig. 9) for the fan.
2. Loosen clamping screw (2).
3. Pull the coupling hub off the shaft.

Fig. 9

448 BOMAG 008 911 49

Repairing the drum 14.4
4. Unscrew all other fastening screws 1 (Fig. 10)
from the flange.
5. Press the flange off the flanged housing with forc-
ing screws (2).

Fig. 10

Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
6. Lift the flange off the flanged housing (Fig. 11).
7. Take the O-ring out of the groove in the flanged
housing.

Fig. 11
8. Unclip the circlip from the groove in the flange
(Fig. 12).

Fig. 12
9. Press the cylinder roller bearing with forcing
screws out of the flange (Fig. 13).

Fig. 13

008 911 49 BOMAG 449

14.4 Repairing the drum

10. Take the exciter unit (Fig. 14) out of the flanged
housing.

Fig. 14
11. Knock the radial seal (Fig. 15) out of the flanged
housing.

Fig. 15
12. Unclip the circlip from the groove in the flanged
housing (Fig. 16).

Fig. 16
13. Press the cylinder roller bearing with forcing
screws out of the flanged housing (Fig. 17).

Fig. 17

450 BOMAG 008 911 49

Repairing the drum 14.4
14. Extract inner ring 1 (Fig. 18) for the radial seal
and inner bearing races (2).

! Danger
Danger of burning!
Wear safety gloves.

i Note
If the rings are very tight, heat them up with a
torch.

Fig. 18
15. Unclip the circlip from the basic weight (Fig. 19).

Fig. 19
16. To change shaft 1 (Fig. 20) knock out dowel pins
(2 and 3) and press the shaft out of the basic
weight.

i Note
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).

Fig. 20

008 911 49 BOMAG 451

14.4 Repairing the drum

Disassembling the exciter unit (vibra-

tion motor side)
1. Unscrew fastening screw 1 (Fig. 21).
2. Take rectangular rubber buffer (2) with spacer
block (3) off the side plate.

i Note
Remove both rectangular rubber buffers.

Fig. 21
3. Unscrew fastening screws 1 (Fig. 22).
4. Force cover (2) together with the attached vibra-
tion motor off the side plate with forcing screws.

Fig. 22
5. To change the vibration motor loosen clamping
screw 1 (Fig. 23) and pull off coupling half (2).

Fig. 23

452 BOMAG 008 911 49

Repairing the drum 14.4
6. Unscrew nut 1 (Fig. 24), take off conical socket
(2) and conical disc (3).
7. Take the vibration motor off the cover.

Fig. 24
8. Remove the coupling element (Fig. 25).

Fig. 25
9. Fasten the lifting device.
10. Unscrew fastening screws 1 (Fig. 26).

! Caution
The four short fastening screws (2) must re-
main screwed in (the two others are not visi-
ble).

Fig. 26
11. Press the exciter unit out of the drum with forcing
screws (Fig. 27).

i Note
The second forcing screw is covered by the side
plate.

Fig. 27

008 911 49 BOMAG 453

14.4 Repairing the drum

! Caution
Danger of squashing!
Do not stand or step under suspended loads.
12. Pull the exciter unit out of the drum (Fig. 28).

Fig. 28

Removing, dismantling the side plate

1. Take off V-ring 1 (Fig. 29).
2. Unclip circlip (2).

Fig. 29
3. Attach the disassembly device to the side plate
(Fig. 30) and force off the side plate.

Fig. 30
4. Lift the side plate of the flanged hub (Fig. 31).

Fig. 31

454 BOMAG 008 911 49

Repairing the drum 14.4
5. Knock the grooved roller bearing out of the side
plate (Fig. 32) and take out the spacer ring.

Fig. 32
6. Unclip the circlip from the side plate (Fig. 33).

Fig. 33
7. Take the mechanical seal off the flanged hub
(Fig. 34).

Fig. 34

008 911 49 BOMAG 455

14.4 Repairing the drum

Dismantling the exciter unit (vibration

motor side)
1. Unscrew the fastening from the coupling hub.
2. Pull coupling hub (2) off the shaft using a pulling
device (Fig. 35).

Fig. 35
3. Loosen hose clamp 1 (Fig. 36).
4. Pull coupling hub (2) off the shaft.

Fig. 36
5. Unscrew all other fastening screws 1 (Fig. 37)
and press the flanged hub off the flanged housing
with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged
housing.

Fig. 37

456 BOMAG 008 911 49

Repairing the drum 14.4
8. Unclip the circlip from the groove in the flanged
hub (Fig. 38).

Fig. 38
9. Knock the cylinder roller bearing out of the flang-
ed hub (Fig. 39).

Fig. 39

Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
10. Lift the exciter unit out of the flanged housing (Fig.
40).

Fig. 40
11. Knock the radial seal (Fig. 41) out of the flanged
housing.

Fig. 41

008 911 49 BOMAG 457

14.4 Repairing the drum

12. Unclip the circlip from the groove in the flanged

housing (Fig. 42).

Fig. 42
13. Press the cylinder roller bearing with forcing
screws out of the flanged housing (Fig. 43).

Fig. 43
14. Extract inner rings 1 (Fig. 44) for the radial seals
and inner bearing races (2) from the shaft.

!Danger
Danger of burning!
Wear protective gloves.

i Note
If the rings are very tight, heat them up with a
torch.

Fig. 44
15. Unclip the circlip from the basic weight and re-
move the cover (Fig. 45).

i Note
The shafts cannot be pressed out. If damaged
they must be replaced with basic weight and cov-
er.
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).

Fig. 45

458 BOMAG 008 911 49

Repairing the drum 14.4
Assembling the exciter unit (vibration
motor side)
! Caution
Ensure strict cleanliness.

i Note
If the shafts are damaged they must be inserted
into the basic weight or the cover as follows.

! Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
Fig. 46 nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.

! Caution
Close the bores on the short shaft with a
screw.
1. Cool the shaft down in liquid nitrogen.
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
46).
3. Secure shaft 1 (Fig. 47) with dowel pins (2 and 3).

! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.

i Note
Unscrew the screw from the shaft.

Fig. 47

! Caution
Close the bores on the short shaft with a
screw.
4. Cool the shaft down in liquid nitrogen.
5. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
48).

Fig. 48

008 911 49 BOMAG 459

14.4 Repairing the drum

6. Secure shaft 2 (Fig. 49) with dowel pins (1 and 3).

! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.

i Note
Unscrew the screw from the shaft.

Fig. 49
7. Insert the fitting key into the keyway in the respec-
tive shaft (Fig. 50).

Fig. 50
8. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 51).

Fig. 51

! Danger
Danger of burning!
Wear safety gloves.
9. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 52).

Fig. 52

460 BOMAG 008 911 49

Repairing the drum 14.4
! Danger

Danger of burning!
Wear safety gloves.
10. Heat the inner ring up to approx. 50° C and slide
it onto the short shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 53).

Fig. 53

!Danger
Danger of burning!
Wear safety gloves.
11. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 54).

Fig. 54

!Danger
Danger of burning!
Wear safety gloves.
12. Heat the inner ring up to approx. 50° C and slide
it onto the longer shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 55).

Fig. 55
13. Press cylinder roller bearing 1 (Fig. 56) with
pressing plate (2) into the flanged housing until it
bottoms.

Fig. 56

008 911 49 BOMAG 461

14.4 Repairing the drum

14. Insert the circlip into the groove in the flanged

housing (Fig. 57).

Fig. 57
15. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 58).
16. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.

Fig. 58

!Caution
Danger of squashing!
Do not stand or step under suspended loads.
17. Insert the exciter unit with the longer shaft for-
ward into the flanged housing (Fig. 59).

Fig. 59
18. Press cylinder roller bearing 1 (Fig. 60) with
pressing plate (2) into the flanged hub until it bot-
toms.

Fig. 60

462 BOMAG 008 911 49

Repairing the drum 14.4
19. Insert the circlip into the groove in the flanged hub
(Fig. 61).

Fig. 61
20. Attach the flanged hub to the flanged housing
(Fig. 62).

! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
21. Unscrew eye bolts (1) and replace them with
short screws.
22. Turn short screws (2) into the tapped bores in the
flanged housing (four screws) and tighten them.

Fig. 62
23. Apply some grease to the sealing lip of radial seal
1 (Fig. 63).
24. Insert the radial seal into the flanged hub with the
sealing lip facing down and press it down against
the stop with pressing bushing (2).

Fig. 63 !Danger
Danger of burning!
Wear protective gloves.
25. Heat the coupling hub up to approx. 80 °C and
slide it onto the shaft against the stop (Fig. 64).

Fig. 64

008 911 49 BOMAG 463

14.4 Repairing the drum

26. Apply some grease to the sealing lip of radial seal

1 (Fig. 65).
27. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).

Fig. 65
28. Cover the thread of screw 1 (Fig. 66) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
29. Slide on the new U-seal ring (2), turn in and tight-
en the screws.

Fig. 66 ! Danger

Danger of burning!
Wear safety gloves.
30. Heat coupling hub 1 (Fig. 67) with marking letter
“L“ up t approx. 80° C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).

Fig. 67

464 BOMAG 008 911 49

Repairing the drum 14.4
Assembling and installing the side
plate
1. Fill grooved ball bearing 1 (Fig. 68) on both sides
with grease.
2. Press the grooved ball bearing completely in us-
ing pressing plate (2).

Fig. 68
3. Insert the circlip into the groove in the side plate
(Fig. 69).

Fig. 69
4. Apply a thick coat of grease to the spacer ring on
both sides and insert it into the side plate (Fig.
70).

Fig. 70

008 911 49 BOMAG 465

14.4 Repairing the drum

5. Fill grooved ball bearing 1 (Fig. 71) on one sides

with grease.
6. Insert the grooved ball bearing with the grease
side forward and press it completely in with
pressing plate (2).

i Note
Grease the other side after installing the exciter
unit.

Fig. 71
7. Insert the oiled loop-ring into the mechanical seal
(Fig. 72).
8. Clean the sliding surfaces of the mechanical seal
and cover them with oil.

Fig. 72
9. Lay one half of the radial seal on the flanged hub
with the sliding surface pointing up (Fig. 73).

Fig. 73
10. Lay the second half of the mechanical seal down
with the sliding face pointing down (Fig. 74).

Fig. 74

466 BOMAG 008 911 49

Repairing the drum 14.4
11. Bolt the threaded section of the assembly device
to the flanged hub (Fig. 75).

Fig. 75 ! Caution
Danger of squashing! Do not stand or step
under suspended loads.
12. Lay the side plate on the flanged hub (Fig. 76).

Fig. 76
13. Attach bushing 2 (Fig. 77) of the assembly device
and turn on nut (1).

Fig. 77
14. Pull the side plate with the assembly device onto
the flanged hub.

! Caution
During assembly make sure that the mechan-
ical seal slides correctly into the side plate
and the loop rings are not damaged (Fig. 78).

Fig. 78

008 911 49 BOMAG 467

14.4 Repairing the drum

15. Remove the assembly device.

16. Insert the circlip into the groove in the flanged hub
(Fig. 79).

Fig. 79

Assembling the exciter unit (travel

motor side)
!Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.

! Caution
Ensure strict cleanliness.
1. Cool the shaft down in liquid nitrogen.
Fig. 80
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
80).
3. Secure shaft 1 (Fig. 81) with dowel pins (2 and 3).

! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.

Fig. 81

468 BOMAG 008 911 49

Repairing the drum 14.4
4. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 82).

Fig. 82

! Danger
Danger of burning!
Wear safety gloves.
5. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 83).

Fig. 83

! Danger
Danger of burning!
Wear safety gloves.
6. Heat the inner ring up to approx. 50° C and slide
it onto the shaft against the shoulder with the wid-
er chamfer facing towards the outside (Fig. 84).

Fig. 84 ! Danger
Danger of burning!
Wear safety gloves.
7. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 85).

Fig. 85

008 911 49 BOMAG 469

14.4 Repairing the drum

8. Press cylinder roller bearing 1 (Fig. 86) with

pressing plate (2) into the flanged housing until it
bottoms.

Fig. 86
9. Insert the circlip into the groove in the flanged
housing (Fig. 87).

Fig. 87
10. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 88).
11. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.

Fig. 88 ! Caution
Danger of squashing! Do not stand or step
under suspended loads.
12. Insert the exciter unit into the flanged housing
(Fig. 89).

Fig. 89

470 BOMAG 008 911 49

Repairing the drum 14.4
13. Press cylinder roller bearing 1 (Fig. 90) with
pressing plate (2) into the flange until it bottoms.

Fig. 90
14. Insert the circlip into the groove in the flange (Fig.
91).

Fig. 91
15. Lift the flange onto the flanged housing and align
it the bores (Fig. 92).

! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.

Fig. 92
16. Turn the screws into the tapped bores of the
flanged housing and tighten them (Fig. 93).

Fig. 93

008 911 49 BOMAG 471

14.4 Repairing the drum

17. Apply some grease to the sealing lip of radial seal

1 (Fig. 94).
18. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).

Fig. 94
19. Cover the thread of screw 1 (Fig. 95) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
20. Slide on the new U-seal ring (2), turn in and tight-
en the screws.

Fig. 95
21. Insert the fitting key into the keyway of the shaft
(Fig. 96).

Fig. 96 !Danger
Danger of burning!
Wear safety gloves.
22. Slide the fan with assembly disc over the shaft.
23. Heat coupling hub 1 (Fig. 97) with marking letter
“R“ up to approx. 80° C and slide it over the shaft
against the shoulder.
24. Turn in and tighten clamping screw (2).
25. Assemble the fan to the coupling hub.

Fig. 97

472 BOMAG 008 911 49

Repairing the drum 14.4
Assembling the exciter unit (travel
motor side)
1. Check coupling elements, replace if necessary.
2. Insert the coupling element into the coupling hub
(Fig. 98).

! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
3. Fasten the lifting device to the exciter unit.

Fig. 98 ! Caution
Danger of squashing! Do not stand or step
under suspended loads.
4. Insert the vibrator unit into the drum (Fig. 99).

Fig. 99

i Note
Insert the exciter unit so that oil filler plug 1 (Fig.
100) is in line with bore (2) in the drum.

Fig. 100

008 911 49 BOMAG 473

14.4 Repairing the drum

5. Turn in and tighten screws 2 (Fig. 101).

6. Remove bracket (1) for the lifting device.

Fig. 101
7. Cover the thread of screws (Fig. 102) with a
screw retention agent (e.g. Loctite green 270).
8. Slide on the new U-seal ring, turn in and tighten
the screws.

Fig. 102

Installing the travel motor

! Danger

Danger of squashing!
Do not stand or step under suspended loads.
1. Fasten the lifting tackle to the travel motor and at-
tach the motor to the drive disc (Fig. 103).

Fig. 103
2. Turn in and tighten the fastening screws (Fig.
104).

Fig. 104

474 BOMAG 008 911 49

Repairing the drum 14.4
3. Mount the support leg to the travel motor, insert
the screws, turn on and tighten the nuts (Fig.
105).

Fig. 105

! Danger
Danger of squashing!
Do not stand or step under suspended loads.
4. Attach the drive disc with the assembled travel
motor to the rubber buffers. Turn on and tighten
the nuts (Fig. 106).

Fig. 106

Installing the exciter unit (vibration

motor side)

! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.

! Danger
Danger of squashing! Do not stand or step
under suspended loads.
1. Fasten the lifting gear to the exciter unit and insert
it into the drum (Fig. 107).

Fig. 107

008 911 49 BOMAG 475

14.4 Repairing the drum

! Caution
Ensure correct engagement of coupling and
alignment of shaft (Fig. 108).
If the shafts are not correctly in line determine
the cause, if necessary measure the drum.

Fig. 108
2. Turn in and tighten screws 1 (Fig. 109).
3. Remove the lifting gear.
4. Fit cover (2) to the drum.

Fig. 109
5. Check the end float of the exciter shafts (Fig.
110).

Nominal value: 0.6...1.8 mm

Fig. 110
6. Attach disc 1 (Fig. 111), turn in and tighten the
fastening screws (2).

Fig. 111

476 BOMAG 008 911 49

Repairing the drum 14.4
7. Lay a new V-ring over the journal of the flanged
hub (Fig. 112).
8. Fill the grooved ball bearing with grease.

Fig. 112
9. Check coupling element, replace if necessary.
10. Insert the coupling element into the coupling hub
(Fig. 113).

Fig. 113
11. Fasten the vibration motor to the cover so that
sockets 1 (Fig. 114) and ventilation bore (2) are
opposite each other.

Fig. 114
12. Slide on coupling half 2 (Fig. 115) and secure with
clamping screw (1).

Fig. 115

008 911 49 BOMAG 477

14.4 Repairing the drum

13. Attach the cover with the installed vibration mo-

tor, turn in and tighten the screws (Fig. 116).

Fig. 116
14. Install rectangular rubber buffers 2 (Fig. 117) with
attached spacer block (3) and screws (1) to the
side plate.

i Note
Assemble both rectangular rubber buffers.

Fig. 117

478 BOMAG 008 911 49

Dismantling, assembling the change-over weights 14.5
14.5 Dismantling, assembling the change-
over weights

Dismantling the change-over weight

1. Unscrew all screws (Fig. 3).

Fig. 1
2. Force the cover off the basic weight with forcing
screws (Fig. 4).

Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.

Fig. 2
3. Take the change-over weight out of the basic
weight (Fig. 5).

Fig. 3

008 911 49 BOMAG 479

14.5 Dismantling, assembling the change-over weights

4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.

Fig. 4

Assembling the change-over weights

!Caution
Ensure strict cleanliness.
1. Install new O-rings 1 and 2 (Fig. 5) with grease.

Fig. 5
2. Insert the change-over weight into the basic
weight (Fig. 6).

Fig. 6
3. Fill silicon oil 47 V 1000 cst up to the upper edge
of the change-over weight (approx. 2,5 litres) into
the basic weight (Fig. 12).

Fig. 7

480 BOMAG 008 911 49

Dismantling, assembling the change-over weights 14.5
4. Attach the cover (Fig. 13), so that the raised are-
as are in line.
5. Turn in screws with screw retention agent (e.g.
Loctite blue 243) and tighten with 120 Nm.
6. Check the end float of the shaft.

iNote
There must be play.

Fig. 8

008 911 49 BOMAG 481

14.6 Changing the rubber buffers and adjusting the pretension

14.6 Changing the rubber buffers and ad-

justing the pretension
Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buff-
ers and rectangular buffers are relieved of any
load (Fig. 1).
2. Loosen all fastening screws.

Fig. 1
3. Turn one screw each into the welded nuts (Fig. 2)
on the spacer blocks.

Fig. 2
4. Remove the compensation shims 1 (Fig. 3).

Fig. 3

482 BOMAG 008 911 49

Changing the rubber buffers and adjusting the pretension 14.6
5. Unscrew the screws (Fig. 4) from the welded
nuts.

Fig. 4
Changing the rubber buffers
6. Unscrew nut 1 (Fig. 3) and remove the washer.
7. Unscrew screws (2).
8. Take off rubber buffer (3).
9. Attach the new rubber buffer to the drive disc and
align the bores to the tapped bores in the drum.
10. Turn in and tighten the fastening screws.
11. Assemble the washer, turn on and tighten the nut.

Fig. 5
Adjusting the pre-load
12. Measure distance „X“ between spacer piece and
side plate (Fig. 6).
13. Calculate the thickness of the compensation
plates.

Nominal value:
Distance „X“ + 2 mm

Fig. 6
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 7).

Fig. 7

008 911 49 BOMAG 483

14.6 Changing the rubber buffers and adjusting the pretension

15. Insert the compensation shims 1 (Fig. 8).

Fig. 8
16. Unscrew the screws (Fig. 9) from the welded
nuts.

Fig. 9
17. Tighten the fastening screws (Fig. 10).
18. Lower the frame again.

Fig. 10

484 BOMAG 008 911 49

 15 Oscillating articulated joint

008 911 49 BOMAG 485

15.1 Special tools

15.1 Special tools

1. Pressing mandrel for rocker bearings

Fig. 1
2. Pressing sleeve for outer race of rocker bearing

Fig. 2
3. Pressing sleeve for inner race of rocker bearing

Fig. 3
4. Guide journal

Fig. 4

486 BOMAG 008 911 49

Special tools 15.1
5. Clamping device

Fig. 5
6. Disassembly device

Fig. 6

008 911 49 BOMAG 487

15.2 Repair overview oscillating articulated joint

1 Housing 12 Rear shell

2 Seal ring
3 Rear shell
4 Self-aligning bearing
5 Bolt
6 Shim/supporting disc
7 Belleville springs
8 Self-aligning bearing
9 Console
10 Belleville springs
11 Shim/supporting disc
13 Rear shell
14 Intermediate ring
15 Self-aligning bearing
16 Intermediate ring
17 Self-aligning bearing
18 Beam
19 Friction bearing
20 V-ring
21 Seal ring

488 BOMAG 008 911 49

Repair overview oscillating articulated joint 15.2

008 911 49 BOMAG 489

15.2 Repair overview oscillating articulated joint

490 BOMAG 008 911 49

Removing and installing the oscillating articulated joint 15.3
15.3 Removing and installing the oscillat-
ing articulated joint
1. Jack up the frame (Fig. 1) at the back and secure
it with trestles or wooden blocks.

Fig. 1
2. Support the rear frame near the oscillating articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.

Fig. 2
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).

Fig. 3

008 911 49 BOMAG 491

15.3 Removing and installing the oscillating articulated joint

4. Unscrew fastening screws 1 (Fig. 4) and take off

axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).

Fig. 4

!Danger
Danger of accident!
7. Support the oscillating articulated joint in the mid-
dle with a suitable jack or a similar device.
8. Unscrew fastening screws 1 (Fig. 5) and take off
with disc (2).

Fig. 5
9. Unscrew nuts 3 (Fig. 6) and take off the clamping
washers (2).
10. Pull out the fastening screws (1).
11. Slightly raise the front frame and lower the oscil-
lating articulated joint to the ground.
12. Pull out the oscillating articulated joint.

Fig. 6
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).

Fig. 7

492 BOMAG 008 911 49

Dismantling the oscillating articulated joint 15.4
15.4 Dismantling the oscillating articulated
joint
1. Unscrew the nuts from hexagon screw 1 (Fig. 1)
and pull out the hexagon screw.
2. Unscrew the screws (2) for the cover.

Fig. 1
3. Take off the cover with Belleville springs, shim
and backing disc (Fig. 2).
4. Disassemble also the cover from the opposite
side.

i Note
No Belleville springs, shim and backing disc are
under this cover.

Fig. 2
5. Drive the console with a plastic hammer to one
side against the end stop (Fig. 3).

i Note
The outer race of the rocker bearing is thereby
stripped off.

Fig. 3

008 911 49 BOMAG 493

15.4 Dismantling the oscillating articulated joint

6. Force inner race 1 (Fig. 4) of the rocker bearing

off the bolt.
7. Take of supporting disc (2).
8. Drive the console to the opposite side and re-
move the rocker bearing in the same way.

Fig. 4
9. Unscrew fastening screws 1 (Fig. 5).
10. Press bolt (3) out of the console with forcing
screws (2).

i Note
Remove the bolt on the opposite side in the same
way.

Fig. 5
11. Lift console 1 (Fig. 6) off housing (2).

Fig. 6
12. Take the seal rings out of the console (Fig. 7).

Fig. 7

494 BOMAG 008 911 49

Dismantling the oscillating articulated joint 15.4
13. Remove the cover from the housing.
14. Take off shims 1 (Fig. 8), backing disc (2) and
Belleville springs (3).

Fig. 8
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).

Fig. 9
16. Take the intermediate ring out of the housing
(Fig. 10).

Fig. 10
17. Place the plate 1 (Fig. 11) on the beam.
18. Attach the puller (2) to the housing (3) and sepa-
rate the carrier from the rocker bearings.

Fig. 11

008 911 49 BOMAG 495

15.4 Dismantling the oscillating articulated joint

19. Pull the housing off the beam (Fig. 12).

Fig. 12
20. Drive the outer race of the friction bearing out of
the housing (Fig. 13).

Fig. 13
21. Drive the friction bearing out of the housing (Fig.
14).

Fig. 14
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.

Fig. 15

496 BOMAG 008 911 49

Dismantling the oscillating articulated joint 15.4
23. Check rocker bearings, if necessary press out of
the housing (Fig. 16).

Fig. 16

008 911 49 BOMAG 497

15.5 Assembling the oscillating articulated joint

15.5 Assembling the oscillating articulated

joint
1. If previously disassembled, press the rocker
bearing fully into the housing with a pressing
mandrel (Fig. 1).

i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly

! Caution
Do not use any grease.

Fig. 1
2. Slide the new V-ring on the beam against the stop
with the lip facing up (Fig. 2).

Fig. 2
3. Lay the seal ring into the beam (Fig. 3).
4. Fill the space between V-ring and seal ring with
multi-purpose grease.

Fig. 3

498 BOMAG 008 911 49

Assembling the oscillating articulated joint 15.5
5. Press the friction bearing fully into the housing
with the chamfered side pointing towards the out-
side (Fig. 4).

Fig. 4
6. Slide the housing over the beam (Fig. 5).

i Note
The journal on the housing must be centrally in
the recess of the beam.

Fig. 5
7. Press the seal ring carefully towards the inside,
until it sits in the recess of the housing (Fig. 6).

Fig. 6
8. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.

! Caution
Do not use any grease.
9. Press the outer rocker bearing race 1 (Fig. 7) in
until it bottoms with the wider outer rim forward
using pressing sleeve (2).

Fig. 7

008 911 49 BOMAG 499

15.5 Assembling the oscillating articulated joint

10. Press inner rocker bearing race 1 (Fig. 8) in until

it bottoms, using pressing sleeve (2).

Fig. 8
11. Insert the intermediate ring (Fig. 9).

Fig. 9
12. Press inner rocker bearing race 1 (Fig. 10) in until
it bottoms, using pressing sleeve (2).

Fig. 10

i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly

! Caution
Do not use any grease.
13. Press the outer rocker bearing race 1 (Fig. 11) in
until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).

Fig. 11

500 BOMAG 008 911 49

Assembling the oscillating articulated joint 15.5
14. Press in intermediate ring 1 (Fig. 12) until it bot-
toms.
15. Attach cover (2) with the machined edge forward.
16. Turn in screws (3) and tighten crosswise.

Fig. 12
Determining the shim thickness
17. Determine the shim thickness, for this purpose
stand the cross-member on a wooden board with
an ∅ 18 mm bore.

! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
Fig. 13 tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.

i Note
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thick-
ness.

Calculation example:
4,7 mm - 4,0 mm = 0,7 mm
measured value: 4,7 mm
fixed value: 4,0 mm
Shim thickness: 0,7 mm
20. Remove the tensioning device.

008 911 49 BOMAG 501

15.5 Assembling the oscillating articulated joint

21. Insert shim 2 (Fig. 14) of appropriate thickness

and backing disc (1) into the cover.

Fig. 14
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).

Fig. 15
23. Assemble cover 2 (Fig. 16) with Belleville springs,
shim and backing disc.
24. Turn in screws (1) and tighten crosswise.

Fig. 16
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).

Fig. 17

502 BOMAG 008 911 49

Assembling the oscillating articulated joint 15.5
26. Lift console 1 (Fig. 18) over the housing (2).

Fig. 18
27. Turn four guide pins into the housing bores (Fig.
19).

Fig. 19

i Note
Perform the following eight work steps on both
sides.
28. Slide the bolt over the guide pins (Fig. 20) and
drive in until it bottoms.

Fig. 20

! Caution
When driving in the bolt make sure that the
seal ring is not pressed out through the back
of the console (Fig. 21).

Fig. 21

008 911 49 BOMAG 503

15.5 Assembling the oscillating articulated joint

29. Unscrew the guide pins .

30. Turn in the screws and tighten with 75 Nm (Fig.
22).

Fig. 22
31. Slide the backing discs over the bolt (Fig. 23).

Fig. 23
32. Drive the inner rocker bearing race on against the
end stop with the wider outer rim forward (Fig.
24).

Fig. 24
33. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.

! Caution
Do not use any grease.
34. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.

Fig. 25

504 BOMAG 008 911 49

Assembling the oscillating articulated joint 15.5
35. Attach cover 1 (Fig. 26) to the bottom side of the
console.
36. Turn in and tighten screws (2).

Fig. 26
Determining the shim thickness
37. Determine the shim thickness, for this purpose in-
sert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.

! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.

Fig. 27
38. Measure the distance from outer rocker bearing
race to console surface (Fig. 28) and write it
down, e.g. 3.4 mm.

i Note
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thick-
ness.

Calculation example:
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
Fig. 28 fixed value: 2,2 mm
Shim thickness: 1.2 mm
39. Remove the tensioning device.

008 911 49 BOMAG 505

15.5 Assembling the oscillating articulated joint

40. Insert shims 2 (Fig. 29) of appropriate thickness

and backing disc (1) into the cover.

Fig. 29
41. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 30).

Fig. 30
42. Assemble cover 1 (Fig. 31) with Belleville springs,
shims and supporting discs.
43. Turn in screws (2) and tighten crosswise.

Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.

Fig. 32

506 BOMAG 008 911 49

Assembling the oscillating articulated joint 15.5
45. Assemble the washer, turn on and tighten the nut
with 120 Nm (Fig. 33).

Fig. 33

008 911 49 BOMAG 507

15.5 Assembling the oscillating articulated joint

508 BOMAG 008 911 49

 16 Suppliers documentation

008 911 49 BOMAG 509

510 BOMAG 008 911 49
 16.1 Travel pump series 90R

008 911 49 BOMAG 511

16.1 Travel pump series 90R

512 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 513

16.1 Travel pump series 90R

514 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 515

16.1 Travel pump series 90R

516 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 517

16.1 Travel pump series 90R

518 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 519

16.1 Travel pump series 90R

520 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 521

16.1 Travel pump series 90R

522 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 523

16.1 Travel pump series 90R

524 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 525

16.1 Travel pump series 90R

526 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 527

16.1 Travel pump series 90R

528 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 529

16.1 Travel pump series 90R

530 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 531

16.1 Travel pump series 90R

532 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 533

16.1 Travel pump series 90R

534 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 535

16.1 Travel pump series 90R

536 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 537

16.1 Travel pump series 90R

538 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 539

16.1 Travel pump series 90R

540 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 541

16.1 Travel pump series 90R

542 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 543

16.1 Travel pump series 90R

544 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 545

16.1 Travel pump series 90R

546 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 547

16.1 Travel pump series 90R

548 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 549

16.1 Travel pump series 90R

550 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 551

16.1 Travel pump series 90R

552 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 553

16.1 Travel pump series 90R

554 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 555

16.1 Travel pump series 90R

556 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 557

16.1 Travel pump series 90R

558 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 559

16.1 Travel pump series 90R

560 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 561

16.1 Travel pump series 90R

562 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 563

16.1 Travel pump series 90R

564 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 565

16.1 Travel pump series 90R

566 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 567

16.1 Travel pump series 90R

568 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 569

16.1 Travel pump series 90R

570 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 571

16.1 Travel pump series 90R

572 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 573

16.1 Travel pump series 90R

574 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 575

16.1 Travel pump series 90R

576 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 577

16.1 Travel pump series 90R

578 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 579

16.1 Travel pump series 90R

580 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 581

16.1 Travel pump series 90R

582 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 583

16.1 Travel pump series 90R

584 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 585

16.1 Travel pump series 90R

586 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 587

16.1 Travel pump series 90R

588 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 589

16.1 Travel pump series 90R

590 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 591

16.1 Travel pump series 90R

592 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 593

16.1 Travel pump series 90R

594 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 595

16.1 Travel pump series 90R

596 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 597

16.1 Travel pump series 90R

598 BOMAG 008 911 49

Travel pump series 90R 16.1

008 911 49 BOMAG 599

16.1 Travel pump series 90R

600 BOMAG 008 911 49

 16.2 Travel drive series 51

008 911 49 BOMAG 601

16.2 Travel drive series 51

602 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 603

16.2 Travel drive series 51

604 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 605

16.2 Travel drive series 51

606 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 607

16.2 Travel drive series 51

608 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 609

16.2 Travel drive series 51

610 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 611

16.2 Travel drive series 51

612 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 613

16.2 Travel drive series 51

614 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 615

16.2 Travel drive series 51

616 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 617

16.2 Travel drive series 51

618 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 619

16.2 Travel drive series 51

620 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 621

16.2 Travel drive series 51

622 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 623

16.2 Travel drive series 51

624 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 625

16.2 Travel drive series 51

626 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 627

16.2 Travel drive series 51

628 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 629

16.2 Travel drive series 51

630 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 631

16.2 Travel drive series 51

632 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 633

16.2 Travel drive series 51

634 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 635

16.2 Travel drive series 51

636 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 637

16.2 Travel drive series 51

638 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 639

16.2 Travel drive series 51

640 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 641

16.2 Travel drive series 51

642 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 643

16.2 Travel drive series 51

644 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 645

16.2 Travel drive series 51

646 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 647

16.2 Travel drive series 51

648 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 649

16.2 Travel drive series 51

650 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 651

16.2 Travel drive series 51

652 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 653

16.2 Travel drive series 51

654 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 655

16.2 Travel drive series 51

656 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 657

16.2 Travel drive series 51

658 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 659

16.2 Travel drive series 51

660 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 661

16.2 Travel drive series 51

662 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 663

16.2 Travel drive series 51

664 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 665

16.2 Travel drive series 51

666 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 667

16.2 Travel drive series 51

668 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 669

16.2 Travel drive series 51

670 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 671

16.2 Travel drive series 51

672 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 673

16.2 Travel drive series 51

674 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 675

16.2 Travel drive series 51

676 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 677

16.2 Travel drive series 51

678 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 679

16.2 Travel drive series 51

680 BOMAG 008 911 49

Travel drive series 51 16.2

008 911 49 BOMAG 681

16.2 Travel drive series 51

682 BOMAG 008 911 49

 16.3 Vibration pump 42R 041

008 911 49 BOMAG 683

16.3 Vibration pump 42R 041

684 BOMAG 008 911 49

Vibration pump 42R 041 16.3

008 911 49 BOMAG 685

16.3
Series 42
1. Introduction
1.1 Using This Manual
The Adjustment and Minor Repair procedures de-
tailed herein may be performed by trained personnel
without voiding the unit warranty.
Cleanliness is a primary means of assuring satisfac-
tory transmission life. Cleaning parts by using a clean
solvent wash and air drying is usually adequate. As
with any precision equipment, all parts must be kept
free of foreign materials and chemicals. When per-
forming service activities, protect all exposed sealing
surfaces and open cavities from damage and foreign
material.
Whenever removing a service component, it is rec-
ommended that any gaskets and O-rings be re-
1.2 Safety Precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury.
The following general precautions should be taken into consideration whenever servicing a hydrostatic system.
Loss of Hydrostatic Braking Ability
WARNING
When Series 42 units are used in vehicular
hydrostatic drive systems, the loss of hydro-
static drive line power in any mode of opera-
tion (e.g. acceleration, deceleration or “neu-
tral” mode) may cause a loss of hydrostatic
braking capacity. A braking system which is
independent of the hydrostatic transmission
must, therefore, be provided which is adequate
to stop and hold the system should the con-
dition develop.
Disable Work Function
WARNING
Certain service procedures may require the
vehicle/machine to be disabled (wheels raised
off the ground, work function disconnected,
etc.) while performing them in order to prevent
injury to the technician and bystanders.
F000719
686 2 BOMAG
Vibration pump 42R 041
Introduction
placed. Lightly lubricate all O-rings with clean petro-
leum jelly prior to assembly. All gasket sealing sur-
faces must be cleaned prior to installing new gaskets.
All exploded view drawings depict the 28cc frame
size. For variances in the 41cc frame size, see the
outline drawings in section 3. Differences in wrench
size and torquing for the two frame sizes are noted in
the text. Note that exterior housing screws are mostly
Torx-type T30 or T45.
These symbols are used within drawings:
Apply petroleum jelly.
Lubricate with clean hydraulic oil.
Fluid Under High Pressure
WARNING
Use caution when dealing with hydraulic fluid
under pressure. Escaping hydraulic fluid un-
der pressure can have sufficient force to pen-
etrate your skin causing serious injury. This
fluid may also be hot enough to burn. Serious
infection or reactions can develop if proper
medical treatment is not administered immedi-
ately.
Flammable Cleaning Solvents
WARNING
Some cleaning solvents are flammable. To
avoid possible fire, do not use cleaning sol-
vents in an area where a source of ignition may
be present.
Copyright 1996-1998, Sauer-Sundstrand GmbH & Co.
All rights reserved. Contents subject to change. Printed in Germany.
008 911 49
Vibration pump 42R 041 16.3

Series 42 Introduction

Contents

1. Introduction ................................................................................................................................ 2
1.1 Using This Manual................................................................................................................................. 2
1.2 Safety Precautions ................................................................................................................................ 2

2. Model Code ................................................................................................................................. 4

3. Component and Port Locations ............................................................................................... 5

3.1 Component Locations ........................................................................................................................... 5
3.2 Ports and Pressure Gauges .................................................................................................................. 6

4. Adjustment and Minor Repair Instructions ............................................................................. 8

4.1 Size and Torque for Plugs and Fittings .................................................................................................. 8
4.2 Pump “Neutral” Adjustment ................................................................................................................... 9
4.3 Control “Neutral” Adjustment for MDC/EDC Controls .......................................................................... 10
4.4 MDC Control Module ............................................................................................................................ 11
4.5 EDC Control Module ........................................................................................................................... 12
4.6 MDC/EDC Control Spool, Control Linkage, and Control Neutral Adjustment Screw ........................... 13
4.7 MDC Neutral Start/Backup Alarm Switch ............................................................................................ 14
4.8 MDC Solenoid Override Valve ............................................................................................................. 16
4.9 FNR, NFPE, and NFPH Controls ........................................................................................................ 17
4.10 System Check Relief Valves (High Pressure Relief, Charge Check, & Bypass Valves) ...................... 18
4.11 Charge Relief Valve............................................................................................................................. 19
4.12 Loop Flushing Valve ............................................................................................................................ 21
4.13 Shaft Seal and Shaft Replacement ..................................................................................................... 22
4.14 Auxiliary Mounting Pads ...................................................................................................................... 24
4.15 Charge Pump ...................................................................................................................................... 25
4.16 Filtration .............................................................................................................................................. 28
4.17 Servo Piston Covers ........................................................................................................................... 29
4.18 Displacement Limiter Adjustment ........................................................................................................ 30

5. Exploded View Parts Drawings............................................................................................... 31

5.1 Shaft Options ...................................................................................................................................... 31
5.2 Filtration, Charge Relief, System Relief, and Loop Flushing ............................................................... 32
5.3 Charge Pump, Auxiliary Pads, and Servo Covers ............................................................................... 33
5.4 Control Options ................................................................................................................................... 34

008 911 49 BOMAG 3687

16.3 Vibration pump 42R 041

688 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Component and Port Locations

3. Component and Port Locations

3.1 Component Locations

A pump with a manual displacement control (MDC) and no filtration adapter is shown. With non-feedback and
automotive controls, the positions of the case drains vary (shown in gray). With a filtration adapter, the porting in
the "Filtration Options" area varies (see section 4.16).

Control Neutral Adjustment Pump Neutral Adjustment

Control Module (MDC/EDC)
(MDC Shown)
Servo Piston
Covers
System Check
Displacement
Relief Valves
Limiters
Charge
Pump Shaft
Seal

Filtration Options
Auxiliary (No Filtration Adapter Shown Here) Charge Relief Valve
Mounting Pad (Loop Flushing
Valve)

Left Side View (Side "2") Right Side View (Side "1")
P100101 E

Series 42 28cc Variable Pump

Control Neutral Adjustment Pump Neutral Adjustment

Control Module (MDC/EDC)
(MDC Shown)
Servo Piston
Covers
Displacement
Limiters System Check
Relief Valves
Charge
Pump
Shaft Seal

Auxiliary
Mounting Filtration Options
Pad Charge Relief Valve (No Filtration Adapter
(Loop Flushing Valve)
Shown Here)
Left Side View (Side "2") Right Side View (Side "1")
P100102 E

Series 42 41cc Variable Pump

008 911 49 BOMAG 5689

16.3 Vibration pump 42R 041

Series 42 Component and Port Locations

3.2 Ports and Pressure Gauges

Proper servicing of pumps and motors requires that ments. The following outlines show the locations of
pressure be measured and monitored at various the various gauge ports. The tables show the recom-
points in the hydraulic circuit. The Series 42 pump mended gauge size and the fitting size for each port.
has several locations at which to take these measure- Refer to this page when installing pressure gauges.

Gauge Recommended Fitting

Pressure Measured
Port Name Gauge Size 028 041
System Pressure for
M1 & M2 600 bar or 10 000 psi 9/16-18 O-Ring Fitting 9/16-18 O-Ring Fitting
Ports A and B
M3 Charge Pressure 60 bar or 1000 psi 3/4-16 O-Ring Fitting 3/4-16 O-Ring Fitting
M4 & M5 Servo Pressure 60 bar or 1000 psi 9/16-18 O-Ring Fitting 9/16-18 O-Ring Fitting
L1 & L2 Case Pressure 35 bar or 500 psi 1-1/16-12 O-Ring Fitting 1-5/16-12 O-Ring Fitting
Charge Pump Inlet 1 bar, absolute
S 1-1/16-12 O-Ring Fitting 1-5/16-12 O-Ring Fitting
Vacuum or 30 in Hg Vacuum
T000 025E

System Pressure Servo Pressure

Gauge Port M2 Gauge Port M5
Charge Pressure
Servo Pressure Gauge Port M3
Gauge Port M4 (Charge Pressure
System
Case Drain Port L2 Supply For
Pressure
(Non-Feedback No Charge Pump
Port B
Controls) Option)
System
Pressure Case Drain
Port A Port L1

Case Drain Port L1 Charge Pump

(Non-Feedback Inlet Port S
Controls)
Case Drain
System Pressure
Port L2
Gauge Port M1

Left Side View (Side "2") Right Side View (Side "1")
P100103 E

28cc Base Unit with MDC and No Filtration Adapter

690 6 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Component and Port Locations

System Pressure Servo Pressure

Gauge Port M2 Gauge Port M5
Servo Pressure Charge Pressure
Gauge Port M4 Gauge Port M3
System (Charge Pressure
Pressure Case Drain Supply For
Port B Port L2 No Charge Pump
Option)

System
Pressure
Port A
Case Drain Charge Pump
Port L1 Inlet Port S

System Pressure
Gauge Port M1

Left Side View (Side "2") Right Side View (Side "1") P100104 E

41cc Base Unit with MDC and No Filtration Adapter

To Filter, Port D
(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Full Flow Pressure Filtration)

From Filter, Port E

(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Partial Flow Pressure Filtration)

Charge Pressure
Gauge Port M3
(Suction Filtration)
P100105 E

Filtration Adapter (28cc and 41cc Models)

008 911 49 BOMAG 7691

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4. Adjustment and Minor Repair Instructions

4.1 Size and Torque for Plugs and Fittings

Plug and fitting sizes are given here. Place a fresh O-ring, lightly lubricated with petroleum jelly, whenever a plug
is removed. Each should be torqued as indicated. A 28cc unit with manual displacement control (MDC) is shown.

Servo Gage
Port M4

11/16 in Hex
27-47 Nm
(20-35 ft•lbf)

28cc: 9/16 in Int. Hex

95-135 Nm
(70-100 ft•lbf)
41cc: 5/8 in Int. Hex Case Drain
125-250 Nm Port L1
(90-190 ft•lbf) Charge Pressure Gage
Port M3 (Position Varies, Charge Pump Inlet
Refer to Filtration Options) Port S
Torque: 115 Nm (85 ft•lbf)

Case Drain 11/16 in Hex

Port L2 27-47 Nm
Port N (20-35 ft•lbf)
(Unused) Servo Gage
Port M5
System Gage
Ports M1 and M2
11/16 in Hex
27-47 Nm
(20-35 ft•lbf)

28cc: 9/16 in Int. Hex

95-135 Nm
(70-100 ft•lbf)
41cc: 5/8 in Int. Hex
125-250 Nm
(90-190 ft•lbf)

11/16 in Hex
System Ports 27-47 Nm
A and B (20-35 ft•lbf)
115 Nm (85 ft•lbf)
E100001 E

692 8 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

4.2 Pump “Neutral” Adjustment

The pump neutral adjustment sets the position of the
servo piston and pump swashplate relative to the
controlling mechanism.

WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
Pump "Neutral"
ground, work function disconnected, etc.) while Adjustment Screw
performing the procedure in order to prevent
injury to the technician and bystanders.

1. Disconnect machine function. Pump "Neutral"

Adjustment Seal
2. Connect a hose between gauge ports M4 and M5 Lock Nut
to equalize the pressures on both ends of the
pump servo piston.
3. Install pressure gauges in gauge ports M1 and
M2 to measure system pressure.
4. Start the prime mover and operate at normal E100002 E
speed.
Pump Neutral Adjustment Screw
5. Loosen the pump "neutral" adjustment seal lock (MDC Control Shown)
nut [28cc 13 mm Hex; 41cc 17 mm Hex]. Turn
the pump "neutral" adjustment screw [28cc 5
mm Hex; 41cc 7 mm Hex] until the system
pressure gauge readings are equal.
6. Turn the adjustment screw clockwise until one of
the gauges registers an increase in system pres-
sure. Note the position of the adjustment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in system pressure.
Note the position of the adjustment screw.
7. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The system pressure gauges should indicate
equal pressures.
8. While holding the adjustment screw in position,
torque the seal lock nut [28cc 20-26 Nm (15-19
ft•lbf); 41cc 28-51 Nm (21-37 ft•lbf)] .
9. Stop the prime mover and remove the hose
between gauge ports M4 and M5. Remove the
pressure gauges installed in gauge ports M1 and
M2. Reinstall the plugs in the gauge ports.
10. Reconnect work function.

IMPORTANT
If the pump is equipped with an MDC or EDC,
the CONTROL "neutral" adjustment MUST also
be performed before putting the pump into
service (see next section).

008 911 49 BOMAG 9693

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.3 Control “Neutral” Adjustment for MDC/EDC Controls

The control neutral adjustment aligns the pump swash-

plate and the control spool so that a zero angle control MDC / EDC Control
setting provides a zero degree swashplate setting. "Neutral" Adjustment Screw
This adjustment should be performed whenever any
part of the control or swashplate mechanisms is
adjusted or removed or after the pump neutral setting
(previous section) is adjusted.

WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
ground, work function disconnected, etc.) while
performing the procedure in order to prevent
injury to the technician and bystanders.

1. Disconnect the work function. Disconnect the

external control linkage (for MDC) or control
signal input (for EDC) from the pump.
2. Install pressure gauges in gauge ports M4 and MDC / EDC Control "Neutral"
M5 to measure pressure on the pump servo Adjustment Seal Lock Nut
piston. E100003 E

3. Start the prime mover and operate at normal Control Neutral Adjustment Screw
speed. (EDC Control Shown)
4. Loosen the CONTROL "neutral" adjustment seal
lock nut (see drawing) [17 mm Hex] . Turn the
control "neutral" adjustment screw [5 mm Int.
Hex] until the servo piston pressure gauge read-
ings are as close to equal as possible.
5. Turn the adjustment screw clockwise until one of
the gauges registers an increase in pressure on
the servo piston. Note the position of the adjust-
ment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in pressure on the
servo piston. Note the position of the adjustment
screw.
6. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The servo piston pressure gauges should indi-
cate nearly equal pressures.
7. While holding the adjustment screw in position,
torque the seal lock nut [14-24 Nm (10-18 ft•lbf)].
8. Stop the prime mover and remove the pressure
gauges installed in gauge ports M4 and M5.
Reinstall the plugs in the gauge ports.
9. Reconnect the external control linkage (for MDC)
or control signal input (for EDC) to the pump.
Reconnect the work function.

694 1 0 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

4.4 MDC Control Module

The manual displacement control (MDC) module Nut
provides control of the pump servo piston through a Lock Washer
connection to the summing link pin within the pump Plug for MDC Handle
housing. The following procedure shows how to Visual
Inspection
remove and install the control housing. Section 4.6
explains how to remove and install the control spool
and linkage. Control
Retaining
1. Clean the external surfaces of the pump. If nec- Screws
essary, remove the MDC handle.
2. Remove the seven (7) control retaining screws Control
Gasket
[Torx T30] that secure the control to the pump
housing. Remove the control and control gasket Hold summing link
from the pump. (and control spool)
in position
Note: See section 4.6 for instructions on remov-
ing/installing the control spool and linkage.
3. Clean the sealing surfaces of the control and the
pump housing. Place a new gasket in position on
the housing.

CAUTION E100004 E
The control orifices are part of the control
gasket. Refer to the appropriate Service Parts MDC Control Module Assembly
List to determine the correct gasket.

4. Hold the summing link pin in position while install-

ing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the slot in the control
cam. A plug is provided on the MDC housing to
permit visual inspection of linkage pin engage- Summing
ment. link pin
MUST enter
Note: It may be easiest to lay the servo piston the slot in
side of the control down first, then watch the link the control
pin engage from the charge pump side of the cam!
E100005 E
pump.
Link Pin Into Cam Slot
5. Install and torque the control screws [15-17 Nm
(11-13 ft•lbf)]. Perform Control Neutral Adjust-
ment (Section 4.3).

WARNING
Failure to properly engage the link pin with the
control cam will result in incorrect control
operation, which may lead to loss of control of
the vehicle / machine.

F100201
Link Pin Into Cam Slot

008 911 49 BOMAG 1 1695

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.5 EDC Control Module

The Electric Displacement Control (EDC) provides a

control function through connections to the summing EDC Control
link pin within the pump housing. The following pro- Pressure Gauge
cedure shows how to remove and install the control Port X1
housings. The next section explains how to remove
and install the control spool and linkage.
1. Clean the external surfaces of the pump. If nec-
essary, remove control input signal.
2. Remove the seven (7) control retaining screws
[Torx T30] that secure the control to the pump
housing. Note the position of the different length
screws. Remove the control and control gasket
from the pump.
Note: See next section for instructions on remov- EDC Control
ing/installing the control spool and linkage. Pressure Gauge
Port X2 P100106 E
3. Clean the sealing surfaces of the control and the
EDC Module Showing Port Locations
pump housing. Place a new gasket in position on
the housing.

CAUTION
The control orifices are part of the control
Control Retaining
gasket. Refer to the appropriate Service Parts Screws (note different sizes)
List to determine the correct gasket.

4. Hold the summing link pin in position while install-

ing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the hole in the control
piston fork.
Control
Note: It may be easiest to lay the servo piston Gasket Summing
side of the control down first, then watch the link link pin
Hold summing MUST enter
pin engage from the charge pump side of the link (and control the hole in
pump. spool) in the control
position piston fork!
5. Install and torque the control screws [15-17 Nm
(11-13 ft•lbf)]. Perform Control Neutral Adjust-
ment (Section 4.3).

WARNING
Failure to properly engage the link pin with
control piston fork will result in incorrect con- E100006 E
trol operation, which may lead to loss of con-
trol of the vehicle / machine. EDC Control Module Assembly

696 1 2 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

4.6 MDC/EDC Control Spool, Control Linkage, and Control Neutral

Adjustment Screw
The control spool, control linkage, and control neutral
adjustment screw can be removed for cleaning and to Summing Link
change the O-rings or the seal lock nut. Linkage Pivot Screw

Removal of Spool, Linkage, and Adjustment Opposite

Screw Feedback Link Bore Plug
Neutral
1. Clean the external surfaces of the pump. Adjustment
Seal Lock
Link
2. Remove the MDC or EDC module and the control Control Neutral Nut
Adjust Screw
gasket from the pump housing (see previous two Control
sections). Spool
and Spring
3. Remove the summing link. Note
orientation!
4. Remove the control spool bore plug [5/16 in Int.
Hex] or screws [Torx T30], cover, and gasket. Housing without
Remove the opposite bore plug [5/16 in Int. Hex], Filtration Adapter
and remove the control spool and spring.
5. Remove the linkage pivot screw [4 mm Int. Hex], Control Spool
feedback link, and neutral adjustment link. Bore Plug

6. Remove the seal lock nut [17 mm Hex] and the

control neutral adjustment screw [5 mm Int. Hex].

Installation of Spool, Linkage, and Adjustment Housing with

Gasket
Screw Filtration Adapter
1. Install the control neutral adjustment screw and
seal lock nut. Do not tighten the nut.
Control Spool
2. Assemble the "neutral" adjustment link and feed- Bore Cover E100007 E
back link, and install as shown. Install and torque
MDC/EDC Control Spool and Linkage
the linkage pivot screw [8-15 Nm (6-11 ft•lbf)].
3. Lubricate and install the control spool and spring
Feedback link
assembly noting proper orientation. must enter slot in
servo piston
WARNING Pivot screw
The control spool and spring assembly MUST
be oriented in the housing as shown for proper
control operation.

4. Install and torque the control spool bore plug [41- Fork on summing link
must engage flats on
94 Nm (30-70 ft•lbf)]. Or install the control spool
Slot in "neutral" adjust link control spool
cover (with a new gasket) or plug, and torque the must engage groove in
screws [15-17 Nm (11-13 ft•lbf)]. adjusting screw E100008 E

5. Install the summing link. Hold the control spool in Servo Piston Linkage and Control Spool
position while engaging the fork on the summing (Internal Parts Shown with Housing Removed)
link with the flats on the spool. If necessary, rotate
the spool to engage the summing link.
6. Install a new control gasket. Hold the summing
link and control spool in position while reinstalling
the MDC or EDC (see section 4.4 or 4.5). Perform
Control Neutral Adjustment (section 4.3).

008 911 49 BOMAG 1 3697

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.7 MDC Neutral Start/Backup Alarm Switch

The Neutral Start Switch (NSS) prevents the engine NSS Cover
and pump from being started when the pump is out of NSS Control Nut
neutral. The NSS should be wired in series with the
NSS Cam
engine starting circuit. The switch contact is closed at
the control handle's neutral position and opens when
the control handle is rotated 1.5 to 2° from neutral.
The Backup Alarm Switch (BUA) outputs an elec- NSS Cavity
tronic signal when the control handle is in a reverse
position. This switch is normally wired in series with
an audio output. The switch contact is open until the NSS with
control handle is rotated 2.6 to 3.75° in the reverse Weatherpack
direction.

CAUTION
The control handle's neutral position must
NSS with Screw
agree with the pump's neutral position for the Terminals
NSS/BUA to work effectively (see section 4.3).
E100009 E
The Neutral Start / Backup Alarm Switch assembly
can be configured for three different settings. NSS Assembly on MDC
i. A Neutral Start Switch only.
ii. A Neutral Start Switch with Backup Alarm for
units where clockwise (CW) handle rotation re-
sults in "reverse" motion.
iii. A Neutral Start Switch with Backup Alarm for Control
units where counterclockwise (CCW) handle ro- Yolk Cam

tation results in "reverse" motion.

The setting must be in accordance with the configu-
ration of the unit. See the model code (section 2) if
NSS only NSS with BUA NSS with BUA
uncertain of the type of NSS you have.
(CW = Reverse) (CCW = Reverse)
Alignment of the NSS requires a special alignment P100107 E

tool. Dimensions are given at right. Top View of NSS Showing Cam Positions

(continued) 9/16 -18UNF 2A THD

.04 x 45 Chamfer
R.125 ø .236–.030
Knurl

35.0
1.250

.306 .354

2.000

Material: .75 DIA x 3 ETD150

(All Dimensions in inches)
P100108 E
Alignment Tool

698 1 4 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

Adjustment is performed by setting the cam position

within the NSS assembly.
1. The MDC module must be removed from the
NSS Cover NSS
pump housing. Refer to section 4.4.
NSS Control Nut
2. Remove NSS [7/8 in Hex].
NSS Cam
3. Remove the NSS cover by inserting a screw-
driver into the NSS cavity and popping off the
cover with a hammer. Be careful not to damage
the internal hardware.
P100109 E
4. Remove the control nut [8 mm Hex]. Side View of NSS and NSS Cavity

5. Use a screwdriver to pop off the cam.

6. Set cam in proper orientation according to the
unit's configuration (i, ii, or iii above).
7. Screw special alignment tool in NSS cavity to
hold cam in place.
8. On the underside of the MDC module, clamp a
pair of locking pliers around the spring contacts of
the control cam. The pliers should hold the nub on
the control cam to the pin underneath. This will
hold the control cam in neutral position.
9. Screw control nut on cam [4.1-6.8 Nm (3-5 ft•lbf)].
10. Press new cover on top of cam cavity. This
requires either an arbor press or a full-sized
punch (punch depth = 1.06 mm (0.0417 in),
punch width = 23.3 mm (0.916 in)). F100202
Underside of MDC Module Showing Where to Clamp
11. Remove the alignment tool and the locking pliers. Locking Pliers
12. Place a new lubricated O-ring on NSS.
13. Reconnect the NSS [25-29 Nm (18-22 ft•lbf)] to
the MDC.
14. Reinstall MDC module onto pump housing (refer
to section 4.4).

008 911 49 BOMAG 1 5699

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.8 MDC Solenoid Override Valve

The solenoid override valve is a safety feature that
connects both ends of the servo control piston to- Port L4
gether when the solenoid is de-energized. Thus the
Port X7
pump can be put into stroke only when the solenoid
is energized.
The solenoid override with brake release includes
hydraulic control of a safety brake. When de-ener-
gized, a spring-applied, hydraulically-released brake
is drained through port X7. For conditions where case
back-pressure on the spring-applied brake is critical,
an external drain to the reservoir can be connected
through port L4.
The solenoid override valve can be removed to
inspect and remove foreign matter.

Removal Solenoid Override Valve

Assembly E100010 E
1. Remove retaining nut [9/16 in Hex].
Solenoid Override Valve Assembly
2. Remove solenoid housing.
3. Remove retaining ring at base of solenoid. Retaining Nut

4. Remove solenoid. This should be connected to Solenoid

internal spool. Housing

Installation
Washer
1. Replace O-ring. Retaining Ring
2. Place spring and plunger inside of solenoid.
Solenoid
3. Attach spool (male notch) to plunger (female
notch).
O-Ring
4. Insert solenoid/spool assembly in solenoid over- Spring
ride bore. Plunger
5. Snap retaining ring over base of solenoid.
Spool
6. Place washer at base of solenoid.
7. Install housing and retaining nut [2-4 Nm (1.5-3.5
ft•lbf)].

E100011 E

Exploded View of Solenoid Override Assembly

700 1 6 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

4.9 FNR, NFPE, and NFPH Controls

The 3-position FNR control and the electric and
hydraulic non-feedback proportional (NFPE and NFPH Ports
(Ports X1 and X2)
NFPH) controls are non-feedback type controls. The
FNR and NFPE controls consist of modules mounted
on the pump housing. The hydraulic input for NFPH
is received through ports on the top of the pump
[9/16–18 SAE O-ring fitting].
The non-feedback controls are set at the factory. The
control modules can be removed to clean the ports
and change the O-rings.
The orifice plugs for the FNR and NFPE are located
inside the servo piston covers. The orifice plugs for E100012 E

the NFPH are located in the NFPH ports. Orifice Position of NFPH Ports
plugs may be cleaned or replaced.
Note: Future models may contain orifice plate
Control Solenoid
between module and pump housing.
Control Module
Removal and Installation of FNR and NFPE
Modules
1. Clean pump and module housings.
2. Remove four (4) screws retaining module to
housing [4 mm Int. Hex], and remove module Control Ports
from pump housing. Locator Pin

3. Remove O-rings from the control ports. Examine

ports for cleanliness.
4. Clean sealing surfaces.
5. Replace locator pin.
6. Install new O-rings.
7. Replace screws [4.7-6.1 Nm (3.5-4.5 ft•lbf].
E100013 E
Removal and Installation of FNR and NFPE NFPE Assembly (FNR Similar)
Control Orifices
Note: Future models may contain an orifice plate Non-Feedback
between module and pump housing. This will Control Orifice
take the place of the orifice plugs beneath the
servo piston cover.
1. Remove servo piston cover (see section 4.17).
2. Remove orifice plug [1/8 in Int. Hex].
3. Examine orifice and port for cleanliness.
4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ft•lbf)].

E100014 E

Location of Non-Feedback Control Orifice

008 911 49 BOMAG 1 7701

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.10 System Check Relief Valves (High Pressure Relief, Charge Check,
& Bypass Valves)
The charge check, high pressure relief, and the loop
bypass functions are all contained within the system
check relief (SCR) valve assembly. This assembly
may be removed for cleaning and installation of fresh With
Bypass Valve
O-rings. The model code specifies whether high Seat
pressure relief valves, combination charge check/ Without
Bypass
high pressure relief valves, and/or loop bypass valves Retaining
Valve Ring
are present or not. Standard
Seat
Plug Bypass
1. Remove the valve seat plugs [9 mm Int. Hex] or Plunger
valve seat/bypass plugs [1 in Hex] from the pump Outer O-Ring
housing. O-Ring Valve
Seat
2. Remove the check poppet or relief valve assem- Backup Plug
Ring
blies from the pump housing. The smaller end of Outer
Inner
each conical spring is crimped to retain it on the O-Ring
O-Ring
check poppet or relief valve. Do not remove. Backup
Ring
3. Inspect the valves and mating seats in the special Inner
plugs for damage or foreign material. O-Ring

CAUTION
The relief valves are factory set and should not
be tampered with, except for replacing the
entire valve.

4. The O-ring on the standard bypass plunger may Check Poppet or

High Pressure
be replaced by removing the retaining ring and Relief Valve
removing the plunger from the special valve seat Conical Spring
plug. Remove the O-ring from the plunger and
install a new O-ring. Reinstall the plunger and
retaining ring.
5. Install a new outer O-ring, new backup ring, and
new inner O-ring on each valve seat plug.
6. Check that the conical springs are properly re-
tained on the check poppets or relief valves.
Install the check poppet or high pressure relief
valve assemblies into the pump housing .

CAUTION
The conical springs MUST be correctly posi-
tioned on the check poppets or relief valves
after installation for proper pump operation. E100015 E

System Check Relief Valve Components

7. Install the valve seat plugs or valve seat/bypass
plugs into the pump housing and torque [40-95
Nm (30-70 ft•lbf)].

702 1 8 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

4.11 Charge Relief Valve

The charge relief valve may be removed for cleaning
and installation of fresh O-rings. The pressure setting
may be changed. However, note that the setting will
vary for different charge flows which depends on
charge pump size and pump speed. The factory
setting is set relative to case pressure at 1800 rpm.
The actual charge pressure will vary at different
speeds.

Shim Adjustable Style

1. Remove the shim adjustable charge relief valve Shim Adjustable
Charge Relief Valve Plug
plug [1 in Hex] from the pump housing. Remove O-Ring
the O-ring from the plug.
Shims
2. Remove the spring and poppet from the housing.
Spring
3. Do not alter the shims which may be installed Poppet
between the spring and valve plug, or inter-
change parts with another valve. Inspect the
poppet and mating seat in the housing for dam-
age or foreign material.
4. If desired, the charge relief valve setting can be
changed. An approximate rule of thumb is 4 bar
/ 1.25 mm (58 psi / 0.050 in). The effective setting
will vary.
To confirm the charge relief valve setting, mea- E100016 E
sure charge pressure (port M3) with the pump in Shim Adjustable Charge Relief Valve Components
stroke. The charge pressure should level off
when the relief setting is reached.
Approximate Relief Setting vs Shim Thickness
5. Install a new O-ring on the valve plug. Reinstall
4 bar / 1.25 mm (58 psi / 0.050 in)
the poppet, spring, and plug (with shims and O-
T000 023E
ring) into the pump housing [55-135 Nm (40-100
ft•lbf)].
(continued)

008 911 49 BOMAG 1 9703

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

Screw Adjustable Style Charge Relief Lock Nut

1. Before removing the screw adjustable relief valve O-Ring

plug, mark the plug, lock nut, and housing so as Screw Adjustable
to approximately maintain the original adjust- Charge Relief Valve Plug
Spring
ment when assembling, Remove the screw ad- Poppet
justable charge relief valve plug by loosening the
lock nut [1-1/16 in Hex] and unscrewing the plug
[8 mm Int. Hex]. Remove the O-ring from the plug.
2. Remove the spring and poppet from the housing.
3. Inspect the poppet and mating seat in the hous-
ing for damage or foreign material.
4. Install a new O-ring on the valve plug. Reinstall
the poppet and spring. Reinstall the plug with its
lock nut [47-57 Nm (34-42 ft•lbf)], aligning the E100017 E
marks made at disassembly.
Screw Adjustable Charge Relief Valve Components
5. Check and adjust, if necessary, the charge pres-
sure. For screw adjustable "anti-stall" charge
relief valves, an approximate rule of thumb is 2.8 Approximate Relief Setting vs Screw Revolution
bar / quarter turn (40 psi / quarter turn).
2.8 bar / 1⁄4 turn (40 psi / 1⁄4 turn)
To confirm the charge relief valve setting, mea- T000 024E

sure charge pressure (port M3) with the pump in

stroke. The charge pressure should level off
when the relief setting is reached.

704 2 0 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

4.12 Loop Flushing Valve

The loop flushing function consists of the loop flush-

ing shuttle valve and the loop flushing relief valve. The Loop Flushing
assemblies may be removed for cleaning and instal- Relief Plug
lation of new O-rings. The relief valve poppet may be Loop Flushing Relief
Plug (Defeat) O-Ring
exchanged for one with a different flow rating, but the
O-Ring Shims
relief valve shims should not be changed out unless
specifically instructed so by Sauer-Sundstrand. The Spring
function also can be defeated.
Poppet
Loop Flushing Valve
1. Remove the loop flushing valve plug from the
Loop
pump housing [11/16 in Hex]. Remove the O-ring Loop Flushing
Flushing
from the plug. Plug (Defeat)
Plug
O-Ring
2. Remove the loop flushing valve spool assembly O-Ring
from the housing.
Loop
3. Inspect the parts for damage or foreign material. Defeat Flushing
Spool Spool
The centering spring must be securely retained to Assembly
the spool by the washer.
4. Install the loop flushing valve spool assembly into
its bore. Install a new O-ring on the loop flushing
plug and install [27-47 Nm (20-35 ft•lbf)].

Loop Flushing Relief Valve

1. Remove the loop flushing relief valve internal hex
plug [5/8 in Hex] from the pump housing. Remove
the O-ring from the plug.
2. Remove the spring and poppet from the housing.
3. Do not alter the shims which are installed be-
tween the spring and valve plug, or interchange
parts with another valve. Inspect the poppet and
mating seat in the housing for damage or foreign
E100018 E
material. Inspect the orifice in the valve poppet.
Loop Flushing Valve and Loop Flushing Defeat
4. Install a new O-ring on the valve plug. Reinstall Components
the poppet, spring, shims, and plug (with O-ring)
into the pump housing [15-34 Nm (15-25 ft•lbf)].

Defeating Loop Flushing

1. Remove the loop flushing valve from the pump
housing.
2. Install the defeat spool into the spool bore in the
housing. Install the plain plug with O-ring into the
housing [11/16 in Hex], and torque [27-47 Nm
(20-35 ft•lbf)].
3. Remove the charge relief valve (these parts are
not necessary).
4. Install the plain hex plug with O-ring into the end
cap [5/8 in Hex], and torque [15-34 Nm (15-25
ft•lbf)].

008 911 49 BOMAG 2 1705

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.13 Shaft Seal and Shaft Replacement

A lip type shaft seal is used in Series 42 pumps. This

seal and/or the shaft can be replaced without major
disassembly of the unit. Replacement generally re- Retaining
Ring
quires removal of the pump from the machine.
1. Position the pump with the shaft facing up. Seal Carrier
Assembly
NOTE: If the unit is positioned horizontally when
the shaft is removed, the cylinder block could
move out of place, making shaft installation diffi-
cult.
2. Remove the retaining ring from the housing.
3. Pull out seal carrier assembly.
4. Remove the O-ring from the seal carrier. To
install a new shaft only, proceed to step 8.
5. Place the seal carrier in an arbor press with the
shaft bearing side down, and press out the old
seal. An appropriately sized pipe spacer or socket
wrench can be used as a press tool. Once re-
moved, the seal is not reusable. E100019 E

6. Inspect the seal carrier and the new seal for Shaft Seal Components
damage. Inspect the sealing area on the shaft for
rust, wear, or contamination. Polish the sealing
area on the shaft if necessary. O-Ring

7. Press the new seal into the shaft bearing side of

the seal carrier. The seal lip must face the outside Sealant may
Seal be used on
of the pump. Be careful not to damage the seal.
outside diameter
The outside diameter of the seal may be coated
with a sealant (e.g. Loctite High Performance Inside Lip
Seal Carrier (face down)
Sealant #59231) prior to installation. This aids in
preventing leaks caused by damage to the seal
bore in the seal carrier.
(continued)

Press Seal
to bottom of Seal Carrier
E100020 E

Installation of Shaft Seal

706 2 2 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

If the shaft is not being replaced proceed to step

11. Retaining Ring
8. Remove the shaft and roller bearing assembly Roller Bearing
from the pump or motor. The bearing assembly
can be transferred to the new shaft (steps 9 and
10).
9. Remove the retaining ring that secures roller Key Shaft
bearing assembly with a snap ring plier. Remove
the roller bearing assembly. OR
Shaft Assembly
10. Place roller bearing assembly on new shaft and OR
secure with the retaining ring.
11. Wrap the spline or key end of shaft with thin
plastic to prevent damage to the seal lip during
installation. Lubricate the inside diameter of the
shaft seal with petroleum jelly.
12. Place the O-ring onto the shaft bearing and
lubricate with petroleum jelly.
13. Slide the seal carrier assembly over the shaft and
into the housing bore. Press against O-ring. Hold
inward pressure against the shaft to compress
the cylinder block spring while pressing the seal
carrier into place.
14. Install the retaining ring.

E100021 E

Shaft Components

008 911 49 BOMAG 2 3707

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.14 Auxiliary Mounting Pads

The following procedure can be used to remove and

install a new auxiliary mounting pad or to install a
fresh O-ring for the current auxiliary mounting pad.
Several auxiliary mounting pads are available.
Auxiliary mounting pads are integrated into the charge
pump cover. When nothing is mounted on the pads,
a flange cover is attached to protect the mounting Pad Cover Screws
flange. This cover is removed when mounting a
Charge Aux Mount Pad Cover
pump.
Pump Retaining
Cover
Removal of Auxiliary Mounting Pad Screws
1. Remove the auxiliary pump or remove the two O-Ring
screws retaining the flange cover ["A" Pad 9/16
in Hex; "B" Pad 3/4 in Hex]. Remove the O-ring.
2. Orient pump so that charge pump cover (auxiliary OR
pad) is facing up.
3. Remove the charge pump cover. The auxiliary
pad is integrated into the charge pump cover.
OR
Use a Torx T45 male driver to remove the screws. Auxiliary
Mounting
Note: If a different auxiliary pad is being installed, Pad "A"
then a new drive coupling must be installed. To do
Gasket
this follow the instructions in the section on re-
moving and installing the charge pump (next
section).
Auxiliary
Note: If the charge pump components come out Mounting
with the charge pump cover refer to section 4.15 Pad "B"
Locating
on how to properly reinstall them. No Charge Pin 1
Pump Defeat Charge Pump
4. Install a new charge pump cover gasket.
Components
5. Install the charge pump cover (auxiliary pump
mounting pad is integrated in cover).
NOTE: The threaded screw holes in the auxiliary Locating
Pin 2
pump mounting pad used on very early produc-
tion pumps with the SAE "A" pad option are drilled
through into the area between the gerotor cover
and charge pump cover. Any of these holes
which are not used to attach the flange cover or E100022 E
auxiliary pump should be plugged with internal
Auxiliary Pad Options and Components
hex set screws installed hand tight to prevent the
entrance of water or dirt into this area.
6. Attach the auxiliary pump. If no pump is to be
attached on an auxiliary mounting pad, the pad
should be protected with a flange cover and O-
ring to prevent leakage.

708 2 4 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

4.15 Charge Pump

The charge pump may be disassembled to inspect
and clean, or to change the auxiliary shaft drive
coupling.
(Screw used with
Note: For units without integral charge pumps "No Pad" and
"A Pad" Only)
see the last page of this section for additional
information. Cover
Retaining
1. Remove auxiliary pump, if necessary. Screws

Charge Pump Cover or Auxiliary Pad

2. Remove the screws retaining the charge pump
cover to the pump housing [Torx T45] (seven (7)
screws are used with the "no pad" or SAE "A"
auxiliary mounting pad charge pump cover, while
six (6) screws are used with the SAE "B" auxiliary
mounting pad charge pump cover). Remove the
charge pump cover, gasket, and the cover locat-
ing pins.
3. Remove the gerotor cover assembly from the
Gasket
charge pump cover or the back of the pump
O-Rings
housing. Remove the gerotor cover O-rings. Two
(2) O-rings are used on the gerotor cover of all
pumps. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.) Geroter
Cover

Charge Pump Components

4. Remove the gerotor assembly from the gerotor
cover or pump housing.
Geroter
5. Remove the gerotor drive pin and drive coupling. Assembly
Remove the gerotor cover locating pin from the Drive Coupling
pump housing.
Geroter Cover Geroter Drive Pin
6. Each part should be inspected separately if they Locating Pin
Charge Pump
are to be reused. If either of the gerotor assembly Charge Pump
Cover Locating
parts needs to be replaced, they must both be Cover
Pin
Locating
replaced. Always replace the O-rings and charge Pin
pump cover gasket. Inspect the journal bearing in
the gerotor cover for excessive wear.
7. Prior to assembly, lubricate the gerotor assembly
with clean hydraulic oil.
8. Install the gerotor drive pin into the hole in the
drive coupling, and retain with grease or petro-
leum jelly.
9. Install the drive coupling onto the pump shaft with
the smaller outside diameter oriented away from
E100023 E
the pump shaft. Different couplings are used
Charge Pump Components
with the different auxiliary pad options.
10. Install the gerotor assembly onto the coupling.
(continued)

008 911 49 BOMAG 2 5709

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

11. Install the gerotor cover locating pin into the

pump housing. Install the gerotor cover assembly
over the gerotor. The locating pin must engage
the slot in the gerotor cover.
NOTE: The charge pump rotation is determined
by the location of the gerotor recess and pressure
balance hole in the gerotor cover. Different
gerotor covers are used for clockwise and
counterclockwise rotation pumps.
12. Install new pressure balance O-rings onto the
gerotor cover and retain with petroleum jelly or
grease. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.)
13. Install the charge pump cover locating pins and a
new charge pump cover gasket.
14. Install the charge pump cover. The cover must
engage the gerotor cover and the locating pins. CW CCW
Install the charge pump cover screws and torque P100110 E
evenly [36-43 Nm (26-32 ft•lbf)]. Determining Charge Pump Orientation Looking
Inside of Gerotor Pump Cover
15. If necessary, reinstall auxiliary pump.
For units without an integral charge pump see the
next section.
(continued)

710 2 6 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

Units without Integral Charge Pump

Variable Pumps without an integral charge pump do (Screw used with
not have a gerotor assembly, gerotor drive pin, or "No Pad" and
gerotor cover locating pin installed. The charge pump "A Pad" Only)
inlet port is plugged with an O-ring plug.
Cover
For these units that are equipped with housings Retaining

Charge Pump Cover or Auxiliary Pad

Screws
without filtration adapters, the gerotor cavity outlet
is plugged with a special plug installed in a housing
passage. The 3/4—16 charge inlet fitting should be
torqued to 68 Nm (50 ft•lbf).
For these units that are equipped with housings that
include filtration adapters, the gerotor cavity outlet
is plugged with an O-ring plug installed in the "To
Filter" port of a "Full Filter Flow" (charge relief valve
after filter) filter adapter. The 7/8—14 charge inlet
fitting should be torqued to 95 Nm (70 ft•lbf). Gasket
O-Rings
CAUTION
A "Partial Filter Flow" (charge relief valve be-
fore filter) adapter must not be used on variable

"No Charge Pump" Components

pumps without an integral charge pump. If this
design adapter is used, the charge relief valve Geroter
Cover
will be defeated.
Charge Pump
Cover Locating
Drive Coupling Pin 1
Charge Pump
Cover Locating
Pin 2

Geroter
Cavity
Outlet Plug
(Charge Charge
Pump Defeat) Inlet

Charge Pump
Charge Pump Inlet Plug Inlet Plug

Charge Inlet
(For Wrench Sizes
and Torquing
See Filtration Section)

E100024 E

No Charge Pump Option Components No Charge Pump Option Components

(Housing with Filtration Adapter) (Housing without Filtration Adapter)

008 911 49 BOMAG 2 7711

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.16 Filtration
Filtration of foreign matter from the hydraulic fluid is M3 Gauge Partial Flow
of primary importance. Dirt and foreign fluids within Port Plug Pressure
Filtration
the hydraulic circuit will greatly reduce the life of the
Full Flow
hydraulic equipment. Pressure
Filtration
Filter-Related Pump Hardware Filtration Plate
Retaining Screws
Filtration mechanisms for the Series 42 pump may
be before (suction filtration) or after (charge pressure Suction
Filtration
filtration) the charge pump. Sauer-Sundstrand pro-
vides a filtration adapter to provide for each type of
filtration configuration. If filtration is provided for
elsewhere in the hydraulic circuit, the pump will not
have a filtration adapter.
Pumps equipped with housings without filtration
adapters have an additional construction bore next to
the charge relief valve which is unused and plugged
[5/8 in Hex, 21-33 Nm (15-25 ft•lbf)]. When these
pumps are equipped with suction filtration, the exter-
nal charge inlet is plugged [5/16 in Int. Hex, 41-94 Nm
(30-70 ft•lbf)].
Pumps equipped with housings that include filtration
adapters have the appropriate adapter and gasket
fastened to the housing with screws [Torx T30, 16
Nm (12 ft•lbf)]. The position of the M3 gauge port [11/ Housing with
16 in Hex, 11-13 Nm (8-10 ft•lbf)] will vary depending Filtration Adapter
on filtration type.

Filter Specifications
Charge Inlet
The selection of a filter depends on a number of
Plug
factors including the contaminant ingression rate,
the generation of contaminants in the system, the Plug
Construction
required fluid cleanliness, and the desired mainte- Bore Plug
nance interval. A filter capable of controlling the fluid
cleanliness to ISO 4406 Class 18/13 or better is
recommended and may be located either on the inlet
(suction filtration) or discharge (charge pressure
filtration) side of the charge pump. E100025 E
Housing without
Filter capacity depends on desired maintenance Filtration Adapter (Suction Filtration Only)
levels. As a rough guide, a capacity in grams equal
to twice the charge flow in gpm or 1/2 charge flow in
l/min has been found to be satisfactory for many Filtration Type β-ratio
closed circuit systems. Closed Circuit Suction Filtration or
β10 ≥ 2
Open Circuit Return Line Filtration
Filter efficiency as measured by a "Beta" (β) ratio* Systems Sharing a Reservoir with
should be as in the table at right. β10 ≥ 10
Other Gears, Clutches, or Cylinders
See Sauer-Sundstrand publication BLN-9887 or Charge Pressure Filtration β10 ≥ 10
697581 and ATI-E 9201 for more information on
* Filter ßx-ratio is a measure of filter efficiency defined by ISO
filtration. 4572. It is defined as the ratio of the number of particles greater
than a given size (x) upstream of the filter to number of particles
greater than the same size downstream of the filter. The ßx-ratio
applies to a specific particle size, measured in microns.

712 2 8 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Adjustments and Minor Repairs

4.17 Servo Piston Covers

The servo piston cover can be removed to change the
gasket or to inspect/change the control orifices for
NFP or FNR controls (section 4.9). Pump Neutral Ajustment
Seal Lock Nut
1. On the right side (side “1”) of the pump, remove
the pump “neutral” adjustment seal lock nut [13
mm Hex]. (Not necessary on side "2") Servo Piston
Servo Piston Cover Cover Screw
2. Remove the servo piston cover screws [Torx
T30]. Servo Piston Cover
(Non-Feedback and
3. The left side (side "2") servo cover can be re-
Automotive controls only)
moved directly.
On the right side (side “1”) of the pump, the cover Pump "Neutral"
Adjustment Screw
should be pushed away from the pump housing.
It is then necessary to turn the “neutral” adjust-
ment screw [5 mm Hex] clockwise (inward) far
enough for the servo cover to clear the nearby
drain port. Then pull the cover away from the
housing and turn the cover counterclockwise to
disengage it from the adjustment screw.
Servo Piston Cover – Right Side (Side "1")
4. Remove the gasket.
Note: FNR and NFPE control orifice plugs are
located here, see section 4.9 for more informa- Servo Piston
tion. Cover Screws

5. Install new gasket. Servo Piston

Cover
6. On the right side (side "1"), screw the servo piston
cover on the neutral adjustment screw. Then,
while holding the cover, turn the neutral adjust-
ment screw CCW to engage the cover to the
screw threads.
7. Install servo piston cover screws (15-17 Nm (11-
13 ft•lbf)].
8. On the right side (side "1"), loosely install neutral Servo Piston Cover – Left Side (Side "2")
adjustment seal lock nut. Perform pump neutral
adjustment (section 4.2). E100026 E
Servo Piston Cover Components
WARNING
After installing the servo piston cover on right
side (side “1”) of the pump, the pump “neutral”
adjustment and control neutral adjustment
MUST be performed before the vehicle / ma-
chine is put back into service.

CAUTION
Performance of the above procedure may ad-
just the position of the displacement limiter
somewhat.

008 911 49 BOMAG 2 9713

16.3 Vibration pump 42R 041

Series 42 Adjustments and Minor Repairs

4.18 Displacement Limiter Adjustment

Displacement limiters can limit the maximum swash- Displacement Limiter

plate position. For Series 42 pumps, displacement Seal Lock Nut
limiters are available on one or both sides of the servo
Displacement Limiter
piston.
Servo Piston
Adjustment of the displacement limiters should be Cover
performed on a test stand.

WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The limiter screw must have full thread
engagement in the servo piston cover, and the
seal lock nut must be retorqued after every
adjustment to prevent unexpected changes in
operating conditions and external leakage dur-
ing unit operation.
Displacement Limiter – Right Side (Side "1")
1. Mount pump on test stand. (Exploded View, No Need to Remove Limiter or Nut)
2. Loosen displacement limiter seal lock nut [13 mm
Hex]. Do not remove.
Displacement Limiter
3. Adjust displacement limiter [4 mm Int. Hex]. Seal Lock Nut
Tighten the seal lock nut every time the pump
Displacement
is to be tested [20-26 Nm (15-19 ft•lbf)].
Limiter
One full turn of the displacement limiter adjust-
ment screw will change the displacement of the Servo Piston
Cover
pump approximately as follows.

28 cc 3.6 cc/rev 0.22 in3/rev

41 cc 5.0 cc/rev 0.31 in3/rev
T000 026E

4. After reaching proper displacement tighten the

Displacement Limiter – Left Side (Side "2")
seal lock nut [20-26 Nm (15-19 ft•lbf)]. (Exploded View, No Need to Remove Limiter or Nut)
If necessary, repeat procedure for displacement lim- E100027 E
iter on other side. Displacement Limiters

714 3 0 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Exploded View Parts Drawings

5. Exploded View Parts Drawings

5.1 Shaft Options

F096
C020
C017

C018
C015

C005
C002

C003
C001
C015 F001
OR

C001

OR
C001

E100028

008 911 49 BOMAG 3 1715

16.3 Vibration pump 42R 041

Series 42 Exploded View Parts Drawings

5.2 Filtration, Charge Relief, System Relief, and Loop Flushing

(F086)
(F086A)

(F043)
(F043A)
(F040)
(F042)
(F043)
(F043A)
(F040) OR
(F042)

F043
F043A OR K001
F040 OR K001
F042
K005
F091 K001A
K002
F091A K001B
F030 K001C K006
F030A K007
G043
F041
G042
G040 K008
G040A G043 K009
G041 G042 K010
G041
G040A
G040
OR
J005
J002
045A F062
G045 F061 J003
F063 H005
F060A
F060 H002
H003
OR F051 F0511
(F060A)
(F060) F0512
F0513
F0514
F0515
F050A
F050 (F091A)
F093
(F091)
OR F093A
F093
(F051)
(F050A) F093A
(F050) N002A
N002

E100029

716 3 2 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Exploded View Parts Drawings

5.3 Charge Pump, Auxiliary Pads, and Servo Covers

L010
L010A

F020
F020A
G005
G010
(G075)
G015
G002 G020
(G021)
G022
G065
G075
G030 G023

F009
G001
M001
OR

(M001)
OR
(G001)
M005
M010A
G036
M010
(M005) OR
(M010A)
(M010) (G080)
G085
M020
M025

(G001) (G036) G090

(G090)
(G036) (G080)

(G085)

E100030

008 911 49 BOMAG 3 3717

16.3 Vibration pump 42R 041

Series 42 Exploded View Parts Drawings

5.4 Control Options

D038 D039
D037
D081
D003
D003A
(D017)
D080 D082 D019
D016

D002 OR

OR
D056 D017

D040

D010
F035 D012

F035A E001 D070

OR
OR
D011
D013 D004
F036

F035
F034 D081

D081

OR

D060
(F010)

F010

D090
D014

D015

D032A
E100031
D032

718 3 4 BOMAG 008 911 49

Vibration pump 42R 041 16.3

Series 42 Exploded View Parts Drawings

Notes

008 911 49 BOMAG 3 5719

16.3 Vibration pump 42R 041

720 BOMAG 008 911 49

 16.4 Vibration motor A10FM

008 911 49 BOMAG 721

16.4 Vibration motor A10FM

722 BOMAG 008 911 49

Vibration motor A10FM 16.4

A10FM

A10FE

RDE 92172-01-R/08.01
ersetzt / replaces 06.99

Reparaturanleitung - A10FM 28 - 60 Baureihe 5

A10FE 28 - 60 Baureihe 5
Repair instructions - A10FM 28 - 60 Series 5
A10FE 28 - 60 Series 5

008 911 49 BOMAG 723

RDE 92172-01-R/08.01
16.4
Hinweis / Inhalt
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Notice / Contents Repair Instructions A10FM / A10FE

HINWEIS
Bezeichnungen, Beschreibungen und Darstellungen
entsprechen dem Informationsstand zum Zeitpunkt der
Drucklegung dieser Unterlage.
Änderungen können den Service am Produkt beein-
flussen, Verpflichtungen entstehen uns daraus nicht.
Methoden und Vorrichtungen sind Empfehlungen, für
deren Resultat wir keine Haftung übernehmen können.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Anga-
be der Fabrik-Nr. bestellt, sind die Basis guter Reparatu-
ren.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf
dem Teststand vorzunehmen.
Schutz von Personen und Eigentum ist durch Vor-
kehrungen sicherzustellen.
Sachkenntnis, die Voraussetzung für jede Service-arbeit,
vermitteln wir in unseren Schulungskursen.
NOTICE
Specifications, descriptions and illustrative material shown
herein were as accurate as known at the time this
publication was approved for printing.
BRUENINGHAUS HYDROMATIK reserves the right to
discontinue models or options at any time or to change
specifications, materials, or design without notice and
without incurring obligation.
Optional equipment and accessories may add cost to the
basic unit, and some options are available only in
combination with certain models or other options.
For the available combinations refer to the relevant data
sheet for the basic unit and the desired option.
Adjustment and tests have to be carried out on the test
bench under operating temperatures.
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

A10FM / A10FE A10FM / A10FE

Schnittbild 3 Sectional view

Allgemeine Reparaturhinweise 4 General repair guidelines
Triebwelle abdichten 5-7 Sealing the drive shaft
Motor demontieren 8-14 Disassemble the motor
Überprüfungshinweise 15 Inspection hints
Motor montieren 16-19 Motor assembly
Spülventil demontieren 20 Disassembly of the flushing valve
Abstimmung- Lagerung / Hinweise 21 Bearing adjustment / Note
Werkzeuge / Hilfswerkzeuge / Tools / auxiliary tools /
Anziehdrehmomente 27 tightening torques

2 Brueninghaus Hydromatik
724 BOMAG 008 911 49
 RDE 92172-01-R/08.01
Vibration motor A10FM
Schnittbild
16.4
Reparaturanleitung A10FM / A10 FE
Sectional view Repair Instructions A10FM / A10FE

A10FM

A10FE

Optional Option
Ausführung mit Spülventil Unit with flushing valve
für geschlossenen Kreislauf for closed circuit application

008 911 49 BOMAG Brueninghaus Hydromatik

725 3
RDE 92172-01-R/08.01
16.4
Allgemeine Reparaturhinweise
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
General repair guidelines Repair Instructions A10FM / A10FE

Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!

Attention!
Observe the following guidelines when carrying out repairs
on hydraulic units!

Alle Öffnungen der Hydraulikaggregate verschließen.

Close off all openings of the hydraulic unit.

Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK
Ersatzteile verwenden.

Replace all of the seals.

Use only original BRUENINGHAUS HYDROMATIK
spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

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

Check all sealing and sliding surfaces for wear.

Attention: Re-work of the sliding surfaces by using, for
example abrasive paper, can damage the surface.

Hydraulikaggregate vor Inbetriebnahme mit

Hydrauliköl befüllen.

Fill the hydraulic unit with hydraulic oil

before commissioning.

4 Brueninghaus Hydromatik
726 BOMAG 008 911 49
 RDE 92172-01-R/08.01
Vibration motor A10FM
Triebwelle abdichten
16.4
Reparaturanleitung A10FM / A10 FE
Sealing the drive shaft Repair Instructions A10FM / A10FE

2
1

2 1. Sicherungsring, 2. Wellendichtring
1
1. Circlip, 2. Shaft seal

3 (Paßfeder ausbauen bei Ausführung Paßfeder))

Triebwelle abkleben.
Sicherungsring ausbauen.

(Remove key, version with keyway)

Protect the drive shaft.
Remove the circlip.

008 911 49 BOMAG Brueninghaus Hydromatik

727 5
RDE 92172-01-R/08.01
16.4
Triebwelle abdichten
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Sealing the drive shaft Repair Instructions A10FM / A10FE

4 Nach der Demontage des gelaufenen Wellendichtringes,

einfetten des neuen WDR.(Kontrolle der Laufflächen, Welle,
Gehäuse).

Change the shaft seal and check its sliding surface (drive shaft)
and housing, grease the sealing ring.

5 Welle mit Schutzhülse oder Klebeband versehen.

Use installation tool or plastic strip for assembling seal.

6 Mit geeignetem Rohr den WDR nur so tief montieren,

daß der Sicherungsring montierbar ist (zu tiefes Montieren
führt zum Ausfall: Berührung mit dem Wellenlager!).

Use a suitable pipe to mount the shaft seal ring, but don't
push it too deap. If the shaft ring touches the bearing ring
you will damage the seal ring.

7 Sicherungsring einsetzen.

Assemble the snap ring.

8 Sicherungsring ganz einrasten.

Assemble the snap ring in the correct position.

6 Brueninghaus Hydromatik
728 BOMAG 008 911 49

Vibration motor A10FM
Triebwelle abdichten
Sealing the drive shaft
Hinweis!
Die hier beschriebene Möglichkeit zum Wechsel der
Antriebswellen - Abdichtung stellt nicht die serienmäßi-
ge Montage dar. Für sicheres Dichtungsverhalten ist eine
Montage des Dichtringes zusammen mit dem Kegel-
rollenlager von innen her durch das Montagegehäuse
durchzuführen. Soll aus Gründen der Vereinfachung im
Reparaturfall die vorgehend beschriebene Vorgehens-
weise durchgeführt werden, so ist beim Ausbau der
Dichtung besonders darauf zu achten, daß die Antriebs-
welle nicht beschädigt wird.
008 911 49 BOMAG
RDE 92172-01-R/08.01
16.4
Reparaturanleitung A10FM / A10 FE
Repair Instructions A10FM / A10FE
Note!
This discription showes how th change the drive shaft
sealing ring but it isn't the way of serial assembly.
The sealing ring is assembled together with the taper
roller bearing from inside the motor housing normally to
get a secure sealing condition. If you decide to repair the
motor in the shown way be very careful while handling
so that the drive shaft wouldn't be damaged during
disassembly of the shaft sealing ring.
Brueninghaus Hydromatik
729 7
RDE 92172-01-R/08.01
16.4
Motor demontieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

A10FM

8 Brueninghaus Hydromatik
730 BOMAG 008 911 49
 RDE 92172-01-R/08.01
Vibration motor A10FM
Motor demontieren
16.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE

A10FE

10

008 911 49 BOMAG Brueninghaus Hydromatik

731 9
RDE 92172-01-R/08.01
16.4
Motor demontieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

11 Demontageposition
Lage der Anschlußplatte zum
Gehäuse kennzeichnen.

Disassembly position
Mark the location of the connection plate
on the housing.

12 Anschlußplattenbefestigung über Kreuz lösen.

Remove the connection plate fixing bolts crosswise.

13 Anschlußplatte abheben.
Verteilerplatte
kann herunterfallen - festhalten.
Verteilerplatte abheben.

Remove the connection plate.

Distributor plate
can drop down - hold tight.
Remove distributor plate.

10 Brueninghaus Hydromatik
732 BOMAG 008 911 49
 RDE 92172-01-R/08.01
Vibration motor A10FM
Motor demontieren
16.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE

14 Verteilerplatte abheben.

Remove control plate.

15 Lageraußenring mit Abziehvorrichtung ausbauen.

Dichtfläche Verteilerplatte nicht beschädigen.

Remove bearing outer ring with withdrawal tool.

Do not damage the sealing surface.

16 Abheben des Kegelrollenlagers (anschlußplattenseitig).

Entfernen der Abstimmscheibe.

Disassemble the taper roller bearing (near by port plate)

Remove the adjustment shim.

008 911 49 BOMAG Brueninghaus Hydromatik

733 11
RDE 92172-01-R/08.01
16.4
Motor demontieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

17 Triebwerk in horizontaler Lage herausziehen.

Remove the rotary group in a horizontal position.

18 Welle nach hinten herausziehen.

Remove the drive shaft to rear side.

19 Hubscheibe mit Sonderwerkzeug ausbauen (siehe Bild 20).

Remove swash plate with special tool (see picture 20).

20 Der Ausbau der Hubscheibe erfolgt mit einer Schleuder,

ein kleiner Haken - aus Rundmaterial Durchmesser 6 mm -
greift dabei unter die Hubscheibe.

Loosen the swash plate with a slide hammer ( a small

hook - diameter 6 mm - catches the end of the swash
plate at the bottom).

21 Lager mit Presse abziehen.

Press down bearing.

12 Brueninghaus Hydromatik
734 BOMAG 008 911 49
 RDE 92172-01-R/08.01
Vibration motor A10FM
Motor demontieren
16.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE

22 Abziehen des Lageraußenringes im Pumpengehäuse.

Zweckmäßige Unterlage benutzen, zur Vermeidung von
Gehäusebeschädigungen (s. a. Hinweis Abb.xx).

The external front bearing ring is pulled out of the pump

housing (tool and surface infos see picture xx, too).

23 Sicherungsring entfernen.

Disassemblecirclip and shaft seal.

24 Wellendichtring und Fixierscheibe entnehmen

Remove shaft seal ring and shim.

008 911 49 BOMAG Brueninghaus Hydromatik

735 13
RDE 92172-01-R/08.01
16.4
Motor demontieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

25 Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

26 Sicherungsring demontieren.
Feder und Druckstifte ausbauen.

Remove circlip.
Remove spring and pressure pins.

27

14 Brueninghaus Hydromatik
736 BOMAG 008 911 49
 RDE 92172-01-R/08.01
Vibration motor A10FM
Überprüfungshinweise
16.4
Reparaturanleitung A10FM / A10 FE
Inspection hints Repair Instructions A10FM / A10FE

28 Kontrolle!
Lauffläche (1) keine Kratzer, keine Metalleinlagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).

Check!
Check to see that there are no scratches or metal deposits
on the sliding surface (1), and that there is no axial play (2),
(pistons must only be replaced as a set).

29 Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).

Check!
Cylinder bores (1), splines (2).

30 Riefenfrei, keine Einlaufspuren

Free of grooves, no signs of wear.

31 Kontrolle!
Zylindergleitfläche riefenfrei, nicht eingelaufen, keine
Einlagerungen, Steuerplatte nicht riefig (nur satzweise
austauschen).

Check!
Cylinder sliding surface free of grooves, no wear, no
embedded foreign particles. That there are no scratches
on the control plate. (Only replace them as a set).

32 Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.

Check!
Mounting surface - control plate undamaged

008 911 49 BOMAG Brueninghaus Hydromatik

737 15
RDE 92172-01-R/08.01
16.4
Motor montieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Motor assembly Repair Instructions A10FM / A10FE

33 Sicherungsring ins Gehäuse montieren.

Fit the circlip into the housing.

34 Wellendichtring und Fixierscheibe gegen

Sicherungsring einsetzen.

Assemble shaft seal ring and shim

against circlip.

35 Montage des Wellendichtringes 1 gegen den Sicherungsring 2,

3 anschließend Fixierscheibe 3 einlegen.

1 Assembly of the shaft seal 1 against the safety ring 2,

back up the shim 3 down to the seal ring.

36 Lageraußenring ins Gehäuse pressen.

Welle mit Lager vormontiert ins Gehäuse einstecken.

Wellendichtring nicht beschädigen.

Wellenverzahnung mit Klebeband umwickeln.

Press outer bearing ring into housing.

Shaft seal with pre-assembled bearing into housing.

Protect splines of the shaft with plastic strip

against damage of the seal lip.

16 Brueninghaus Hydromatik
738 BOMAG 008 911 49
 RDE 92172-01-R/08.01
Vibration motor A10FM
Motor montieren
16.4
Reparaturanleitung A10FM / A10 FE
Motor assembly Repair Instructions A10FM / A10FE

37 Hubscheibe montieren.

Assemble swash plate.

38 Mit Vorrichtung Druckstifte montieren.

Fit pressure pins using an assembly aid.

39 Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

40

41 Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note:
Oil piston and slipper pad.

008 911 49 BOMAG Brueninghaus Hydromatik

739 17
RDE 92172-01-R/08.01
16.4
Motor montieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Motor assembly Repair Instructions A10FM / A10FE

42 Rotationsgruppe montieren!

Montagehilfe:
Mit O-Ring Kolben festhalten.

Fit rotary group!

Assembly aid:
Hold the pistons by using an O-ring.

43 Lager (1) in Anschlußplatte montieren.

4 Zylinderstift (2) einsetzen.
O-Ring (3) einsetzen.
Verteilerplatte (4) aufsetzen.
3
Montagehilfe:
Teile mit Fett fixieren.
1

Fit bearing (1) in connection plate.

2 Fit cyilindrical pin (2).
Fit O-ring (3).
Fit distributor plate (4).

Assembly:
Hold the components in place with grease.

18 Brueninghaus Hydromatik
740 BOMAG 008 911 49
 RDE 92172-01-R/08.01
Vibration motor A10FM
Motor montieren
16.4
Reparaturanleitung A10FM / A10 FE
Motor assembly Repair Instructions A10FM / A10FE

44 Verteilerplatte montieren.
Montagehilfe: Fett

Fit distributor plate.

Assembly aid: Grease

45 Anschlußplatte aufsetzen und mit Schrauben

über Kreuz anziehen.

Fit the connection plate and fix it with

the screws crosswise.

A10FM A10FE

46

008 911 49 BOMAG Brueninghaus Hydromatik

741 19
RDE 92172-01-R/08.01
16.4
Spülventil demontieren
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Disassembly of the flushing valve Repair Instructions A10FM / A10FE

47 Beidseitig Schrauben 1 lösen und Federn mit Scheiben 2

entnehmen.

Loosen screws 1, take out springs and shims 2.

1
2

2
1

48 Spülschieber 3 vorsichtig zu einer Seite heausdrücken.

Take out spool carefully.

49 Verschlußschraube Speisedruckventil 4 lösen,

Feder und Einsatz entnehmen.

Loosen the screw of the boost valve and take out

the spring and the cartridge.

Montage in umgekehrter Reihenfolge!

Assembling by opposite steps!

20 Brueninghaus Hydromatik
742 BOMAG 008 911 49
 RDE 92172-01-R/08.01
Vibration motor A10FM
Abstimmung- Lagerung / Hinweise
16.4
Reparaturanleitung A10FM / A10 FE
Bearing adjustment / Note Repair Instructions A10FM / A10FE

Montage - Abstimmung (Kegelrollenlager) / Taper roller bearing initial tension

AA10FM Baureihe 50
AA10FM Series 50
0 .... 0,05 mm

Pos. 12

Abstimmung der Triebwerkslagerung Adjustment of stopper min displacement

Die Vorspannung der Triebwerkslagerung muß im
Gußgehäuse von 0 bis 0,05 mm durch Abschleifen der
Abstimmscheibe Pos. 12 hergestellt werden.
Einstellhinweis: Qmin-Anschlag
Bei gegebenem Zusatzstrom wird bei drucklosem
Umlauf der Anschlag Qmin so eingestellt, daß die gemes-
sene Drehzahl des Motors einem Schluckvolumen von
12 cm3 entspricht (vgmin).
Eine kontinuierliche Verstellung bis vgmax = 45 cm3 ist
möglich - Volumenänderung pro Gewindestiftum-
drehung ca. 3,1 cm3 (s. a. Seite 3).
Q Zulauf x 1000
Schluckvolumen vgmin =
Meßdrehzahl
Cast iron housing must have initial tension of bearings:
0 ...... 0,05 mm , grind Pos. 12 if necessary.
Adjustment: Qmin- stopper
With a given inflow and pressureless circulation adjust
the stopper Qmin displacement so that the measured
speed of the motors results in a displacement of 12 cm3
(vgmin).
Increase of adjustment is possible to vgmax = 45 cm3
Differential volume is appr. 3,1 cm3 (see page 3).
Q inflow x 1000
Displacement vgmin =
Measurement speed

Achtung: Falsch eingestellte Qmin Anschläge können zu Attention: Wrong adjustments of stopper Qmin
überhöhten Drehzahlen bis hin zum Ausfall der Bauteile displacement increases the speed of the motor up to a
führen. possible failure of parts of the unit.

008 911 49 BOMAG Brueninghaus Hydromatik

743 21
RDE 92172-01-R/08.01
16.4
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Tools / auxiliary tools / tightening torques Repair Instructions A10FM / A10FE

49 Plastikhammer

Soft hammer

50 Schleuder

...

Anziehdrehmomente /
Tightening torques

Festigkeitsklassen 8,8; 10,9; 12,9

Bolt tensile strength grade:

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8,8 2,3 5,0 8,5 21 41 72 115 176 240 350 600 1220

Ma 10,9 3,2 7,2 12 29 58 100 165 250 350 490 840 1670

12,9 4,1 8,5 14,5 35 70 121 195 300 410 590 990 2000

Ma (Nm) = max. Anziehdrehmoments (geölte Schrauben μ = 0,125)

Ma (Nm) = max. tightening torques (lubricated screws μ = 0,125)
51

22 Brueninghaus Hydromatik
744 BOMAG 008 911 49
 16.5 MS/MSE 02 ..... 18

008 911 49 BOMAG 745

16.5 MS/MSE 02 ..... 18

746 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
Hydraulikmotoren
MS
Hydraulic motors
Reparaturen
Repairs

02 05 08 11 18
MS
MSE

Störungsbeseitigung
Trouble Shooting

Wartungsarbeiten
Maintenance

Reparaturen
Repairs
5767

Ersatzteile
Spare Parts

5763 5765
0549 5766 0545

5764
0550 0547

Ref : 800378128J POCLAIN HYDRAULICS Industrie

B.P. 106
REPAR MS2-18 D/GB 60411 VERBERIE CEDEX - FRANCE POCLAIN HYDRAULICS
Tel.: 33 3 44 40 77 77
Rev : A - Avr - 00 Fax: 33 3 44 40 77 99
www.poclain-hydraulics.com Certifié ISO 9001

008 911 49 BOMAG 747

 16.5
POCLAIN HYDRAULICS
Dieses Dokument richtet sich an die Hersteller von Maschinen und Sy-
stemen, die Produkte von POCLAIN-HYDRAULICS einbauen, deren
Artikelnummer auf der Titelseite genannt sind. Es beschreibt die Instal-
lationsangaben und den Inbetriebnahmevorgang, damit ihre optimale
Funktionsweise gewährleistet wird.
Es wird empfohlen, daß sämtliche Arbeiten von Monteuren mit einer an-
gemessene Ausbildung durchgeführt werden. Sie müssen die Informa-
tionen in diesem Dokument gelesen und verstanden haben und vom
Hersteller der Maschine bevollmächtigt sein.
Selbstverständlich müssen die Monteure die Richtlinien zur Sicherheit
und zur Unfallverhütung beachten.
Dieses Dokument enthält wichtige Hinweise zur Sicherheit. Sie werden
auf folgende Weise gekennzeichnet:
! Sicherheitshinweis.
Dieses Dokument enthält weiterhin wesentliche Anweisungen zum Be-
trieb des Produkts sowie allgemeine Informationen. Sie werden auf fol-
gende Weise gekennzeichnet:
Wesentliche Anweisung.
Allgemeine Information.
POCLAIN HYDRAULICS kann nicht für Vorfälle haftbar gemacht wer-
den, die auf die Anwendung der in diesem Dokument empfohlenen Ver-
fahren zurückgehen.
POCLAIN HYDRAULICS ist nicht verantwortlich für die Konstruktion
und die Betriebsbedingungen der Maschinen und Systeme, die mit PH-
Produkten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS we-
der für die Folgen eines falschen Einbaus der Produkte noch für ein fal-
sches Parametrieren einstellbarer Werte, noch für ungültige oder unvoll-
ständige Gebrauchs- und Wartungsanweisungen, die den Endverbrau-
chern von den Maschinenherstellern zur Verfügung gestellt worden sind,
verantwortlich.
Jegliche Änderung einstellbarer Parameter der PH Produkte kann eine
Neuzulassung der Maschinen erforderlich machen.
Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HY-
DRAULICS seinen Kunden, jede Anwendung von POCLAIN HY-
DRAULICS prüfen und freigeben zu lassen.
Das Öffnen der Produkte führt zum Garantieverlust. Verwenden Sie nur
Original-Ersatzteile von POCLAIN HYDRAULICS. Die Montage von
Teilen anderen Ursprungs könnte den Betrieb des Bauteils und des Sy-
stems sowie die Sicherheit beeinträchtigen.
Stets um die Verbesserung seiner Erzeugnisse bemüht, behält sich
POCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankündigung
alle Änderungen vorzunehmen, die als nützlich für die in diesem Doku-
ment beschriebenen Produkte bewertet werden.
Dieses Dokument enthält Abschnitte auf deutsch und kursiv gedruckte Ab-
schnitte, die Übersetzung in englischer Sprache darstellen.
Im Zweifelsfall ist die französische Version ausschlaggebend.
Die Maße sind in metrischen Einheiten angegeben. Die Entsprechungen
in anderen Meßsystemen (vor allem angelsächsisch) werden zur Unter-
richtung angegeben.
Die Abbildungen haben unverbindlichen Charakter.
© POCLAIN HYDRAULICS Industrie 1998.
Die Handelsmarke POCLAIN HYDRAULICS ist das Eigentum von PO-
CLAIN HYDRAULICS SA.
Dieses Dokument ist das Eigentum von POCLAIN HYDRAULICS Indu-
strie. Es ist streng vertraulich. Es darf ohne unseres vorheriges schriftli-
ches Einverständnis weder gesamt noch teilweise verwendet, vervielfäl-
tigt, kopiert oder an Dritte weitergegeben werden.
FACOM ist ein eingetragenes Warenzeichen der FACOM SA.
LOCTITE ist ein eingetragenes Warenzeichen der LOCTITE SA.
AUTO-TOP ist ein eingetragenes Warenzeichen der AGIP SPA.
2 REPAR MS2-18 D/GB
748 BOMAG
MS/MSE 02 ..... 18
This document is provided to machine manufacturers integrating PO-
CLAIN-HYDRAULICS products.. It suggests processes that manufac-
turers may utilize to repair products after the warranty period.
It is recommended that all operations be performed by technicians
trained accordingly. The technicians should read and understand the
information given in this document and be authorized by the machine
manufacturer.
It is essential that the technicians comply with safety instructions to pre-
vent injury.
This document includes major safety warnings announced in this way:
! Safety warning.
Additionally, this document includes instructions essential to product
function as well as those providing general information. Both are an-
nounced similar to the following examples:
Essential instruction.
General information.
POCLAIN HYDRAULICS designs products that are integrated by its
customers in the machines they design.
Subsequently POCLAIN HYDRAULICS disclaims liability for conse-
quences of improper integration of its products and of improper set-up
of adjustable devices. In the same way, POCLAIN HYDRAULICS may
not be liable for incomplete or improper operating and maintenance in-
structions provided to the end user by the machine manufacturer nor for
failures resulting from operations performed by any person using these
suggested procedures.
A re-certification of the machine may be required for every change in
set-up of adjustable devices.
In order to offer the best quality service, POCLAIN HYDRAULICS rec-
ommends to its customers to have applications approved by POCLAIN
HYDRAULICS.
Opening of products voids the warranty contract.
Use only POCLAIN HYDRAULICS genuine spare parts. Using parts
from different sources could reduce the performance of the product and
pose a safety hazard..
In accordance with its policy of continuous improvement, POCLAIN
HYDRAULICS reserves the right to modify the specifications of all
products described herein without prior notice.
This document contains sections written in German and sections
printed in italics composing the English translation of the French sec-
tions. The French sections will be the reference in case of dispute.
All measures are expressed in metric units. Converted values to other
systems (notably US and UK) are given for reference only.
The illustrations for information only.
© POCLAIN HYDRAULICS Industrie 1998.
The trademark POCLAIN HYDRAULICS is the property of POCLAIN
HYDRAULICS S.A.
This document is the property of POCLAIN HYDRAULICS Industrie.
It is strictly confidential. It must not be used, duplicated, copied or dis-
closed to a third party in full or in part without our prior written consent.
FACOM is FACOM SA registered trademark.
LOCTITE is LOCTITE SA registered trademark.
AUTO-TOP is AGIP SPA registered trademark.
800378128J
008 911 49
 MS/MSE 02 ..... 18
Inhaltsverzeichnis
INHALTSVERZEICHNIS ............................................. 3
SICHERHEIT UND QUALITÄT ................................... 4
VOR DEN W ARTUNGSARBEITEN ....................................... 4
W ÄHREND DER W ARTUNGSARBEITEN............................... 4
NACH DEN W ARTUNGSARBEITEN ..................................... 4
IDENTIFIZIERUNG DES BAUTEILS ....................................... 5
STÖRUNGSBESEITIGUNG........................................ 6
WARTUNGSARBEITEN.............................................. 8
AUSTAUSCHEN DES MOTORS........................................... 8
Ausbau..................................................................... 8
Einbau...................................................................... 8
MECHANISCHE BREMSLÖSUNG ........................................ 9
KONTROLLE DER STATISCHE HALTEBREMSE. ................... 10
REPARATUREN. ...................................................... 11
AUSWECHSELN DER BREMSKOLBENDICHTUNG................. 11
Demontage ............................................................ 11
Wiedereinbau......................................................... 13
AUSWECHSELN DES LAGERTEILES (070)......................... 16
Demontage ............................................................ 16
Wiedereinbau......................................................... 18
AUSWECHSELN DER BREMSBACKEN ............................... 20
Demontage ............................................................ 20
Wiedereinbau......................................................... 23
AUSWECHSELN DES NOCKENRINGS (026)....................... 27
Demontage ............................................................ 27
Wiedereinbau......................................................... 27
AUSWECHSELN DES KOMPLETTEN ZYLINDERBLOCKS (010) 28
Demontage ............................................................ 28
Wiedereinbau......................................................... 28
AUSWECHSELN DES VERTEILERS (047). ......................... 29
Demontage ............................................................ 29
Wiedereinbau......................................................... 29
AUSWECHSELN DER DECKELDICHTUNG (045).................. 32
Demontage ............................................................ 32
Wiedereinbau......................................................... 33
AUSWECHSELN DES DREHZAHLSENSORS (OPTION).......... 34
Demontage ............................................................ 34
Wiedereinbau......................................................... 35
WERKZEUG-LISTE .................................................. 36
Standard Werkzeug................................................ 36
Spezialwerkzeuge .................................................. 37
ANZIEHDREHMOMENTE NM ± 10%........................... 38
ERSATZTEILE.......................................................... 39
MOTOREN MIT KONSTANTEM HUBVOLUMEN MS, MSE 02-
05-08-11-18. .............................................................. 42
MOTOREN MIT UMSCHALTBAREM HUBVOLUMEN MS, MSE
02-05-08-11-18. ......................................................... 44
800378128J REPAR MS2-18 D/GB
008 911 49 BOMAG
16.5
POCLAIN HYDRAULICS
Contents
CONTENTS................................................................. 3
SAFETY AND QUALITY ............................................. 4
BEFORE SERVICING ........................................................ 4
DURING SERVICING ......................................................... 4
AFTER SERVICING ........................................................... 4
IDENTIFICATION OF THE COMPONENT................................. 5
TROUBLE SHOOTING ............................................... 7
MAINTENANCE .......................................................... 8
REPLACING THE MOTOR .................................................. 8
Removal................................................................... 8
Installation................................................................ 8
MECHANICAL BRAKE RELEASE .......................................... 9
CHECKING THE PARKING BRAKE EFFICIENCY..................... 10
REPAIRS. ................................................................. 11
REPLACEMENT OF THE O-RING OF THE BRAKE PISTON....... 11
Disassembly........................................................... 11
Reassembly. .......................................................... 13
REPLACEMENT OF THE BEARING SUPPORT (070).............. 16
Disassembly........................................................... 16
Reassembly ........................................................... 18
REPLACING THE BRAKE SHOES....................................... 20
Disassembly........................................................... 20
Reassembly ........................................................... 23
REPLACEMENT OF THE CAM (026) .................................. 27
Disassembly........................................................... 27
Reassembly ........................................................... 27
REPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)28
Disassembly........................................................... 28
Reassembly ........................................................... 28
REPLACEMENT OF THE VALVING (047). ........................... 29
Disassembly........................................................... 29
Reassembly ........................................................... 29
REPLACEMENT OF THE O-RING (045) OF THE END COVER . 32
Disassembly........................................................... 32
Reassembly ........................................................... 33
REPLACING THE SENSOR (OPTIONAL) .............................. 34
Disassembly........................................................... 34
Reassembly ........................................................... 35
TOOLING INVENTORY............................................. 36
Standard tools ........................................................ 36
Special tools........................................................... 37
TIGHTENING TORQUES IN [LBF.FT] ± 10% .......... 38
SPARE PARTS LIST ................................................ 39
SINGLE DISPLACEMENT MOTORS MS, MSE 02-05-08-11-
18. ............................................................................. 42
DUAL DISPLACEMENT MOTORS MS, MSE 02-05-08-11-18.44
3
749
 16.5
POCLAIN HYDRAULICS
Sicherheit und Qualität
Vor den Wartungsarbeiten
• Alle notwendigen Sicherheitsvorkehrungen treffen
(Menschen und Material) und die geltenden Sicher-
heitsvorschriften beachten.
• Parkbremse betätigen und Maschine mit Keilen
festsetzen.
• Energieerzeugung (Motor) des Hydrauliksystems
abstellen und die Stromversorgung ausschalten.
• Gegebenenfalls eine Sicherheitszone einrichten.
• Die Außenflächen der Bauteile reinigen, um
Schmutz und Fett restlos zu entfernen.
• Warten, bis das Hydrauliksystem vollständig abge-
kühlt und druckentlastet ist (die Speicher entlasten).
Das heiße oder unter Druck stehende Öl
! kann zu schweren Verbrennungen mit
Entzündung führen.
Bei einem Unfall einen Arzt hinzuziehen.
Während der Wartungsarbeiten
• Bestimmte Bauteile sind sehr schwer. Sie müssen
bei der Abnahme vom Rahmen mit einer angemessen
ausgelegten Hebevorrichtung gehalten werden.
• Die Sauberkeit ist wesentlich beim Betrieb der Hy-
draulikbauteile. Die meisten Teile können mit einem
sauberen Lösungsmittel gereinigt werden.
• Während der Handhabung alle empfindlichen Ober-
flächen gegen Stöße schützen (Zentrierungen, gleitende
Teile, Auflagen, Dichtungs- und Lagerauflagen usw.).
• Diese Flächen vor dem Wiederzusammenbau reinigen.
• Systematisch die demontierten Dichtungen beim
Wiederzusammenbau durch neue ersetzen. Wir emp-
fehlen, vor der Montage alle Dichtungen zu fetten.
• Alle gleitenden Flächen durch Aufbringen eines Films
sauberer Hydraulikflüssigkeit ölen, der eine korrekte
Schmierung beim ersten Neustart gewährleistet.
• Niemals die Hydraulikflüssigkeit, die sich bei hohen
Temperaturen entzünden kann, erwärmen. Einige Lö-
sungsmittel sind ebenfalls entzündlich.
Während der Arbeiten nicht rauchen.
Nach den Wartungsarbeiten
Die Bauteile wieder einbauen und das Hydrauliksystem
gemäß den Anweisungen in den folgenden Dokumen-
ten wieder in Betrieb nehmen:
• INSTALLATION MS D/GB (ref: 800078173V)
• INSTALLATION CIRCUITS D/GB (ref. 677777853U)
Die Einstellung der Sicherheitsventile
! nicht erhöhen.
4 REPAR MS2-18 D/GB
750 BOMAG
MS/MSE 02 ..... 18
Safety and Quality
Before servicing
• Be extremely careful to prevent personal injury and
to avoid damage to material. Comply with all safety
regulations.
• Apply the parking brake and prevent the machine
from rolling with tire blocks.
• Stop the hydraulic system power source (engine)
and disconnect the battery.
• If necessary, block off the safety area.
• Wash dirt and grease from exterior of the compo-
nents.
• Await the complete cooling down and depressuriza-
tion of the hydraulic system (accumulators must be
purged).
Hot or pressurized hydraulic fluid may
! cause serious burns & infections to the
human body.
Consult a physician in case of accident.
During servicing
• Some hydraulic components are very heavy. Se-
cure them with a lifting device of adequate capacity
when removing from the machine frame.
• Cleanliness is essential to functioning of the hy-
draulic components. Most of the parts may be cleaned
with a clean solvent.
• During handling, protect all sensitive surfaces from
shocks (piloting and interface surfaces, thrust & bear-
ings surfaces, seal races, etc...)
• Clean up these surfaces before reassembling.
• Always install new O-rings, seals & gaskets dis-
carding the old ones. We recommend lubricating all
seals prior to assembly.
• Lubricate all surfaces which have relative motion
between parts by coating them with a film of clean hy-
draulic fluid to assure lubrication at first start.
• Never heat hydraulic fluid, as it may flame at high
temperature. Some solvents are also flammable.
Do not smoke during servicing.
After servicing
Reinstall the components and restart the hydraulic
system according to instructions defined in the following
documents:
• INSTALLATION MS F/GB (ref. 677777844K)
• INSTALLATION CIRCUITS F/GB (ref. 677777831V)
! Do not overset relief valves.
800378128J
008 911 49
MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Identifizierung des Bauteils Identification of the component

MS18-2-D11-F19-2A10-K000
B D
000143896J

C 40712
001
0349

A : Handelsbezeichnung: A: Commercial description:

Ex : MSE18-2-D11-F19-2A10-K000 E.g : MSE18-2-D11-F19-2A10-K000

B : Code : Artikelnr.: B: Code: Part number.

Ex : 000143896J E.g : 000143896J

C : Serie : Herstellungsnummer C: Series: Manufacturing batch number.

Ex : 001 E.g : 001

D : Num : Chronologische Ordnungsnummer D: Num: Chronological serial number.

Ex : 40712 E.g : 40712

Bei sämtlichen Ersatzteilbestellungen The part number and the chronological

müssen die Artikelnummer und die chro- serial number must be specified to order
nologische Ordnungsnummer angege- spare parts.
ben werden.

800378128J REPAR MS2-18 D/GB 5

008 911 49 BOMAG 751

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Störungsbeseitigung
BECHÄDIGUNG → ABRIEB → ERKENNUNG DURCH FILTER → VORBEUGUNG……

Störung Ursachen Abhilfe

Regelmäßiges Lagerteil verschlissen Lagerteil ersetzen
Ohne Brummen
Last Lockere Befestigungen Mit entsprechendem Drehmo-
LAUTE Vibrationen
und / oder Anschlüsse ment anziehen
GERÄUSCHE DES
MOTORS Speise- und Austauschdruck-
Klappern Speisedruck zu niedrig
Unter ventil kontrollieren.
Last Zylinderblock und Ölverteiler
Kavitation Interne Lecks zu groß ersetzen

Der Motor wird nicht ver- Den Antrieb der Pumpe und ih-
sorgt re Versorgung überprüfen
Kein Druckanstieg im Hochdruck-Begrenzungsventile
MOTOR DREHT SICH Kreis kontrollieren (Regler)
NICHT Zylinderblock und Ölverteiler
Interne Lecks zu groß
ersetzen
Die Bremse bleibt angezo- Den Steuerkreis der Bremse
gen kontrollieren

Die Antriebsdrehzahl und den

Der Fördermenge der
Zustand der Pumpe kontrollie-
Pumpe ist unzureichend
ren
DER MOTOR DREHT
SICH NICHT MIT Den Zustand des Zylinder-
NORMALER LAST- Interne Lecks zu groß blocks und des Ölverteilers
DREHZAHL überprüfen
Der Betriebsdruck ist zu Den Zustand des Sicherheits-
niedrig ventils kontrollieren (Regler)

Die Fördermenge der Steuerdruck und Fördermenge

DER MOTOR DREHT Pumpe schwankt der Pumpe kontrollieren
SICH UNREGEL- Den Zustand des Zylinder-
MÄSSIG Interne Lecks zu groß blocks und des Ölverteilers
überprüfen.

Gehäusedruck zu groß Den Leckagekreis und den Zu-

stand des Filters überprüfen
Dichtungen beschädigt Die Dichtungen ersetzen
ÄUSSERE ÖLUN-
DICHTIGKEITEN Das Anziehmoment der Monta-
geschrauben, der Entlüftungs-
Fehlerhafte Montage
schrauben und der Anschlüsse
kontrollieren

6 REPAR MS2-18 D/GB 800378128J

752 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Trouble shooting
DAMAGE → IRON PARTICLES → DETECTION BY FILTERS → PREVENTION……

Troubles Causes Remedies

Regular rum- Worm bearing support Replace the bearing support
Without bling
load Mountings and/or hydraulic
Vibrations Tighten to torque
piping becoming loose
NOISY MOTOR
Check the setting and condi-
Clattering Boost pressure too low
tion of counter-pressure valve
Under load Replace the cylinders- block
Cavitation Excessive internal leaks and distribution valve assem-
bly

Check pump drive and pump

No supply to the motor
inlet
The circuit does not reach Check condition of safety
THE MOTOR DOES working pressure valve (regulator)
NOT REVOLVE Replace the cylinders block
Excessive internal leaks and distribution valve assem-
bly
The brake stays engaged Check the brake pilot circuit

Check drive speed and condi-

Pump flow is too low
tion of the pump
THE MOTOR DOES
Check condition of cylinders-
NOT REVOLVE AT
Excessive internal leaks block and distribution valve
ITS NORMAL SPEED
assembly
UNDER LOAD
Working pressure is too Check safety valve setting
low pressure (regulator)

Irregular flow Check the pump flow

THE MOTOR RE-
VOLVES IRREGU- Check condition of cylinders-
LARLY Excessive leaks block and distribution valve
assembly

Too high casing pressure Check the leakage circuit and

filter condition
EXTERNAL OIL Seals damaged Replace seals
LEAKS
Check tightening of mounting
Incorrect assembling screws, bleed screws and
unions

800378128J REPAR MS2-18 D/GB 7

008 911 49 BOMAG 753

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Wartungsarbeiten Maintenance
Austauschen des Motors Replacing the motor
Ausbau Removal
• Druck im Arbeitskreis abbauen. • Release the pressure in the supply circuit.
• Leckageleitung am Tank abschrauben, um ein • Disconnect the drain line at the tank level to avoid
Leerlaufen zu verhindern. its siphoning.
• Die Rohre oder Schläuche, die am Motor ange- • Disconnect and plug the pipes or hoses which are
schlossen sind, abklemmen. connected to the motor.
• Drehzahlsensor abklemmen. • Disconnect the speed sensor.
• Die Befestigungsschrauben demontieren und den • Disconnect the mounting screws, and remove the
Motor ausbauen. motor.
• Das Motorgehäuse entleeren. • Drain the casing.

Einbau
Die zum Ausbau angegebenen Arbeitsgänge in umge-
kehrter Reihenfolge ausführen.
Für weitere Informationen beziehen Sie sich bitte auf
folgende Dokumente:
• INSTALLATION MS D/GB (ref: 800078173V)
• INSTALLATION CIRCUITS D/GB (ref: 677777853U)
Installation
Execute the removal operations in the reverse order.
Please refer to the following documentation brochures:
• INSTALLATION MS F/GB (ref: 677777844K)
• INSTALLATION CIRCUITS F/GB (ref: . 677777831V)

8 REPAR MS2-18 D/GB 800378128J

754 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Mechanische Bremslösung Mechanical brake release

Bei bestimmten Reparaturfällen In certain service situations, it may

oder zum Abschleppen der Maschi- be necessary to release the motor
ne muß die integrierte Parkbremse brake.
gelöst werden.

• Stopfen (142) aus der Schutz- • Extract and release the plug 142
kappe (141) herausziehen. (142) from the brake cover (141).

6499

• Schraube im Kolben festziehen • Tighten the screw in the piston

6556

• Mutter so weit anziehen, bis die • And tighten the nut until the
Welle frei dreht. motor shaft turns freely.

6555

Entsprechendes
Bremsen Brakes Kraft N Force [lbf] Equivalent torque [lbf.ft] Mutter Nut
Drehmoment Nm
F02-F04 18000 [4.000] 42 [30.9] M12
F05-F07 20000 [4.500] 47 [34.6] M12
F08 34000 [7.600] 110 [81.1] M16
F11 45000 [10.000] 140 [103] M16
F12 45000 [10.000] 140 [103] M16
F19 45000 [10.000] 140 [103] M16

Nach Bremslösung, einen neuen Stopfen After brake release, mount a new plug
! (142) einbauen. ! (142).

800378128J REPAR MS2-18 D/GB 9

008 911 49 BOMAG 755

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS

Kontrolle der statische Haltebremse. Checking the parking brake efficiency.

Bei fahrbaren Maschinen den Test auf ebenem For a rolling machine, make the test on a hori-
! Grund durchführen. ! zontal ground.

Bremssteuerdruck: mini 12 bar Pilot brake pressure : minimum 12 bar [174 PSI]
Maxi 30 bar. Maximum 30 bar [435 PSI]

• Sich vergewissern, daß der Bremsversorgungs-
druck gleich Null ist,
• Die Bremse über die höchstgelegene Schraube
(112) entlüften,
• Den Motor mit Maximaldruck beaufschlagen,
Make sure that the brake supply pressure is zero,
• Purge the brake using the screw (112) located at
the highest level,
• Supply the motor up to the setting pressure.

• Die Motorwelle darf sich nicht drehen, da andern- • The motor shaft must not turn, otherwise it is nec-
falls die Bremse ausgetauscht werden muß : essary to replace the brake :

! Mehrscheibenbremsen nicht einfahren. ! Do not run multidisc brakes in.

10 REPAR MS2-18 D/GB 800378128J

756 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Reparaturen. Repairs.

Auswechseln der Brems- Replacement of the O-ring

kolbendichtung of the brake piston.
Demontage Disassembly
• Den Motor ausbauen. • Remove the motor.
• Motor auf das Lagerteil stellen. • Place the motor on the bearing
support.

Muttern zum Schutz der

Protect the studs by
! Gewindebolzen wieder
aufsetzen
! reinstalling the nuts

• Schutzkappe (141) abnehmen • Remove and discard the brake

und beseitigen. cover.(141) 141

6500

• O-Ring (143) herausziehen und • Extract and discard the O-ring

143
beseitigen. (143).

6501

• Tellerfeder (108) zusammen- • Compress the washer (108).

drücken:

• Mit Hilfe des Dorns und Ab-
ziehers (siehe Werkzeug Seite
36) (fig 6502)
• Mit Hilfe des Dorns und einer
Schraube Klasse 12.9 (siehe
Werkzeug Seite 36)
• Mit Hilfe des Dorns und einer
Presse (fig 6503). Die Kraft F
beibehalten (siehe Schaubild
Seite 9)
• Using a mandrel and an ex-
tractor (see tools page 36)
(fig 6502)
• Using a mandrel and a
screw class 12.9 (see tools 6502
page 36)
• Using a mandrel and a press
(fig 6503). Respect the force F
(see table page 9)

Einsatzrichtung des Si- Mark the mounting di-

cherungsrings markieren. rection of the snap ring.

6503

800378128J REPAR MS2-18 D/GB 11

008 911 49 BOMAG 757

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
• Sicherungsring (109) mit Hilfe • Remove the snap ring (109)
einer Zange für Innenringe heraus- using internal snap ring pliers. (see
nehmen (siehe Werkzeuge Seite tools page 36)
36)
• Extractor and pliers (fig 6504 6504 6505
• Abzieher und Zange (fig and 6505)
6504 und 6505) • Press and pliers (fig 6506
• Presse und Zange (fig 6506 and 6507)
und 6507)
6506 6507
Bei Verwendung der Pres- If you use the press do

!
se das Lagerteil nicht auf
den Gewindebolzen ab- ! not place the bearing
support on the studs.
stützen.

• Tellerfeder (108) herausziehen. • Extract the washer (108).

108

6508

• Bremskolben (107) herauszie- • Extract the brake piston (107)

hen.

6513

• O-Ring (106) beseitigen. • Discard the O-ring (106).

106

6511

12 REPAR MS2-18 D/GB 800378128J

758 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Wiedereinbau.
Vor dem Wiedereinbau ist unbedingt
sicherzustellen, daß alle Teile, Nuten
und Dichtungs-Auflageflächen sauber
sind.
Es dürfen keine Rost-,
! Schmutz- oder Wasser-
spuren vorhanden sein
Reassembly.
Before reassembling, it is neces-
sary to ensure that all parts, the
surface condition of the piston seal
contact surface and the grooves are
clean.
All traces of rust, mud,
! water must be removed.

Mit Korrosionsschutzfett (siehe

Werkzeug Seite 36) einschmieren:
die Nut, die obere Fläche des
Bremskolbens, die Tellerfeder, den
Sicherungsring und die Auflagefläche
der Kolbendichtung im Bremsgehäuse.
• Neuen O-Ring (106) auf den
Kolben (107) montieren.
Coat with anti-oxidizing grease (see
tools page 36), the grooves, the top
of the brake piston, the spring
washer, the snap ring and the pis-
ton seal contact surface in the
brake body.
• Install a new O-ring (106) on
the piston (107).

Der Ring muß fest an The ring should be tight

! den Kolben gepreßt und
nicht verdreht werden. ! on the piston and not
twisted. 106

6512

• Bremskolben (107) einsetzen. • Install the brake piston (107).

Achtung, wenn die Take care when passing 107

Dichtung über die Nut
! des Sicherungsrings ! the seal over the snap
ring groove.
geführt wird.

6509

• Tellerfeder (108) einlegen. Install the spring washer (108). 108

6513

800378128J REPAR MS2-18 D/GB 13

008 911 49 BOMAG 759

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
• Tellerfeder (108) zusammen- • Compress the spring washer
drücken: (108).

• Mit Hilfe des Dorns und Ab-
ziehers (siehe Werkzeug Seite
36) (fig 6502)
• Mit Hilfe des Dorns und einer
Presse (fig 6503). Die Kraft F
einbehalten (siehe Schaubild
Seite 9)
Bei Verwendung der
• Using a mandrel and an ex-
tractor (see tools page 36)
(fig 6502)
• Using a mandrel and a press
(fig 6503). Respect the force F
(see table page 9) 6502
If you use the press do

!
Presse das Lagerteil
nicht auf den Gewinde- ! not place the bearing
support on the studs.
bolzen abstützen.

6503

• Sicherungsring (109) mit Hilfe • Install the snap ring (109) using
einer Zange für Innenringe gemäß internal snap ring pliers in line with
der bei der Demontage ange- the mark made during disassembly
brachten Kennzeichnung montie- . (see tools page 36)
ren: (siehe Werkzeuge Seite 36) 6504 6505
• Abzieher und Zange (fig • Extractor and pliers (fig 6504
6504 und 6505) and 6505)
• Presse und Zange (fig 6506 • Press and pliers (fig 6506
und 6507) and 6507)
6506 6507

• Neuen, mit Korrosionsschutzfett • Install a new O-ring (143)

eingeschmierten O-Ring (143) in coated with anti-oxidizing grease in 143
die Nut einsetzen (siehe Werkzeu- its groove. (see tools page 36)
ge Seite 36).

6515

• Neue Schutzkappe (141) auf • Place the new cover (141) on

141
den Anschnitt legen. the entry chamfer .

6516

14 REPAR MS2-18 D/GB 800378128J

760 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS
• Schutzkappe mit Hilfe des • Click the cover into place using
Dorns einrasten lassen (siehe the right mandrel. (see tools page
Werkzeug Seite 36). 36).

Sich vergewissern, daß Make sure that the outer

!
der Außenrand des
Schutzkappe in die Nut ! edge of the cover is en-
gaged in the groove.
eingreift ist.
6517

• Neuen Stopfen (142) einsetzen. • Install a new plug (142).

Sich vergewissern, daß Make sure about the con- 142

zwischen Schutzkappe
! und Stopfenrille ein- ! tact between the cover
and the plug groove.
wandfreier Kontakt be-
steht.

6518

• Motor wieder einsetzen. • Install the motor.

800378128J REPAR MS2-18 D/GB 15

008 911 49 BOMAG 761

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS

Auswechseln des Lager- Replacement of the bearing

teiles (070) support (070)
Demontage Disassembly

Motor herausnehmen. Remove the motor.

Motor auf der Bremse oder Ver- Place the motor on the brake or on
schlussplatte abstützen (Motor ohne the end cover (motor without
Bremse). brake).

• Position des Lagerteiles • Mark the position of the

(070) in Bezug auf Nockenring bearing support (070) in relation to 070
(026) und Verteilerdeckel (040) the cam (026) and to the valving
kennzeichnen. cover (040).
025

040
6519

• Schrauben (042) heraus- • Remove the screws (042).

nehmen.

042

6520

• Lagerteil (070) herausneh- • Remove the bearing support

men. (070).
070

6521

• Nockenring (026) heraus- • Remove the cam (026).

nehmen. 026

6524

16 REPAR MS2-18 D/GB 800378128J

762 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS
• O-Ring (027) vom Verteiler- • Discard the O-ring (027)
deckel (041) entfernen. from the valving cover (041). 027

041

6525

• O-Ring (027) vom Lagerteil • Discard the O-ring (027)

(071) entfernen. from the bearing support (071) 027

071

6522

800378128J REPAR MS2-18 D/GB 17

008 911 49 BOMAG 763

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Wiedereinbau Reassembly

Vor dem Wiedereinbau ist unbe- Before reassembling it is necessary

dingt sicherzustellen, daß die Nut to ensure that the groove is clean
sauber ist
Es dürfen keine Rost-, All traces of rust, mud,
! Schmutz- oder Wasser-
spuren vorhanden sein.
! water must be removed

• Neuen, mit Korrosions- • Install a new O-ring (027) 027

schutzfett eingeschmierten O-Ring coated with anti-oxidizing grease
(027) in die Nut des Lagerteiles (see tools page 36) in the groove of
(071) einsetzen (siehe Werkzeuge the bearing support (071).
Seite 36) .

071

6523

• Neuen, mit Korrosions- • Install a new O-ring (027)

schutzfett eingeschmierten O-Ring coated with anti-oxidizing grease
(027) in die Nut des Verteilerdek- (see tools page 36) in the groove of
kels (041) einsetzen (siehe Werk- the valving cover (041)
zeuge Seite 36) .

041

6525

• Nockenring (026) gemäß der • Install the cam (026) in line

bei der Demontage markierten with the marks made during disas- 026
Kennzeichnung montieren. sembling.

Große Ansenkungen in The big chamfers oriented

! Richtung Lagerteil ! towards bearing support

Den Nockenring anhand von zwei Center the cam using two screws 6526
einander gegenüberliegenden (042) diametrically opposite.
Schrauben (042) zentrieren.

18 REPAR MS2-18 D/GB 800378128J

764 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS
• Lagerteil montieren • Install the bearing support

Bei Wellenmotoren For shaft motors the

müssen die Anschlüsse ports must be perpen-
! quer zur Einbauachse
des Motors liegen.
! dicular to the mounting
axis of the motor. (Fig
(Abb. 6521) 6521)

6521

6527

• Befestigungsschrauben (042) • Install and tighten the mounting

einsetzen und mit dem angegebe- screws (042) to the right torque.
nen Drehmoment anziehen. (siehe (see table page 38).
Schaubild Seite 38).

042

6520

• Motor wieder einsetzen. • Install the motor.

800378128J REPAR MS2-18 D/GB 19

008 911 49 BOMAG 765

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS

Auswechseln der Brems- Replacing the brake shoes.

backen

Vor der Demontage kann man die Before disassembling it is possible

Abnutzung der Bremsbeläge durch to make a visual checking of the
die Inspektionsöffnungen kontrollie- brake pads wear via the inspection
ren. ports.

2055

Demontage Disassembly

Das Auswechseln des The same repairs

Bremsbacken und das should be made on
Schleifen der Trommeln each motor of the same
! muß auf allen Motoren ! axle when replacing
shoes and brake
der gleichen Achse vor-
genommen werden. drums.

• Befestigungsmuttern der Felge • Loosen the wheel rim retaining

lösen.
• Maschine auf der Höhe der
auszubauenden Felge hochheben.
• Rad abnehmen (Reifen).
• Mechanische Bremse lösen.
nuts.
• Raise the machine on the side
of the wheel rim to be removed.
• Remove the wheel rim (tyre).
• Release the mechanical brake.

• Trommel (096) abziehen. • Extract the drum (096).

Reibfläche der Trommel Check the friction sur-

überprüfen, die weder tiefe
Rillen (tiefer als 0,2 mm)
noch abnormale Abnut-
! zungserscheinungen auf-
! (deeper than 0,2 mm
weisen darf, sonst muß
sie geschliffen werden.
(Ra 1,6 bis 3,2)
face condition of the
drum which should show
no deep scratches
[0.0078 in]) nor abnormal
096
wear. Otherwise, the
brake drum should be 6528
replaced. (Ra 1.6 to 3.2)

20 REPAR MS2-18 D/GB 800378128J

766 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS
• Rückholfeder (154.a) abbauen. • Remove the return spring
(154.a).

154.a
6529

6530

• Halterungsfedern (154.b) ab- • Remove the retention springs

bauen. (154.b). 1

154.b
2
6531

• Bremsbacken aus der Betäti- • Release the brake shoes from

gungsvorrichtung lösen. the regulating mechanism.

6532

• Rückholfedern (154.c) abbau- • Remove the return springs

en. (154.c).

154.c

6533

800378128J REPAR MS2-18 D/GB 21

008 911 49 BOMAG 767

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
• Bremsbacke (154.1) abbauen. • Remove the brake shoe (154.1)

154.1
6534

• Den mechanischen Bremshebel • Releasing the mechanical brake

vom Bremsseil lösen und Brems- control lever from its cable, remove
backe (154.2) entfernen the brake shoe (154.2)
154.2

6535

6536

22 REPAR MS2-18 D/GB 800378128J

768 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Wiedereinbau Reassembly

Vorrichtung entstau- Remove all dust from the

ben, sich vergewissern, whole assembly. Make
! daß der Radzylinder ! sure there are no leaks at
the wheel cylinder.
dicht ist.

Reibfläche der Trommel überprü- Check the friction surface condition

fen, die weder tiefe Rillen (tiefer als
0,2 mm) noch abnormale Abnut-
zungserscheinungen aufweisen
darf, sonst muß sie geschliffen
werden.
of the drum which should show no
deep scratches (deeper than 0.2 6549
mm) [0.0078in] nor abnormal wear.
Otherwise, the brake drum should
be replaced.

• Den Bremshebel am Bremsseil • Attaching the control lever on

(098) befestigen und Bremsbacke the brake cable (098), install the
(154.2) einbauen brake shoe (154.2)
098

154.2

6536

6535

800378128J REPAR MS2-18 D/GB 23

008 911 49 BOMAG 769

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
• Rückholplatte an die Brems- • Mount the return plate on the
backe (154.2) montieren. brake shoe (154.2)

6537

6538

• Bremsbacke (154.1) einsetzen. • Install the brake shoe (154.1)

6539

• Bremsbacken auf der Betäti- • Position the brake shoes on the

gungseinrichtung positionieren. regulating mechanism.

6532

• Rückholfedern (154.c) einset- Install the return springs (154.c)

zen.

154.c

6533

24 REPAR MS2-18 D/GB 800378128J

770 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS
• Bremsbacken in die Betäti- • Install the brake shoes in the
gungseinrichtung einbauen. regulating mechanism

6532

• Halterungsfedern (154.b) ein- • Install the retention springs

setzen. (154.b).
1

154.b
2 6531

• Rückholfedern (154.a) einset- • Install the return spring (154.a).

zen.

154.a
6530

• Reibungsdurchmesser D der • Measure the brake drum friction

Trommel und der eingesetzten Ba- diameter D and that of the brake
cken messen. shoes, which have been installed.

Durchmesser D diameter
6529

800378128J REPAR MS2-18 D/GB 25

008 911 49 BOMAG 771

 16.5
POCLAIN HYDRAULICS
• Backendurchmesser anpassen,
um bei Bremsen mit mechanischer
Einstellvorrichtung mit Hilfe des ei-
nen Zahnrads (156.1), oder bei
Bremsen mit automatischer Brem-
sennachstellung mit Hilfe der zwei
Zahnräder (156.2 und 156.3), das
nötige Spiel zwischen Belag und
Trommel zu erzielen. In diesem
Fall muß die Wirkung auf die Zahn-
räder symmetrisch (a) sein. Den
Hebel (156.4) muss zu diesem
Zweck freigängig sein.
MS/MSE 02 ..... 18
• Adjust the brake shoes diame-
ter to obtain correct clearance be- 1 5 6 .4
tween the brake padding and the
1 5 6 .2 1 5 6 .3
drum using the adjusting wheel
(156.1) for brakes equipped with
mechanical adjustment system or
two adjusting wheels (156.2 and
a a
156.3) for brakes equipped with
automatic clearance adjustment. In
this case, the adjusting wheels 6540
should be adjusted symmetrically
(a). Release the lever slightly
(156.4) to enable this operation to
take place.

Trommeldurchmesser (mm)
Bremsen Drum diameter [in] Total Spiel (mm)
Brake Total clearance [in]
nominal maximum
250 x 60 250 [9.84] 252 [9.92] 0.55 [0.02]
270 x 60 270 [10.63] 272 [10.70] 0.80 [0.03]
325 x 80 325 [12.79] 327 [12.87] 0.80 [0.03]
350 x 60 350 [13.78] 352 [13.85] 0.80 [0.03]

• Trommel aufsetzen und über- • Install the drum, check that it

prüfen, ob sie frei dreht. can turn freely.

6528

• Wenn nötig, den Radzylinder • Bleed the wheel cylinder, if

entlüften. necessary.
• Felge montieren. • Install the wheel rim.
Siehe Dokument INSTALLATION See documentation INSTALLATION
MS D/GB (ref: 800078173V) MS F/GB (ref 677777844K )

26 REPAR MS2-18 D/GB 800378128J

772 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Auswechseln des Nocken- Replacement of the cam

rings (026) (026)

Demontage
Dazu die im Kapitel « Auswechseln
des Lagerteils » unter « Demontage »
beschriebenen Arbeiten ausführen,
Seite 16
Wiedereinbau
Dazu die im Kapitel « Auswechseln
des Lagerteils » unter " Wiederein-
bau " beschriebenen Arbeiten ausfüh-
ren, Seite 18.
Allerdings muß bei Motoren mit 2
Schluckvolumen mit einem
Schluckvolumenverhältnis über
oder unter 2 die Winkelposition be-
rücksichtigt werden.
Beispiel: Motor MS18, Schluckvolu-
men 1747-1049-698
3
Kleines Schluckvolumen: 698 cm
Buchstabe P
3
Mittleres Schluckvolumen: 1 049 cm
Buchstabe M
Die Buchstaben P oder M müssen
sich in der Achse befinden und in
Richtung des Schiebers für das
Wechseln des Schluckvolumens
zeigen, auf der der Nockenring auf
dem Lagerteil befestigt ist.
Disassembly
Do operations described in chapter
"replacement of the bearing sup-
port" section "disassembly" page 16
Reassembly
Do operations described in chapter
"replacement of the bearing sup-
port" section "reassembly" page 18.
The angular position of the cam
must be respected on dual dis-
placement motors with a displace-
ment ratio different from 2.
Example : Motor MS18 with dis-
placement 1747-1049-698.
3
Small displacement : 698 cm
[42.59 cu.in] letter P
3
Medium displacement : 1049 cm
[64.01 cu.in] letter M.
The letter P or M must be located in
the axis and towards the displace-
ment change spool, with the blind
hole towards the fixing of the cam
on the bearing support.

M P

M P
MS08
MSE08
A R A R
MS18
MSE18

P M

M P

A R A
MS11
MSE11

P M 2035

800378128J REPAR MS2-18 D/GB 27

008 911 49 BOMAG 773

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS

Auswechseln des komplet- Replacement of the cylin-

ten Zylinderblocks (010) ders block assembly (010)

Demontage Disassembly

Dazu die im Kapitel « Auswechseln Do operations described in chapter

des Lagerteils » unter « Demontage » "replacement of the bearing sup-
beschriebenen Arbeiten ausführen, port" section "disassembly" page 16
Seite 16

• Nach Demontage des Nocken- • After removing the cam, re-

rings den Zylinderblock ausbauen. move the cylinders block.

6541

Wiedereinbau Reassembly

• Neuen O-Ring (027) einsetzen. • Install a new O-ring (027).

6542

• Kompletten Zylinderblock (010) • Install the cylinders block as-

einsetzen. sembly (010).

6541

• Dazu die im Kapitel • Do operations described in

« Auswechseln des Lagerteils » unter chapter "replacement of the bearing
"Wiedereinbau" beschriebenen Ar- support" section "reassembly" page
beiten ausführen, Seite 18 18

28 REPAR MS2-18 D/GB 800378128J

774 BOMAG 008 911 49

MS/MSE 02 ..... 18
Auswechseln des Verteilers
(047).
Demontage
• Dazu die im Kapitel
« Auswechseln des kompletten Zy-
linderblocks (010)» unter
« Demontage » beschriebenen Ar-
beiten ausführen, Seite 28.
Position des Verteilers
(047) in Bezug auf Ver-
! teilerdeckel (041) kenn-
zeichnen. (Motor mit 2
Hubvolumen).
• Den Verteiler (047) durch An-
heben an den Ausrichtungszapfen
oder am Flansch vom Verteilerdek-
kel (041) abmontieren.
Den Verteiler vor Staub
! schützen.
• Federn (052) ausbauen.
• Dichtungen und Gegendichtun-
gen (048) vom Verteilerdeckel
(041) herausziehen und beseitigen.
Wiedereinbau
Es dürfen keine Rost-,
! Schmutz- oder Wasser-
spuren vorhanden sein.
• Neue Dichtungen und Gegen-
dichtungen (048) ölen und einset-
zen; dabei die Gegendichtungen so
wenig wie möglich verformen.
• Die Federn (052) in ihr zuvor
mit Fett gefülltes Gehäuse einset-
zen.
• Die Dichtungsauflageflächen
des Verteilers (047) fetten.
• Den Verteiler(047) in den Ver-
teilerdeckel (041) drücken
800378128J
008 911 49
16.5
POCLAIN HYDRAULICS
Replacement of the valving
(047).
Disassembly
• Do operations described in
chapter "replacement of the cylin-
ders bloc assembly (010)" section
"disassembly" page 28.
Mark location to the
valving (047) in relation
! to the valving cover
(041) (Dual displace-
ment motor).
• Separate the valving (047) from
the cover (041) by levering at the
indexing pins or at the flange.
2031
Protect the valving from
! dusts.
• Remove the springs (052).
• Remove and discard the seals
and back-up rings (048) from the
cover (041).
Reassembly
All traces of rust, mud,
! water must be removed.
• Lubricate and install new seals
and back-up rings (048), ensuring
the back up rings are twisted as lit-
tle as possible.
1135
• Place the springs (052) in their
housings, previously filled with
grease.
• Lubricate the faces of the seals
of the valving (047).
• Press the valving (047) into the
cover (041).
REPAR MS2-18 D/GB 29
BOMAG 775
 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS

Die Einbaurichtung des Respect the assembly

Verteilers (047) in bezug sense of the valving
! auf den Verteilerdeckel ! (047) in relation to the
cover (041).
(041) beachten).

Den Einsatz des Vertei-

Do not force when in-
lers (047) in den Vertei-
! lerdeckel (041) nicht
!
stalling the valving
(047) into the cover
forcieren. (041).

Montage der Verteileraus- Valving assembly type sin-

führung 1C (konstanter gle displacement motor.
Hubvolumen).
• Keine besondere Montagerich- • No particular assembly sense.
tung.

041
047 2031

Montage der Verteilerausfüh- Valving assembly type Dual

rung 2C (umschaltbarer displacement motor.
Hubvolumen).

• Den gewählten Buchstaben, der • Write the chosen letter indicate

die Drehrichtung anzeigt, gegen- the rotation sense in front of the
über dem Steuerkolben (053) an- displacement change spool (053).
ordnen.

POSITIONIERUNG DES VERTEI- VALVING POSITIONING

LERS
G/L Links G/L Left

041

R 047
L
053
6758
R A
053
3 2 2 7

30 REPAR MS2-18 D/GB 800378128J

776 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

D/R Rechts D/R Right

047

R L 041

6757
R A
053
3 2 2 8

• Falls kein Buchstabe vorhanden • If there is no letter, do the in-

ist, die Ausrichtung anhand der beim dexing according to the marks
Ausbau festgelegten Markierungen made during disassembly.
vornehmen.

• Dazu die im Kapitel • Do operations described in

« Auswechseln des kompletten Zy- chapter "replacement of the cylin-
linderblocks (010)» unter ders block" section "reassembly"
« Wiedereinbau » beschriebenen Ar- page 28.
beiten ausführen, Seite 28.

Motoren SE02 und S05 Situation of SE02 and S05 mo-

tors

SE02 Motor :
SE02 motor : G/L Links D/R Rechts
G/L Left D/R Right

6 9 5 9
6959
S05 Motor :
S05 motor
G/L Links D/R Rechts
G/L Left D/R Right

053

6 9 4 8
6948

800378128J REPAR MS2-18 D/GB 31

008 911 49 BOMAG 777

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS

Auswechseln der Deckel- Replacement of the O-ring

dichtung (045) (045) of the end cover

Demontage Disassembly
•
• Motor auf Lagerteil stellen • Place the motor on the bearing
(Muttern sind zum Schutz der Ge- support (fitted with nuts for studs
windebolzen aufgesetzt) protection)
• Schrauben (066) herausneh- • Remove the screws (066)
066
men.

6543

• Verschlussplatte abnehmen. • Remove the end cover

6544

• O-Ring (045) entfernen. • Discard the O-ring (045)

045
057

6545

• Wenn Motor mit 2 Hubvolu- • Discard the O-ring (057) if the

men, O-Ring (057) entfernen motor has 2-displacement

6546

32 REPAR MS2-18 D/GB 800378128J

778 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Wiedereinbau Reassembly

• Neuen O-Ring (045) einsetzen. Install a new O-ring (045).

6547

• Wenn Motor mit 2 Hubvolu- • Install a new O-ring (057) if the

men, neuen O-Ring (057) einset- motor has 2-displacement. If not go
zen, andernfalls zum nächsten to the next section
Schritt übergehen

6548

• Verschlussplatte montieren. • Install the end cover

6544

• Schrauben (066) einsetzen und • Install and tighten the screws

mit entsprechendem Drehmoment (066) to the right torque (see table
anziehen (siehe Schaubild Seite 38) page 38)

6543

800378128J REPAR MS2-18 D/GB 33

008 911 49 BOMAG 779

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS

Auswechseln des Dreh- Replacing the sensor (op-

zahlsensors (Option) tional)
Demontage Disassembly

• Stecker (161.3) abziehen • Disconnect the connector

(161.3)

6550

• Schraube (165) aufschrauben • Unscrew and remove the screw

und ausbauen (165) 165

6551

• Sensor (161) mit dem Träger • Extract the sensor (161) with its
166
(166) abziehen support (166)

161

6552

34 REPAR MS2-18 D/GB 800378128J

780 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Wiedereinbau Reassembly

Der Dichtung (164) auf Make sure that the seal

Sauberkeit der Auflage- mounting surface (164)
! fläche dem Verteiler- ! on the valving cover
(041) is clean.
deckel (041) prüfen.

• Neuen Haltering (163) und • Install the new brake washer

neue Dichtung (164) auf den Sen-
sor (161) mit seiner Distanzscheibe
(167) schieben.
• Den Sensor in die Halterung
(166) stecken, so daß die Dichtung
(164) korrekt in ihrer Aufnahme
sitzt.
(163) and the new seal (164) on the
sensor (161) fitted with its adjusting
sticker (167).
• Push the sensor assembly into
the support (166) until the seal
(164) is in its housing.

6552

• Sensor (041) in die Bohrung • Push the sensor into the valving
des Verteilerdeckels bis zum Kon- cover (041) until it comes in contact
takt mit dem Zylinderblock (011) with the cylinders block (011),
schieben.

2064

Die Kerbe im Steckeranschluss des the notch of the sensor should be

Sensors muss radial zur Mitte des oriented towards the center of the
Motors (Richtung Welle) zeigen. motor. 1 5 ° m a x i

1 5 ° m a x i
6558

• Schrauben (165) einsetzen und • Install and tighten the screw

mit entsprechendem Drehmoment (165) to the right torque (see table
anziehen (siehe Schaubild Seite page 38)
38)

6551

• Stecker (161.3) wieder an- • Reconnect the connector

schließen. (161.3).

6550

800378128J REPAR MS2-18 D/GB 35

008 911 49 BOMAG 781

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Werkzeug-Liste Tooling inventory

Standard Werkzeug Standard tools

Hollow head
• Innensechskant-Schlüssel 5 6 8 10 12 14
wrench
• Ring-/Maulschlüssel für
Hex head wrench 13 17 19 22 24
Sechskantschraube
• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 bis 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 bis 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 bis 800 N.m [120 à 600 lbf.ft]
Auto-top 2000 Anti-oxidizing Leuchtend grüne Farbe / fluores-
• Korrosionsschutzfett
origine AGIP grease cent green color

Internal snap ring

• Zange für Innenringe FACOM 499.32
pliers

• Abzieher FACOM U 20 B Extractor

6553
• Sechskantschlüssel für
Hex head wrench 13 17 19 22 24
Innensechskantschraube
• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]

36 REPAR MS2-18 D/GB 800378128J

782 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Spezialwerkzeuge Special tools

Ø A
Ø B
• Montagewerkzeug
zum Anheben der • Mandrel for reassembling the
Schutzkappe oder zum brake cover or to compress the

F
E

G
Komprimieren der Tel- spring washer.
lerfeder.
Ø C
Ø D

0759

ØA ØB ØC ØD E F G
mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch]
F02
110 [4.3] 100 [4.0] 125 [4.9] 135 [5.3]
F03
F04 M12 50 [1.96] 10 [0.39] 20 [0.78]
F05 125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25]
F07
F08
125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25] 50 [1.96] 10 [0.39] 20 [0.78]
F09
F11
50 [1.96] 20 [0.78]
F12 M16
F18 190 [7.48] 180 [7.08] 205 [8.07] 215 [8.46] 10 [0.39]
F19 70 [2.75] 30 [1.18]
F21

• Rohr zum Festsetzen

[0 .9 8 " d ia ]

Tube to immobi-
Ø 2 5

Ø 1 6

des Motors lize the motor [0 .6 2 " d ia ]

5 5
[2 .1 6 " ]

7 0 0
[2 7 .5 5 " ]

M 1 2 x 1 2 0 M 1 6 x 1 2 0
c l. 1 0 .9
H M 1 2 H M 1 6
Z 1 2 N

A = 2 0 0 A = 2 8 0 A
• Werkzeuge zur me- Tools for me-
F 0 2 F 1 1
chanischen Bremslö- chanical brake F 0 3 F 1 2
sung. release F 0 4 F 1 8
F 0 5 F 1 9 Ø 1 6 .5
F 0 7 F 2 1 [0 .6 4 ]
F 0 8
F 0 9
6 0 x 3 0 5 0 x 5

800378128J REPAR MS2-18 D/GB 37

008 911 49 BOMAG 783

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Anziehdrehmomente Tightening torques
Nm ± 10% in [lbf.ft] ± 10%
(Gemäß Norm DIN 912) (According to the standard DIN 912)

Größe Size 8.8 10.9 12.9 8.8 10.9 12.9

M6 10 14 17 7.5 10 12.5
M8 25 35 41 18.4 26 30
M10 49 69 83 36 51 61
M12 86 120 145 63.4 88.4 107
M14 135 190 230 100 140 170
M16 210 295 355 155 218 262
M18 290 405 485 214 299 358
M20 410 580 690 302 428 509

38 REPAR MS2-18 D/GB 800378128J

784 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Ersatzteile Spare parts list

Nummer Bezeichnung Item Description
010 Kompletter Zylinderblock 010 Cylinders-block assembly
012 Kompletter Kolben Cl. 0 012 Piston Cl 0 assembly
013 Kompletter Kolben Cl. 1 013 Piston Cl 1 assembly
015 Reparatursatz 015 Repair kit

026 Kompletter Nockenring 026 Cam assembly

027 O-Ring 027 O-ring

040 Komplettes Verteilerdeckel 040 Valving cover assembly

041 Verteilerdeckel 041 Valving cover part
042 Schraube 042 Screw
043 Dichtungsring 043 Seal washer
044 Schraube 044 Screw
045 O-Ring 045 O-ring
047 Verteiler 047 Valving
048 Dichtungssatz 048 Seal kit
050 Stopfen 050 Plug
051 O-Ring 051 O-ring
052 Feder 052 Spring
053 Umschaltkolben 053 Valve spool
054 Scheibe 054 Washer
055 Sicherungsring 055 Snap ring
056 Feder 056 Spring
057 O-Ring 057 O-ring
059 Stift 059 Pin

065 Kompletter Verschlussplatte 065 End cover assembly

066 Schraube 066 Screw
067 Dichtring 067 Sealing ring

070 Komplettes Lagerteil 070 Bearing support assembly

071 Lagerteil 071 Bearing support part
072 Innerer Lippendichtring 072 Radial lip seal
073 Rollenlager 073 Roller bearing
074 Rollenlager 074 Roller bearing
075 Scheibensatz 075 Set of shims
076 Stützring 076 Thrust ring
077 Sicherungsring 077 Snap ring
078 Äußerer Dichtring 078 Lip seal
079 Abweiser 079 Deflector
081 Dichtungsträger 081 Seal support
087 Passfeder 087 Key
090 Welle 090 Shaft
091 Radbolzensatz 091 Set of studs
096 Bremstrommel 096 Drum brake
097 Schraube 097 Screw
098 Bremsseil 098 Brake cable
099 Sicherungsring 099 Snap ring
154 Komplette Bremsbacke 154 Brake shoe sub-assembly
155 Kompletter Radzylinder 155 Brake cylinder sub-assembly
156 Gegenhalter 156 Brake adjustment

800378128J REPAR MS2-18 D/GB 39

008 911 49 BOMAG 785

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Nummer Bezeichnung Item Description
100 Komplette Bremse 100 Brake assembly
101 Bremsgehäuse 101 Brake body
102 Schraube 102 Screw
106 O-Ring 106 O-ring
107 Kolben 107 Brake piston
108 Tellerfeder 108 Spring washer
109 Sicherungsring 109 Snap ring
110 Welle 110 Brake shaft
111 Dichtsatz Bremswelle 111 Seal
112 Schraube 112 Screw
113 Dichtungsring 113 Seal washer
135 Satz Bremslamellen 135 Brake kit
141 Schutzkappe 141 Cover
142 Stopfen 142 Plug
143 O-Ring 143 O-ring

150 Drehzahlsensor-Vorbereitung 150 Speed sensor predisposition

152 Scheibe 152 Washer
153 Scheibe 153 Washer

160 Kompletter Sensor 160 Speed sensor assembly

161 Sensor 161 Speed sensor part
162 Mutter 162 Nut
163 Scheibe 163 Washer
164 Dichtung 164 Seal

Als Satz lieferbare Baugruppe Sub-assembly sold assembled

40 REPAR MS2-18 D/GB 800378128J

786 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 41

008 911 49 BOMAG 787

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS

Motoren mit konstantem Hubvolumen MS, MSE 02-05-08-11-18.

Single displacement motors MS, MSE 02-05-08-11-18.

0987

42 REPAR MS2-18 D/GB 800378128J

788 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Dichtungssatz
Seal kit 0988

800378128J REPAR MS2-18 D/GB 43

008 911 49 BOMAG 789

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS

Motoren mit umschaltbarem Hubvolumen MS, MSE 02-05-08-11-18.

Dual displacement motors MS, MSE 02-05-08-11-18.

0990

44 REPAR MS2-18 D/GB 800378128J

790 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

Dichtungssatz
Seal kit
0989

800378128J REPAR MS2-18 D/GB 45

008 911 49 BOMAG 791

 16.5 MS/MSE 02 ..... 18
POCLAIN HYDRAULICS

46 REPAR MS2-18 D/GB 800378128J

792 BOMAG 008 911 49

MS/MSE 02 ..... 18 16.5
POCLAIN HYDRAULICS

800378128J REPAR MS2-18 D/GB 47

008 911 49 BOMAG 793

16.5 MS/MSE 02 ..... 18

China España & Portugal

POCLAIN HYDRAULICS BEIJING rep. office POCLAIN HYDRAULICS SPAIN S.L.
Unit A0808, Hui Bin Officies Gran Via Carlos III no84 – 1o 3a
No.8 Beichendong St. 08028 BARCELONA
BEIJING 100101 ESPAÑA
CHINA Tel.: 349 3 409 54 54
Tel.: 86 10 6499 3988 Fax: 349 3 490 21 79
Fax: 86 10 6499 3979 e-mail: info-espana@poclain-hydraulics.com
e-mail: info-china@poclain-hydraulics.com

France

POCLAIN HYDRAULICS SRO POCLAIN HYDRAULICS France SAS

Kšírova 186 B.P. 106
61900 BRNO 60411 VERBERIE CEDEX
FRANCE
Tel.: 420 5 43217830 Tel.: 33 3 44 40 77 77
Fax: 420 5 43217818 Fax: 33 3 44 40 77 91
e-mail: info-ceskarepublika@poclain-hydraulics.com e-mail: info-france@poclain-hydraulics.com

Deutschland Japan
POCLAIN HYDRAULICS GMBH POCLAIN HYDRAULICS KK
Bergstrasse 106 5-4-6 Kugenumashinme
64319 PFUNGSTADT FUJISAWA 251
DEUTSCHLAND JAPAN
Tel.: 49 6157 9474 0 Tel: 81 466 50 4400
Fax: 49 6157 9474 74 Fax: 81 466 50 4422
e-mail: info-deutschland@poclain-hydraulics.com e-mail: info-japan@poclain-hydraulics.com

Italia United Kingdom

POCLAIN HYDRAULICS SRL POCLAIN HYDRAULICS LTD
Via Svizzera 4/A Nene Valley Business Park
41012 CARPI (MODENA) Oundle
ITALIA PETERBOROUGH, Cambs PE8 4HN
ENGLAND
Tel.: 390 59 64 22 44 Tel.: 44 1832 273773
Fax: 390 59 64 20 44 Fax: 44 1832 274990
e-mail: info-italia@poclain-hydraulics.com e-mail: info-uk@poclain-hydraulics.com

Nederland USA
POCLAIN HYDRAULICS BENELUX BV POCLAIN HYDRAULICS INC.
Penningweg 32C 7900 Durand Avenue
4879 AM ETTEN-LEUR P.O. BOX 801
NEDERLAND STURTEVANT, WI 53177
USA
Tel.: 31 76 5021152 Tel.: 1 262 554 6739
Fax: 31 76 5012279 Fax: 1 262 554 4860
e-mail: info-netherlands@poclain-hydraulics.com e-mail: info-america@poclain-hydraulics.com

POCLAIN HYDRAULICS INDUSTRIE S.A.S. au capital de 85 124 000 Francs

B.P. 106
60411 VERBERIE CEDEX - France
Tel.: 33 3 44 40 77 77
Fax: 33 3 44 40 77 99
e-mail: info@poclain-hydraulics.com
www.poclain-hydraulics.com
Siège social: Route de Saint Sauveur
VERBERIE (OISE)
R.C.S. Senlis B 414 781 823
Siret 414 781 823 00011

794 BOMAG 008 911 49

 16.6 Axle DANA 192

008 911 49 BOMAG 795

16.6 Axle DANA 192

796 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 797

16.6 Axle DANA 192

798 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 799

16.6 Axle DANA 192

800 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 801

16.6 Axle DANA 192

802 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 803

16.6 Axle DANA 192

804 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 805

16.6 Axle DANA 192

806 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 807

16.6 Axle DANA 192

808 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 809

16.6 Axle DANA 192

810 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 811

16.6 Axle DANA 192

812 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 813

16.6 Axle DANA 192

814 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 815

16.6 Axle DANA 192

816 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 817

16.6 Axle DANA 192

818 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 819

16.6 Axle DANA 192

820 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 821

16.6 Axle DANA 192

822 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 823

16.6 Axle DANA 192

824 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 825

16.6 Axle DANA 192

826 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 827

16.6 Axle DANA 192

828 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 829

16.6 Axle DANA 192

830 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 831

16.6 Axle DANA 192

832 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 833

16.6 Axle DANA 192

834 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 835

16.6 Axle DANA 192

836 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 837

16.6 Axle DANA 192

838 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 839

16.6 Axle DANA 192

840 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 841

16.6 Axle DANA 192

842 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 843

16.6 Axle DANA 192

844 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 845

16.6 Axle DANA 192

846 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 847

16.6 Axle DANA 192

848 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 849

16.6 Axle DANA 192

850 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 851

16.6 Axle DANA 192

852 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 853

16.6 Axle DANA 192

854 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 855

16.6 Axle DANA 192

856 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 857

16.6 Axle DANA 192

858 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 859

16.6 Axle DANA 192

860 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 861

16.6 Axle DANA 192

862 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 863

16.6 Axle DANA 192

864 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 865

16.6 Axle DANA 192

866 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 867

16.6 Axle DANA 192

868 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 869

16.6 Axle DANA 192

870 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 871

16.6 Axle DANA 192

872 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 873

16.6 Axle DANA 192

874 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 875

16.6 Axle DANA 192

876 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 877

16.6 Axle DANA 192

878 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 879

16.6 Axle DANA 192

880 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 881

16.6 Axle DANA 192

882 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 883

16.6 Axle DANA 192

884 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 885

16.6 Axle DANA 192

886 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 887

16.6 Axle DANA 192

888 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 889

16.6 Axle DANA 192

890 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 891

16.6 Axle DANA 192

892 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 893

16.6 Axle DANA 192

894 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 895

16.6 Axle DANA 192

896 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 897

16.6 Axle DANA 192

898 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 899

16.6 Axle DANA 192

900 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 901

16.6 Axle DANA 192

902 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 903

16.6 Axle DANA 192

904 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 905

16.6 Axle DANA 192

906 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 907

16.6 Axle DANA 192

908 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 909

16.6 Axle DANA 192

910 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 911

16.6 Axle DANA 192

912 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 913

16.6 Axle DANA 192

914 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 915

16.6 Axle DANA 192

916 BOMAG 008 911 49

Axle DANA 192 16.6

008 911 49 BOMAG 917

16.6 Axle DANA 192

918 BOMAG 008 911 49

 17 Circuit diagrams

008 911 49 BOMAG 919

Circuit diagrams
l
The circuit diagrams valid at the date of printing are
part of these repair instructions.
l The circuit diagrams valid for the machine serial
number can be found in the spare parts catalogue
for the machine.

920 BOMAG 008 911 49

 17.1 Wiring diagram

008 911 49 BOMAG 921

17.1 Wiring diagram

Wiring diagram 582 702 06 from serial number

101 583 091 001 BW 211 D-4

101 583 101 001 BW 211 PD-4
101 582 461 001 BW 213 PD-4
101 582 501 167 BW 213 D-4
101 583 081 001 BW 213 D-4
101 583 131 001 BW 213 PD-4
101 582 721 113 BW 219 D-4
101 582 731 001 BW 219 PD-4

922 BOMAG 008 911 49

 Inhaltsverzeichnis: BW 177..219 D−4/D−40

008 911 49
table of contents: BW 177..219 D−4/D−40
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
Wiring diagram

001 582 702 09 Stromlaufplan Circuit Diagram

002 582 702 09 Versorgung, Starten, Motordrehzahl supply, starting unit, engine−speed
003 582 702 09 Motor−Heizflansch, Signalhorn, Geschwindigkeit−Anz. engine heating−flange cont., warning horn, speedometer
004 582 702 09 Bremse, Rückfahrwarneinr., Anzeige brake, back up alarm, indicator
005 582 702 09 Fahrstufen, Sitzkontaktsch., Vibration speed−ranges, seat−switch, vibr.
006 582 702 09 ZA Messtechnik option measurement equipm.
007 582 702 09 BOMAG Compaction Management BCM BOMAG Compaction Management BCM
008 582 702 09 ZA Beleuchtung und StvZO opt. illumination and StvZO
009 582 702 09 ZA Kabine, Beleuchtung, Radio, Tachograph opt. cabin, headlights, radio, tachograph
010 582 702 09 ZA Kabinenheizung, Klimaanlage, Zusatzheizung opt. cabin−heater, air conditioning, add. heater
101 582 702 09 Bauteilliste component listing

BOMAG
16.11.2005
001 001
Vogt Stromlaufplan 582 702 09
16.11.2005
17.1

923
circuit diagram 001
Seis
924
30 6:1
K30
9:2
15:54
17.1

2:10 K11 30
X1
X1:15E 2:10
17E
87 87a
1

X1:9
F13 1

X1:10
F105
30A
2 20A
X1:15A 2 K11/87 3:1

X1
X37:A
17A X1
S00 30 X1:30E

X36:B

X36:A
30 27E
B+
2:11 K35 1
2:16 F14 1 F39
15A 15A

4qmm
Startschalter 87a 87 2 2
starting switch 15 54 58 19 17 50a
X1 X1 X1:30A
15:54 27A
2:13 80 K32:86
X1 9:2
79 S120 11 23
30 F14:2
5:9
K114
X37:B 2:14 S01:21
X1:3 X1:4 5:9
nur ohne Sitzkontaktschalter
without switch seat−contact

V01
3:2 87a 87

switch engine speed

30 12 24

Schalter Motordrehzl
2 1 K11:86 K05 X1:151
4:5
6:5

30(3)

main fuse
125mA
4:3

Hauptsicherung
K14 21 11 31 ?

heating−flange
K61 87 87a

Sicherung Heizflansch
3:5 86 1 K61 30 S01
87(4) 86
F48 2 F00 2 R10 2:5 22 12 32 ?
82 OHM K35
87 87a NOT−AUS
85 2 K05/87

125A
125A
1 1 3:2 85 Emerg.−Stop
X1:53

BOMAG
4:13 X1:152
K61/85
6:2 B+ X1 X1 X1 X1 30
X1:60 K22
X1 D+ MESX 2:5 7 8 58 59
1 4:9
G03 + G01 + X1 2x2.5qmm 87 87a
65 X38:A 2

nur bei Klimaanlage

B+ X1
− − D+ 3.9A
81 V47 X1

only acc.to air conditioning

G02

125mA
50A / 10A
30 50 1 AW 54
86
AUX

86 86 86 Y01 2 + HW 1

167A
K09 Y13
B− W M01 K114 Y120
1 1 K36 K11 M
S30 W 1 70A/1A − 2

31−1
R19 85
X1:66 85 85 85 −
2 X1
X1 X1 55

nur bei BW 219D−4 und D−40 USA Version, sonst Option

only at BW 219 D−4 and D−40 USA version, otherwise option
X1:55 X1:56
2
3.8A

62 63

Option
option
X1:168

31 31 3:1
2:8 4:4 10:7 2:18 2:16 2:13

Trennschalter Batterie
break switch battery
Heizflansch Batterie Batterie Generator Starter Startmehrmenge Hubmagnet Drehzahl Kraftstoffabschaltug
heating−flange battery battery generator starter start boost fuel sol. engine speed fuel shut off

16.05.2005
1 1

008 911 49
Wiring diagram

Vogt Versorgung, Starten, Motordrehzahl 582 702 09

16.05.2005
Seis supply, starting unit, engine−speed 002
 2:20 K11/87 K11/87 4:1

F24:2
4:10
4:19
GLÜH
2:10 K11:86 X1

008 911 49
52
2:13 K05/87 X1
78 X1
X1 28E
Wiring diagram

75
F23 1
10A
2 X1
X1 92
28A

X1:155 +
15/54
Lern
Test
OUT+

Modul Geschw. A05 P04

13 23 modul speedometer
speedometer

5 2 7 1 S03 −
−
in
Geschwindigkeitsanz.

X1
OUT−

14 24
A13
93
X1 X1
3 4 6 97 98

Anbau im Motorbereich
X1 X1 ZA Geschwindigkeitsanzeige

assembled in engine−area
101 102 option speedometer

Modul Heizflanschsteuerung
modul heating−flange−control
1

Taster Signalhorn
push but. warning horn

BOMAG
X1:171
K14

2
2
+

V21
V22
dir. X1:173

4.2A
4.2A

1
1
B60 DIR MESX 6:2

Relais Heizflansch
Nur bei BW 219 D−4 und D−40 USA Version, sonst Option
only at BW 219 D−4 and D−40 USA version, otherwise option
speed

relais heating−flange
B11 1 B11 1 SPEED MESX 6:2

Anbau im Motorbereich
assembled in engine−area
− X1:172
2 SPEED TAC
9:6
1 2 2
nicht bei D−40/BW211D−4 ohne SN1
not at D−40/BW211D−4 ohne SN1

B113
2

X1 X1 X1 X1
57 64 99 100 X1:174

2:20 31 31 4:1

Kühlmitteltemperatur Signalhorn Signalhorn Sensor Achse

collant temperature warning horn warning horn sender axle

nur bei ZA Messtechnik, Geschw.−Anzeige und Tachograph

only at opt. measurement−equ., speedometer and tachograph

16.11.2005
1 1 582 702 09
Vogt Motor−Heizflansch, Signalhorn, Geschwindigkeit−Anz.
16.11.2005
17.1

925
Seis engine heating−flange cont., warning horn, speedometer 003
926
3:20 K11/87 K11/87 5:1
Zentralstecker Sammelanzeige (Ansicht von hinten)
X1 X1:31E mainplug monitoring module (view from backside)
29E
17.1

9 8 7 6 5 4 3 2 1
1 1
F25 F24
10A 10A
2 2 X5:1−20
Sammelanzeige 201918 1716151413 121110
X1
X1:31A monitoring module
29A 6 Vorglühen
A15 GLÜH
F24:2 3:5
3:15 Warnbl.
7 BL−W
8:16
X1 15/54 Blinker rechts
20 FUEL 19 BL−R
HOURS 8:17
X1:156 86 OUT2 Blinker links
9 18 BL−L
F25:2 8:17
5:2 OUT1 Sitz
1 12 A68/6
5:9
Bel.
8 4
X12 X13 8:5
1 1 BEL 10 3

geöffnet in 0
Position (Bremse ein)
BR/BN 30 BR/BN
30 2 14 11 13 15 17 16 5

D+
K48 K26

GND
B13 B14
4:2 4:6

Bremse

5:9
5:9

Luftfilter
87a 87 87a 87

Tankanzeige
BL/BU SW/BK BL/BU SW/BK
Motoröldruck

Öltemperatur

Hydraulikölfilter

D+
Wasserabscheider

30 X1 X1 X1
B06:1
Kühlmittelfüllstand

K36 69 87 76

Initiator Farhebel"0
2:7

Initiator Vorw. und Null

87a 87 X1 X1 X1 X1
X12 3 X12 2 X13 3 X13 2 110 71 X1:77 X1:72 111 112
X1 X1 X1 X1 X1
K48:87A 106 67 X1:74 73 X1:68 107 108
4:13

BOMAG
X1:147 K26/87A

proximity switch travel lever "0"−position

5:9

proximity switch forwards and "0"−position

11

S01 X1

K61/85
2:18 109 2:6
X1:61

12 SITZWARN.
K48/86 5:9 5:9 X1
X1:150 X1 X1
105
X1:148 X1:153 114 90 K48:87A X8 1 X8 2
6:2 4:3
X10

300mA
X1:113 BRAKE MESX 2 X21:1
Sensor

X1 or B21 3 B03 3 2 1 B06 1 B55 B124

2.5A
125mA
X9 89 +
86 86 Y04 86 1 86 R03
K48 K05 1 K26 K22 P P _t P Q
H14+ + bl 4 4 B30 2 −
− P

H07
85 85 2 85 X9 85 X10 X21:2
2 3 X1:117 X1:57

125mA
125mA
X1:149 X1 X1:82 X1:117
X1:117 129 X1:117
3:20 31 31 5:1

4:3 2:11 4:8 2:18 nicht bei D−40

not at D−40 nicht bei D−40/BW177 D−4
not at D−40/BW177 D−4

Magnetventil Bremse Rückfahrwarnsummer Warnsummer Störung Tankgeber Luftfilter Motoröldruck Sensor Wasserabschei
solenoid valve brake buzzer back up alarm buzzer failure sender fuel
air cleaner engine oil pressure sens. water separator
Hydraulikölfilter Öltemperatur Kühlmittelstand
Resist. buzzer hydraulik oil cleaner oil temperature coolant stock level

16.11.2005
1 1

008 911 49
Wiring diagram

Vogt Bremse, Rückfahrwarneinr., Anzeige 582 702 09

16.11.2005
Seis brake, back up alarm, indicator 004
 4:20 K11/87 K11/87 8:1

X1:32E

D+ F03 1
4:13
15A 2

008 911 49
B06:1
4:17 X1:32A
4:3 K48/86

F14:2 Nur mit Sitzkontaktschalter

Wiring diagram

2:20
only with switch seat−contact

nur D−40/BW177D−4 Standard D−Maschinen/D−40 USA

only D−40/BW177D−4 Standard D−maschines/D−40 USA

Fahren
Öldruck
D+
F25:2 1 12 13 14 30 56
4:8
K04
31
A68 Modul Sitzschalter/Vibration
module seatswitch/vibration

S 56b
modul vibration
Modul Vibration

13 4 6 9 11 15 5
S42 1234 2
S42

1 5 7 3 S01:21
14 2:20 X1:158 X1:157
Fahrstufensch.
switch speed ranges K26/87A

switch speed ranges

Nur ohne Sitzkontaktschalter
without switch seat−contact

4:8 X14 X11

Schalter Fahrstufen
2
1
B 1 X1:159
V09 X1 14
S13
88
23 13
A68/6 3 S35
S58
4:19 13

X1:143 X1:144 X1:162 X1:143 SITZWARN. 4

4:10 24 14

BOMAG
2
1
V05 X1:161 X1:160
V02 V03
2 1 1 2
GA MESX
6:2
Taster Vibration
pushbutton vibration

KA MESX 6:2
X1:141 X1:137 X1:142 X1:141
X1:116 X1:115
switch seat−contact
Sitzkontaktschalter

1.23A
1.23A
1.23A
X6 X7
Y31 Y30 Y31 X14 X11 1 1
1 1 1 1 Y07 Y08
3.33A
3.33A

A 2
9:7 KA
9:6 GA

a b
2 2 2 2
X6 X7
2 2
X1:124 X1:138 X1:124 X1:124
X1:149
X1:154
X1:149
X1:149

31
X1:118

4:20 31 6:1

Schalter Vibration klein/groß

nur BW216+219D−4 switch vibration small/big ampl.
only BW216+219D−4
Stufenumsch. hinten Stufenumschaltung vorn Stufenumschaltung hinten Vibration vorne groß
switching axle switching drum switching axle vibration big ampl.
Vibration vorne klein
Stufenumschaltung vorn
switching drum vibration small ampl.

16.11.2005
1 1 582 702 09
Vogt Fahrstufen, Sitzkontaktsch., Vibration
16.11.2005
17.1

927
Vogt speed−ranges, seat−switch, vibr. 005
928
Beschleunigungssensoren Beschleunigungssensoren Drucker Anzeige BMFSA Display Messtechnik BOP
acc. sensor front acc. sensor rear printer Display BMFSA display measurem. BOP
GND
30
17.1

2:20 30 8:1
Pot 30
K11/87
8:20 Pot 15

X2:66 X2:70 X2:47 X2:48 X2:49

X1:145 X42:1 X42:2 X42:3
X2:71
X46:B X46:A X46:E
X1:33E X1:35E 31
+ −
1 1 S01
F148 F146 2:18 X2:56 X2:53 X2:60 X2:57
10A 15A
2 2 32
X48:2 X48:1 X49:2 X49:1 P33
X1:33A X1:35A X1:146

X4:C
X4:E
X4:D
P16
B62 B62 F1 F2

+/sw
+/sw
nur bei BEM
only at BEM

F148:2 X1:34E −/gg −/gg

7:15
CAN+ CAN−
nur bei BTM+/BTM prof
only at BTM+/BTM prof

F84 1 X46:D X46:F

10A 15g/bl 15g/bl

X74:3
X74:5
X74:4
2 X42:4 X42:5
X2:57 X1:34A P11

20g/br
20g/br
nur bei BTM prof
X48:3 X48:4 X49:3 X49:4

only at BTM prof

X74:1 X74:2
X2:50 X2:51
X2:54 X2:55 X2:58 X2:59 X4:A X4:B R20
1 2
60OHM
X2:64 X2:65

Pot. 15
Leistung
Elektronik
AGND MESX

Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
CAN1+
CAN1−

RxD TxD

BOMAG
X44:1

X44:7
X44:5

X44:4

X44:31

X44:56
X44:57
X44:59
X44:60
X44:30

X44:58
X44:29
X44:27
X44:26

X44:28
X44:54
A83
Messtechnik−Rechner

X44:38
X44:15
X44:35
X44:14
X44:32
X44:36
X44:37
X44:38
X44:41
X44:53
X44:33

measurement calc. unit

X44:3

X44:55
X44:65
X44:66
X44:67
X44:68

GA MESX CAN3+ CAN3−

GND
5:17
EVIB

KA MESX
GND

5:17 CAN3− 7:15

SPEED MESX X1:85
3:16
DIR MESX X2:49 X2:52 + CAN3+
3:16 7:15
PITCH MESX P07 E
VIB
4:5 BRAKE MESX
−
D+ MESX
2:6 X2:63 X2:66 X1:82

8:4 BEL MESX

31 31 7:1
5:20

EVIB−Meter
EVIB−meter
nur bei BEM
only at BEM

16.11.2005
1 1

008 911 49
Wiring diagram

Vogt ZA Messtechnik 582 702 09

16.11.2005
Seis option measurement equipm. 006
 F148:2
6:2

008 911 49
CAN3−
6:18

6:18 CAN3+
Wiring diagram

CAN3+ CAN3−
1 R242
120 OHM
X2:61 X2:62
R25
1 2
120 OHM

X4:N X4:M

X75:7 X75:2

A87
USB−CAN Schnittst.
USB−CAN Interface BCM

X2:70

BOMAG
X76:1 X4:G

X76:2
P15
X4:F
X2:63

BCM 05
nur bei BCM
only at BCM

6:20 31 31 8:1

16.11.2005
1 1 582 702 09
Vogt BOMAG Compaction Management BCM
16.11.2005
17.1

929
Seis BOMAG Compaction Management BCM 007
930
5:20 K11/87 K11/87 6:2
6:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
17.1

F11 F18 F07 F08

15A 10A 15A 15A
30
X1:18A K06 X1:19A X1:25A
X1:26A
8:4 X1:305
X1:83

X1:301
Schalter StvZO 87 87a
switch, StvZO
13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO L0R Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:306
X1:307

X3:4 X3:5 with cabin 30 49L 49R

STV1

X1:302
9:17 A02
STV2
9:17
X1:23E X1:24E
K16 30 31 82 L R
8:9 F09 F10
15A 15A
87 87a X1:23A X1:24A

4:11 BL−L X1:91

4:19
13 BEL BL−R
4:19
X1:96
S53 14

BOMAG
switch, working head lights
Schalter Arbeitsbeleuchtung
X1:308

X1:304

X1:303
13 23
01
01
S14

X1:311

X1:310
X1:319
X1:312

lights without StvZO

X1:313

Anschluß Arbeitsschein−
werfer ohne StvZO
connection working head
X1:314

X1:84
Warnblinkschalter 14 24
6:2 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.

X61:3 X1:320

X59:5
X60:3
X59:3

X58:5 X1:309
X58:3
X61:1 X1:322

X60:1 X1:321
X59:2

X58:2

BEL MESX BL−W

0,125A
0,125A
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 4:19 E08 1 E09 1 E10 1 E11 1

+
2 2 86 2 2 2 2 86 2 2 2 2 H06 2 2 2 2
K06 K16

4,6A
4,6A
4,6A
4,6A

−
X61:2

X59:6

X58:6
X60:2

85 85
X3:1

X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6

4,6A
4,6A
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A

X1:323 X60:4
X1:324 X61:4
X1:315
X1:316

X1:323
X1:324

7:20 9:1
31
8:10 Schlußleuchte links 8:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
Anschluß Arbeitsscheinwerfer
Scheinwerfer rechts parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
head light RH Parkleuchte rechts Blinkleuchte HL
parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schlußleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH

16.11.2005
1 1

008 911 49
Wiring diagram

Vogt ZA Beleuchtung und StvZO 582 702 09

16.11.2005
Seis opt. illumination and StvZO 008
 F42:H 10:13 F41:5 10:13
X3:6
2:11 K30 2:11 K32:87 10:2
X3:7
K32:86 K32 30 STV2
X3:8 8:13
2:20 9:2 STV1

008 911 49
8:13
87 87a E F
G H A B C

X3:3
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3
5 6
Wiring diagram

F42 10:8
F130 9:9 F130 F130 10:7
9:14

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
9:16 E29 E70
− − − − 1
87 87a 2 2 2 1
31 S21 5 4 S20 5 4
Radio
radio

Steckdose Fahrerst.
3,8A
3,8A
1 Tachographenmodul

socket operator platform

E71 1 module, tachograph
XS
+ R80 A2+A3
X3:17
4,6A
4,6A
4,6A
4,6A

2 4 6 A1 XS

Nachtleuchte
− 3:16 P09 +

indicator
X55:1
X56:1

X55:3
X56:3
12V 2 1

X55:4
X56:4
night illumination
SPEED TAC A16 1 B3 E27 1 E28 1 E23 1 E25

Kontrolleuchte
Innenleuchte
inside light, cabin
socket cabin

−
12V
Steckdose Kabine

+ 7,8,9 2 B4 2 2 2 2
A01 5 3 C3

A5+A6
S45 TK −

Heizung Heckscheibe
4 1

heating rear screen

BOMAG
A51

Schalter Innenleuche
switches interior lights
3
5A

86 S86 + 3 2 5 + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31

X3:16
X3:15
− −
3 min

85 − M07 − M06 4

KA

GA
2,9A
ZA

Nur bei Geländer/Rops/SD

4,7A

X55:2 X56:2 option

Abfallverzögert

only at hand−rail/Rops/sun−roof
5:17
5:16
10:18
Relais Kabine Türkontaktschalter Frequenzmodul Tachograph KABINE 31
relais cabin door switch module, frequency tachograph Schalter Nachtleuchte
switch, night illumination

X3:1
X3:2
Schalterbel.
switch illum.

8:20 31 31 10:1

9:6 Wascher hinten Wascher vorn 9:2 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

16.11.2005
1 1 582 702 09
Vogt ZA Kabine, Beleuchtung, Radio, Tachograph
16.11.2005
17.1

931
Seis opt. cabin, headlights, radio, tachograph 009
932
9:20 K32:87 9:19 F41:5
Potential 15 aus Kabine
9:17 F130 F42:H
9:4
F42 Potential 15 aus Kabine
9:9
17.1

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
2:8
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
_t

BOMAG
_t 2 2

Thermofühler Klimaanlage
X19:2
X20:1 X18:2

X17:1 X1:163
temperature sensor air conditioning

X17:3 X1:166

X17:2 X1:165
Thermofühler Heizung
temperature sensor heating unit
B104 4
P
HP X77:1

1A
LP 3

ge rt or ge rt or
Y138 1 1
X1:170 9:19

X20:4
X20:3
V06 Y14 KABINE 31

Überwachung Kühlmitteldruck
monitoring coolant pressure
M09 M M09 M
Kabinenlüfter 2 2
br br
X20:2
X77:2
Y15 1 2
X17:4 V04 X1:168
2 1

3,5A
X1:164
9:20 31 31

Kabinenlüfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit

Vogt
1 1

008 911 49
Wiring diagram

Seis ZA Kabinenheizung, Klimaanlage, Zusatzheizung 582 702 09

16.11.2005
Seis opt. cabin−heater, air conditioning, add. heater 010
 Wiring diagram 17.1
Name Bl. Pf. Benennung title TYP
005 4 MAX. 1,67A

A02 008 17 Blinkrelais indicator relay

A05 003 17 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer MODUL
A12 009 5 Radio Radio
A13 003 3 Steuergeraet Heizung Control unit, heating
A15 004 16 Ueberwachungsmodul monitoring module
A16 009 7 Elektronik Tachograph Electronic system, tachograph
A51 009 6 Platine Frequenzanzeige Circuit board,frequenzy meter
A68 005 10 Modul Sitzkontakt Modul seat contact MAX. 0,12A
A72 010 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A83 006 6 Elektronik Messtechnik electronic measurement−equipment
A87 007 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
Seis
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Vogt
16.11.2005

B03 004 15 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B06 004 17 Druckschalter Motoroel Pressure switch, engine oil
B11 003 9 Signalhorn Warning horn MAX.5A
B11 003 11 Signalhorn Warning horn MAX.5A
B13 004 2 Naeherungsinitiator Fahrhebel links Proximity switch, travel lever, lh.
B14 004 6 Naeherungsinitiator Fahrhebel rechts Proximity switch, travel lever, rh.
B21 004 14 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B30 004 16 Temperaturschalter Motoroel Temperature switch, engine oil
B51 009 5 Lautsprecher Radio Speaker radio
B51 009 6 Lautsprecher Radio Speaker radio
B55 004 17 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B60 003 14 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 006 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 006 8 Beschleunigungsaufnehmer Acceleration sensor
B62 006 10 Beschleunigungsaufnehmer Acceleration sensor
B103 010 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 010 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B113 003 3 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B124 004 19 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 010 10 Temperaturschalter Heizung Temperature switch, heating

E08 008 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 008 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 008 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 008 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 008 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 008 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 008 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 008 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
component listing

E16 008 2 Scheinwerfer links Head light, lh. MAX. 4,6A

E17 008 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
Bauteilliste

E23 008 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 009 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 008 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 009 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 008 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 009 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 008 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 009 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 009 4 Innenleuchte Kabine Inside light, cabin 1,75A
E30 010 13 Heizgeraet Heating unit
E32 009 19 Kennleuchte Warning light 5A
E70 009 15 Nachtleuchte Night lamp 0,83A
E71 009 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 009 16 Beleuchtung Bedienschalter illum. Switches

F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A

F03 005 18 Sicherung Vibration Fuse, vibration MAX. 1,23A
F07 008 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 008 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 008 6 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 008 8 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 008 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F14 002 18 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 15A
F15 010 18 Sicherung Heizgeraet Fuse, heating unit BOX2
F18 008 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 008 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 008 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 003 9 Sicherung Signalhorn Fuse, warning horn 10A
F24 004 10 Sicherung Ueberwachungsmodul Fuse, monitoring module 10A
F25 004 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F31 010 3 Sicherung Kabinenluefter Fuse, cabin ventilator
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 010 13 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
F41 009 19 Sicherung Rundumkennleuchte Fuse, rotary beacon
F42 009 4 Sicherung Kabineninnenleuchte Fuse, inside light cab
F43 009 10 Sicherung Wischermotor hinten Fuse, wipermotor rear
1

F44 009 13 Sicherung Wischermotor vorn Fuse, wipermotor front

F48 002 3 Sicherung Gluehanlage Fuse, glow plug system 125A
F84 006 5 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
FM4 006 11 Platinensicherung Multifuse
F105 002 16 Sicherung Motordrehzahl Fuse, motor speed 20A
6

F130 009 15 Sicherung Nachtleuchte Fuse, night lamp

F143 009 2 Sicherung Heckscheibenheizung fuse rear screen heating unit
F144 009 20 Sicherung Kabinensteckdose Fuse cabin−socket
F146 006 4 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30)
582 702 09

F148 006 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15)

G01 002 4 Batterie Battery 103A

G02 002 5 Generator Generator
G03 002 3 Batterie Battery 103A
101

H06 008 15 Meldeleuchte Warnblinker Indicator light, hazard light

H07 004 10 Warnsummer Betriebsstoerung Warning buzzer, breakdown MAX. 0,12A

008 911 49 BOMAG 933

 17.1 Wiring diagram
Name Bl. Pf. Benennung title TYP
H14 004 8 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX. 0,12A

K04 005 18 Schrittrelais Vibration Toggle relay, vibration MAX. 1,23A

K05 004 3 Relais Startstrom Relay, starting current BOSCHW
K06 008 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW
K14 003 5 Relais Vorgluehen Relay, glow plug system BOSCHL
K16 008 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K22 004 9 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K26 004 6 Relais Rueckfahrwarneinrichtung Relay, back up alarm BOSCHW
K32 009 2 Relais Kabine Relay, cabin BOSCHW
K35 002 16 Relais Selbsthaltung Relay, holding contact BOSCHW
K36 002 7 Relais Bremskontrolle Relay, brake control BOSCHW
Seis
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Vogt
16.11.2005

K48 004 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K61 002 5 Relais Ladekontrolle Relay, charge control BOSCHW
K114 002 14 Relais Motordrehzahl Relay, engine rpm BOSCHW
K141 009 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW

M01 002 11 Starter Starter 2.3 KW

M04 009 13 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 009 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 009 14 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 009 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 010 3 Kabinenluefter Cabin ventilator
M09 010 4 Kabinenluefter Cabin ventilator

P04 003 19 Geschwindigkeitsanzeige Speedometer

P07 006 15 Omegameter Omegameter
P09 009 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 006 14 Drucker Printer
P15 007 16 BCM 03 Bildschirm BCM 03 terminal
P16 006 16 Diagnose, Variomatic Diagnostics, varimatic
P33 006 18 Opus 21 Opus 21

R03 004 12 Geber Tankanzeige Sender, level gauge

R10 002 6 Parallelwiderstand Parallel resistor 82 OHM
R19 002 2 Heizflansch heater flange 167A
R20 006 17 Widerstand Resistor 60OHM
R24 007 15 Widerstand Resistor 120 OHM
R25 007 15 Widerstand Resistor 120 OHM
R80 009 2 Heizung Heckscheibe heating rear screen
component listing

S00 002 10 Startschalter Starter switch

S01 002 18 Schalter NOT AUS Switch, emergency off
Bauteilliste

S03 003 9 Taster Signalhorn Push button, warning horn

S13 005 13 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 008 15 Warnblinkschalter Switch, hazard light
S15 008 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 009 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 009 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 010 17 Schalter Kabinenheizung Switch, cabin heating
S30 002 3 Batterietrennschalter Switch, battery disconnect
S35 005 15 Vibrationsschalter klein/gross Switch, vibration low/high
S37 008 18 Schalter Blinker Switch, indicator
S38 009 19 Schalter Kennleuchte Switch, warning light
S42 005 3 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S42 005 7 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S44 010 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 009 4 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 008 4 Schalter Arbeitsbeleuchtung Switch, working lights
S58 005 13 Schalter Aetherstartanlage Push button, ether starting unit
S86 009 4 Schalter Tuer, links Switch door, lh.
S120 002 14 Schalter Motordrehzahl Switch, engine speed
S158 009 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 009 16 Schalter Heckscheibenheizung switch rear screen heating unit

V01 002 6 Diode Diode 4UF004

V02 005 6 Diode Diode MAX. 1,23A
V03 005 7 Diode Diode MAX. 1,23A
V04 010 8 Diode Diode FE5B
V05 005 10 Diode Diode MAX. 0,12A
V06 010 9 Diode Diode
V09 005 10 Diode Diode MAX. 0,12A
V21 003 10 Diode Diode
V22 003 11 Diode Diode
V47 002 15 Diode (A7) Diode (A7) FE5B

X1:1 002 5 WAGO,E−Kasten WAGO,E−BOX

X1:2 008 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:3 002 9 WAGO,E−Kasten WAGO,E−BOX
X1:4 002 10 WAGO,E−Kasten WAGO,E−BOX
2

X1:7 002 11 WAGO,E−Kasten WAGO,E−BOX

X1:8 002 11 WAGO,E−Kasten WAGO,E−BOX
X1:9 002 4 WAGO,E−Kasten WAGO,E−BOX
X1:10 002 4 WAGO,E−Kasten WAGO,E−BOX
X1:52 003 2 WAGO,E−Kasten WAGO,E−BOX
6

X1:53 002 12 WAGO,E−Kasten WAGO,E−BOX

X1:54 002 18 WAGO,E−Kasten WAGO,E−BOX
X1:55 002 10 WAGO,E−Kasten WAGO,E−BOX
X1:55 002 18 WAGO,E−Kasten WAGO,E−BOX
582 702 09

X1:56 002 15 WAGO,E−Kasten WAGO,E−BOX

X1:57 003 3 WAGO,E−Kasten WAGO,E−BOX
X1:57 004 15 WAGO,E−Kasten WAGO,E−BOX
X1:58 002 16 WAGO,E−Kasten WAGO,E−BOX
X1:59 002 16 WAGO,E−Kasten WAGO,E−BOX
102

X1:60 002 16 WAGO,E−Kasten WAGO,E−BOX

X1:61 004 15 WAGO,E−Kasten WAGO,E−BOX
X1:62 002 16 WAGO,E−Kasten WAGO,E−BOX

934 BOMAG 008 911 49

 Wiring diagram 17.1
Name Bl. Pf. Benennung title TYP
X1:63 002 16 WAGO,E−Kasten WAGO,E−BOX
X1:64 003 3 WAGO,E−Kasten WAGO,E−BOX
X1:65 002 5 WAGO,E−Kasten WAGO,E−BOX
X1:66 002 6 WAGO,E−Kasten WAGO,E−BOX
X1:67 004 15 WAGO,E−Kasten WAGO,E−BOX
X1:68 004 17 WAGO,E−Kasten WAGO,E−BOX
X1:69 004 13 WAGO,E−KASTEN WAGO, E−box
X1:71 004 15 WAGO,E−KASTEN WAGO, E−box
X1:72 004 17 WAGO,E−Kasten WAGO,E−BOX
X1:73 004 17 WAGO,E−Kasten WAGO,E−BOX
X1:74 004 16 WAGO,E−Kasten WAGO,E−BOX
X1:75 003 4 WAGO,E−Kasten WAGO,E−BOX
X1:76 004 17 WAGO,E−KASTEN WAGO, E−box
X1:77 004 16 WAGO,E−KASTEN WAGO, E−box
Seis
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Vogt
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X1:78 003 4 WAGO,E−Kasten WAGO,E−BOX

X1:79 002 10 WAGO,E−Kasten WAGO,E−BOX
X1:80 002 14 WAGO,E−Kasten WAGO,E−BOX
X1:81 002 14 WAGO,E−Kasten WAGO,E−BOX
X1:82 004 11 WAGO,E−Kasten WAGO,E−BOX
X1:82 006 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:83 008 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:84 008 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:85 006 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:86 004 10 WAGO,E−Kasten WAGO,E−BOX
X1:87 004 13 WAGO,E−KASTEN WAGO, E−box
X1:88 005 11 WAGO,E−Kasten WAGO,E−BOX
X1:89 004 10 WAGO,E−Kasten WAGO,E−BOX
X1:90 004 9 WAGO,E−Kasten WAGO,E−BOX
X1:91 008 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:92 003 19 WAGO,E−Kasten WAGO,E−BOX
X1:93 003 19 WAGO,E−Kasten WAGO,E−BOX
X1:96 008 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:97 003 9 WAGO,E−Kasten WAGO,E−BOX
X1:98 003 10 WAGO,E−Kasten WAGO,E−BOX
X1:99 003 10 WAGO,E−Kasten WAGO,E−BOX
X1:100 003 11 WAGO,E−Kasten WAGO,E−BOX
X1:101 003 9 WAGO,E−Kasten WAGO,E−BOX
X1:102 003 10 WAGO,E−Kasten WAGO,E−BOX
X1:105 004 12 WAGO,E−Kasten WAGO,E−BOX
X1:106 004 14 WAGO,E−Kasten WAGO,E−BOX
X1:107 004 19 WAGO,E−Kasten WAGO,E−BOX
X1:108 004 20 WAGO,E−Kasten WAGO,E−BOX
X1:109 004 12 WAGO,E−KASTEN WAGO, E−box
component listing

X1:110 004 14 WAGO,E−KASTEN WAGO, E−box

X1:111 004 19 WAGO,E−Kasten WAGO,E−BOX
Bauteilliste

X1:112 004 20 WAGO,E−Kasten WAGO,E−BOX

X1:113 004 5 WAGO,E−Kasten WAGO,E−BOX
X1:114 004 8 WAGO,E−Kasten WAGO,E−BOX
X1:115 005 16 WAGO,E−Kasten WAGO,E−BOX
X1:116 005 14 WAGO,E−Kasten WAGO,E−BOX
X1:117 004 5 WAGO,E−Kasten WAGO,E−BOX
X1:117 004 8 WAGO,E−Kasten WAGO,E−BOX
X1:117 004 12 WAGO,E−Kasten WAGO,E−BOX
X1:117 004 14 WAGO,E−Kasten WAGO,E−BOX
X1:118 005 14 WAGO,E−Kasten WAGO,E−BOX
X1:124 005 3 WAGO,E−Kasten WAGO,E−BOX
X1:124 005 6 WAGO,E−Kasten WAGO,E−BOX
X1:124 005 8 WAGO,E−Kasten WAGO,E−BOX
X1:129 004 6 WAGO,E−Kasten WAGO,E−BOX
X1:137 005 4 WAGO,E−Kasten WAGO,E−BOX
X1:138 005 4 WAGO,E−Kasten WAGO,E−BOX
X1:141 005 3 WAGO,E−Kasten WAGO,E−BOX
X1:141 005 8 WAGO,E−Kasten WAGO,E−BOX
X1:142 005 6 WAGO,E−Kasten WAGO,E−BOX
X1:143 005 3 WAGO,E−Kasten WAGO,E−BOX
X1:143 005 8 WAGO,E−Kasten WAGO,E−BOX
X1:144 005 6 WAGO,E−Kasten WAGO,E−BOX
X1:145 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:146 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:147 004 5 WAGO,E−Kasten WAGO,E−BOX
X1:148 004 2 WAGO,E−Kasten WAGO,E−BOX
X1:149 004 1 WAGO,E−Kasten WAGO,E−BOX
X1:149 005 12 WAGO,E−Kasten WAGO,E−BOX
X1:149 005 13 WAGO,E−Kasten WAGO,E−BOX
X1:149 005 19 WAGO,E−Kasten WAGO,E−BOX
X1:150 004 5 WAGO,E−Kasten WAGO,E−BOX
X1:151 002 18 WAGO,E−Kasten WAGO,E−BOX
X1:152 002 18 WAGO,E−Kasten WAGO,E−BOX
X1:153 004 6 WAGO,E−Kasten WAGO,E−BOX
X1:154 005 13 WAGO,E−Kasten WAGO,E−BOX
X1:155 003 9 WAGO,E−Kasten WAGO,E−BOX
X1:156 004 2 WAGO,E−Kasten WAGO,E−BOX
3

X1:157 005 13 WAGO,E−Kasten WAGO,E−BOX

X1:158 005 13 WAGO,E−Kasten WAGO,E−BOX
X1:159 005 16 WAGO,E−Kasten WAGO,E−BOX
X1:15A 002 10 WAGO,E−Kasten WAGO,E−BOX
X1:15E 002 10 WAGO,E−Kasten WAGO,E−BOX
6

X1:160 005 16 WAGO,E−Kasten WAGO,E−BOX

X1:161 005 14 WAGO,E−Kasten WAGO,E−BOX
X1:162 005 7 WAGO,E−Kasten WAGO,E−BOX
X1:163 010 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
582 702 09

X1:164 010 5 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:165 010 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:166 010 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:167 010 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:168 002 8 WAGO,E−Kasten WAGO,E−BOX
103

X1:168 010 10 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:169 010 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:170 010 7 WAGO ZENTRALELEKTRIK WAGO E−BOX

008 911 49 BOMAG 935

 17.1 Wiring diagram
Name Bl. Pf. Benennung title TYP
X1:171 003 14 WAGO,E−Kasten WAGO,E−BOX
X1:172 003 15 WAGO,E−Kasten WAGO,E−BOX
X1:173 003 15 WAGO,E−Kasten WAGO,E−BOX
X1:174 003 14 WAGO,E−Kasten WAGO,E−BOX
X1:17A 002 16 WAGO,E−Kasten WAGO,E−BOX
X1:17E 002 16 WAGO,E−Kasten WAGO,E−BOX
X1:18A 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:18E 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:19A 008 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:19E 008 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:21A 008 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:21E 008 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:22A 008 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:22E 008 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
Seis
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Vogt
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X1:23A 008 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:23E 008 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:24A 008 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:24E 008 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:25A 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:25E 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:26A 008 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:26E 008 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:27A 002 18 WAGO,E−Kasten WAGO,E−BOX
X1:27E 002 18 WAGO,E−Kasten WAGO,E−BOX
X1:28A 003 9 WAGO,E−Kasten WAGO,E−BOX
X1:28E 003 9 WAGO,E−Kasten WAGO,E−BOX
X1:29A 004 2 WAGO,E−Kasten WAGO,E−BOX
X1:29E 004 2 WAGO,E−Kasten WAGO,E−BOX
X1:301 008 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:302 008 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:303 008 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:304 008 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:305 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:306 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:307 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:308 008 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:309 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:30A 002 19 WAGO,E−Kasten WAGO,E−BOX
X1:30E 002 19 WAGO,E−Kasten WAGO,E−BOX
X1:310 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:311 008 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:312 008 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:313 008 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

X1:314 008 19 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:315 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:315 008 7 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:315 008 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:316 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:316 008 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:316 008 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:319 008 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:31A 004 10 WAGO,E−Kasten WAGO,E−BOX
X1:31E 004 10 WAGO,E−Kasten WAGO,E−BOX
X1:320 008 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:321 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:322 008 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:323 008 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:323 008 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:324 008 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:324 008 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:32A 005 18 WAGO,E−Kasten WAGO,E−BOX
X1:32E 005 18 WAGO,E−Kasten WAGO,E−BOX
X1:33A 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:33E 006 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:34A 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:34E 006 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:35A 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:35E 006 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X2:47 006 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:48 006 19 WAGO−MESSTECHNIK Wago−measurement equip.
X2:49 006 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:49 006 19 WAGO−MESSTECHNIK Wago−measurement equip.
X2:50 006 17 WAGO−MESSTECHNIK Wago−measurement equip.
X2:51 006 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:52 006 13 WAGO−MESSTECHNIK Wago−measurement equip.
X2:53 006 8 WAGO−MESSTECHNIK Wago−measurement equip.
X2:54 006 7 WAGO−MESSTECHNIK Wago−measurement equip.
X2:55 006 8 WAGO−MESSTECHNIK Wago−measurement equip.
X2:56 006 7 WAGO−MESSTECHNIK Wago−measurement equip.
X2:57 006 2 WAGO−MESSTECHNIK Wago−measurement equip.
X2:57 006 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:58 006 9 WAGO−MESSTECHNIK Wago−measurement equip.
4

X2:59 006 10 WAGO−MESSTECHNIK Wago−measurement equip.

X2:60 006 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:61 007 15 WAGO−MESSTECHNIK Wago−measurement equip.
X2:62 007 16 WAGO−MESSTECHNIK Wago−measurement equip.
X2:63 006 13 WAGO−MESSTECHNIK Wago−measurement equip.
6

X2:63 007 18 WAGO−MESSTECHNIK Wago−measurement equip.

X2:64 006 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:65 006 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:66 006 14 WAGO−MESSTECHNIK Wago−measurement equip.
582 702 09

X2:66 006 14 WAGO−MESSTECHNIK Wago−measurement equip.

X2:67 006 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:68 006 12 WAGO−MESSTECHNIK Wago−measurement equip.
X2:69 006 12 WAGO−MESSTECHNIK Wago−measurement equip.
X2:70 006 15 WAGO−MESSTECHNIK Wago−measurement equip.
104

X2:70 007 18 WAGO−MESSTECHNIK Wago−measurement equip.

X2:71 006 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:73 006 11 WAGO−MESSTECHNIK Wago−measurement equip.

936 BOMAG 008 911 49

 Wiring diagram 17.1
Name Bl. Pf. Benennung title TYP
X2:74 006 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:75 006 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:76 006 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:77 006 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:78 006 11 WAGO−MESSTECHNIK Wago−measurement equip.
X3:1 008 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 009 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:2 009 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:3 009 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:4 008 10 STECKER ROPS/SD conn. ROPS/SR
X3:5 008 12 STECKER ROPS/SD conn. ROPS/SR
X3:6 009 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:7 009 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:8 009 2 STECKER KABINE/ROPS conn. cabin/ROPS
Seis
16.11.2005
Vogt
16.11.2005

X3:9 010 3 STECKER KABINE/ROPS conn. cabin/ROPS

X3:10 010 3 STECKER KABINE/ROPS conn. cabin/ROPS
X3:11 010 4 STECKER KABINE/ROPS conn. cabin/ROPS
X3:12 010 4 STECKER KABINE/ROPS conn. cabin/ROPS
X3:13 010 7 STECKER KABINE/ROPS conn. cabin/ROPS
X3:14 010 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:15 009 7 STECKER KABINE/ROPS conn. cabin/ROPS
X3:16 009 6 STECKER KABINE/ROPS conn. cabin/ROPS
X3:17 009 6 STECKER KABINE/ROPS conn. cabin/ROPS
X4:A 006 14 KABINENST. MESST. con. measurem.equipm.
X4:B 006 14 KABINENST. MESST. con. measurem.equipm.
X4:C 006 14 KABINENST. MESST. con. measurem.equipm.
X4:D 006 14 KABINENST. MESST. con. measurem.equipm.
X4:E 006 15 KABINENST. MESST. con. measurem.equipm.
X4:F 007 18 KABINENST. MESST. con. measurem.equipm.
X4:G 007 18 KABINENST. MESST. con. measurem.equipm.
X4:M 007 16 KABINENST. MESST. con. measurem.equipm.
X4:N 007 15 KABINENST. MESST. con. measurem.equipm.
X6:1 005 14 DEUTSCH DEUTSCH connector
X6:2 005 14 DEUTSCH DEUTSCH connector
X7:1 005 16 DEUTSCH DEUTSCH connector
X7:2 005 16 DEUTSCH DEUTSCH connector
X8:1 004 19 DEUTSCH DEUTSCH connector
X8:2 004 20 DEUTSCH DEUTSCH connector
X9:1 004 8 DEUTSCH DEUTSCH connector
X9:2 004 8 DEUTSCH DEUTSCH connector
XS 009 1 Steckdose Socket
XS 009 20 Steckdose Socket
X10:2 004 12 AMP SUPERSEAL AMP connector
component listing

X10:3 004 12 AMP SUPERSEAL AMP connector

X11:1 005 13 DEUTSCH DEUTSCH connector
Bauteilliste

X11:2 005 13 DEUTSCH DEUTSCH connector

X12:1 004 2 DEUTSCH DEUTSCH connector
X12:2 004 2 DEUTSCH DEUTSCH connector
X12:3 004 1 DEUTSCH DEUTSCH connector
X13:1 004 6 DEUTSCH DEUTSCH connector
X13:2 004 6 DEUTSCH DEUTSCH connector
X13:3 004 6 DEUTSCH DEUTSCH connector
X14:A 005 13 DEUTSCH DEUTSCH connector
X14:B 005 13 DEUTSCH DEUTSCH connector
X17:1 010 3 STECKER LÜFTER HKL conn. blower
X17:2 010 3 STECKER LÜFTER HKL conn. blower
X17:3 010 4 STECKER LÜFTER HKL conn. blower
X17:4 010 5 STECKER LÜFTER HKL conn. blower
X18:1 010 10 STECKER THERMOFÜHLER conn. sender temp.
X18:2 010 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 010 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X19:2 010 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X20:1 010 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:2 010 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:3 010 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:4 010 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X21:1 004 17 STECKER KÜHLMITTEL connector coolant sensor
X21:2 004 17 STECKER KÜHLMITTEL connector coolant sensor
X36:A 002 4 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 4 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 10 ST. ZÜNDSCHLOß E−KAST connector ignition switch
X37:B 002 11 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 11 ST.STARTER E−KASTEN connector starter e−box
X42:1 006 18 STECKER ADAPTER BOP conector adapter BOP
X42:2 006 19 STECKER ADAPTER BOP conector adapter BOP
X42:3 006 19 STECKER ADAPTER BOP conector adapter BOP
X42:4 006 18 STECKER ADAPTER BOP conector adapter BOP
X42:5 006 18 STECKER ADAPTER BOP conector adapter BOP
X44:1 006 13 MESX STECKER MESX Stecker
X44:3 006 15 MESX STECKER MESX Stecker
X44:4 006 14 MESX STECKER MESX Stecker
X44:5 006 14 MESX STECKER MESX Stecker
5

X44:7 006 10 MESX STECKER MESX Stecker

X44:9 006 12 MESX STECKER MESX Stecker
X44:14 006 5 MESX STECKER MESX Stecker
X44:15 006 5 MESX STECKER MESX Stecker
X44:23 006 11 MESX STECKER MESX Stecker
6

X44:26 006 18 MESX STECKER MESX Stecker

X44:27 006 17 MESX STECKER MESX Stecker
X44:28 006 2 MESX STECKER MESX Stecker
X44:29 006 7 MESX STECKER MESX Stecker
582 702 09

X44:30 006 9 MESX STECKER MESX Stecker

X44:31 006 8 MESX STECKER MESX Stecker
X44:32 006 6 MESX STECKER MESX Stecker
X44:33 006 18 MESX STECKER MESX Stecker
X44:35 006 5 MESX STECKER MESX Stecker
105

X44:36 006 6 MESX STECKER MESX Stecker

X44:37 006 7 MESX STECKER MESX Stecker
X44:38 006 4 MESX STECKER MESX Stecker

008 911 49 BOMAG 937

 17.1 Wiring diagram
Name Bl. Pf. Benennung title TYP
X44:38 006 7 MESX STECKER MESX Stecker
X44:41 006 7 MESX STECKER MESX Stecker
X44:46 006 11 MESX STECKER MESX Stecker
X44:47 006 10 MESX STECKER MESX Stecker
X44:53 006 17 MESX STECKER MESX Stecker
X44:54 006 5 MESX STECKER MESX Stecker
X44:55 006 13 MESX STECKER MESX Stecker
X44:56 006 4 MESX STECKER MESX Stecker
X44:57 006 4 MESX STECKER MESX Stecker
X44:58 006 4 MESX STECKER MESX Stecker
X44:59 006 5 MESX STECKER MESX Stecker
X44:60 006 5 MESX STECKER MESX Stecker
X44:65 006 13 MESX STECKER MESX Stecker
X44:66 006 13 MESX STECKER MESX Stecker
Seis
16.11.2005
Vogt
16.11.2005

X44:67 006 14 MESX STECKER MESX Stecker

X44:68 006 14 MESX STECKER MESX Stecker
X46:A 006 19 STECKER BOP Connector BOP
X46:B 006 18 STECKER BOP Connector BOP
X46:D 006 18 STECKER BOP Connector BOP
X46:E 006 19 STECKER BOP Connector BOP
X46:F 006 18 STECKER BOP Connector BOP
X47:A 006 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 006 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:C 006 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X48:1 006 8 STECKER AUFN. VORNE conn. sender front
X48:2 006 7 STECKER AUFN. VORNE conn. sender front
X48:3 006 7 STECKER AUFN. VORNE conn. sender front
X48:4 006 8 STECKER AUFN. VORNE conn. sender front
X49:1 006 10 STECKER AUFN. HINTEN conn. sender rear
X49:2 006 9 STECKER AUFN. HINTEN conn. sender rear
X49:3 006 9 STECKER AUFN. HINTEN conn. sender rear
X49:4 006 10 STECKER AUFN. HINTEN conn. sender rear
X53:B 010 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 010 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 010 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:L 010 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 010 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 010 11 STECKER HEIZSTEUERUNG conn. heating controller
X54:2 010 11 STECKER HEIZSTEUERUNG conn. heating controller
X54:3 010 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:4 010 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:6 010 7 STECKER HEIZSTEUERUNG conn. heating controller
X54:11 010 10 STECKER HEIZSTEUERUNG conn. heating controller
component listing

X54:12 010 11 STECKER HEIZSTEUERUNG conn. heating controller

X55:1 009 11 STECKER WISCHER HINTE connector wiper rear
Bauteilliste

X55:2 009 10 STECKER WISCHER HINTE connector wiper rear

X55:3 009 10 STECKER WISCHER HINTE connector wiper rear
X55:4 009 10 STECKER WISCHER HINTE connector wiper rear
X56:1 009 14 STECKER WISCHER VORNE conn. wiper front
X56:2 009 13 STECKER WISCHER VORNE conn. wiper front
X56:3 009 13 STECKER WISCHER VORNE conn. wiper front
X56:4 009 13 STECKER WISCHER VORNE conn. wiper front
X58:2 008 17 STECKER STVZO VL Con. STVZO FL
X58:3 008 7 STECKER STVZO VL Con. STVZO FL
X58:5 008 2 STECKER STVZO VL Con. STVZO FL
X58:6 008 2 STECKER STVZO VL Con. STVZO FL
X58:6 008 7 STECKER STVZO VL Con. STVZO FL
X58:6 008 17 STECKER STVZO VL Con. STVZO FL
X59:2 008 19 STECKER STVZO VR Con. STVZO FR
X59:3 008 7 STECKER STVZO VR Con. STVZO FR
X59:5 008 2 STECKER STVZO VR Con. STVZO FR
X59:6 008 2 STECKER STVZO VR Con. STVZO FR
X59:6 008 7 STECKER STVZO VR Con. STVZO FR
X59:6 008 19 STECKER STVZO VR Con. STVZO FR
X60:1 008 18 STECKER STVZO HL Con. STVZO BL
X60:2 008 18 STECKER STVZO HL Con. STVZO BL
X60:3 008 6 STECKER STVZO HL Con. STVZO BL
X60:4 008 6 STECKER STVZO HL Con. STVZO BL
X61:1 008 19 STECKER STVZO HR Con. STVZO BR
X61:2 008 19 STECKER STVZO HR Con. STVZO BR
X61:3 008 8 STECKER STVZO HR Con. STVZO BR
X61:4 008 8 STECKER STVZO HR Con. STVZO BR
X74:1 006 14 STECKER DRUCKER con. printer
X74:2 006 14 STECKER DRUCKER con. printer
X74:3 006 14 STECKER DRUCKER con. printer
X74:4 006 15 STECKER DRUCKER con. printer
X74:5 006 14 STECKER DRUCKER con. printer
X75:2 007 16 SUB−D STECKER BCM INT con. SUB−D BCM
X75:7 007 15 SUB−D STECKER BCM INT con. SUB−D BCM
X76:1 007 17 STECKER VERS. BCM con. Power−sup. BCM
X76:2 007 17 STECKER VERS. BCM con. Power−sup. BCM
X77:1 010 13 STECKER PUMPE STANDHE Conn. pump add. heater
6

X77:2 010 13 STECKER PUMPE STANDHE Conn. pump add. heater

Y01 002 12 Magnetventil Startmehrmenge Solenoid valve, start boost fuel MAX. 3.9A
Y04 004 5 Magnetventil Bremse Solenoid valve, brake MAX. 1,8A
Y07 005 14 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high MAX. 2,5A
6

Y08 005 16 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low MAX. 2,5A
Y13 002 18 Hubmagnet Motor Shut off solenoid, engine MAX. 3.8A
Y14 010 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 010 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
582 702 09

Y30 005 6 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front MAX. 1,67A
Y31 005 3 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y31 005 8 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y120 002 16 Magnetventil Motordrehzahl hoch Solenoid valve, rpm engine high
Y138 010 10 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
106

Y140 006 10 Magnetventil Erreger auf solenoid valve exciter up

Y141 006 11 Magnetventil Erreger ab solenoid valve exciter down

938 BOMAG 008 911 49

 X38
X37
X36

008 911 49
Wiring diagram

Nur bei StvzO

only acc. To StvZO illumination

BOMAG
A02 R10 K05

K11 K16 K06

K36 K22

K09 Nur bei Klimaanlage

only acc. to aircond. K35

K48

K61

A68 K114

K26

Nur wenn Sitzkontakt angebaut

only acc. if seatswitch is assembled

Nur wenn kein Sitzkontakt angebaut

K04 only acc. if no seatswitch is assembled

Gez.: 19.10.2005 Seite: 1 von: 2

Name: Vogt Übersicht Schaltkasten BW 177...219 D-4/D-40 page: 1 from: 2
582 702 09
17.1

939
Gepr.: 19.10.2005 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box BW 177...219 D-4/D-40 Replaces: Sheet No.: 201
 Nur bei VM8
only acc. To VM8

940
F1 F2

CAN 1
17.1

BOMAG
CAN 1 OPUS 21

A83
Messtechnik Steuerung

CAN 3 BCM

008 911 49
Wiring diagram

Gez.: 19.10.2005 Seite: 2 von: 2

Name: Vogt
Übersicht Schaltkasten-Tür BW 177...219 D-4/D-40 page: 2 from: 2
582 702 09
Gepr.: 19.10.2005 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box door BW 177...219 D-4/D-40 Replaces: Sheet No.: 201
Wiring diagram 17.1
WAGO smart DESIGNER 4.1

1 05756417

2 05756421
3 2 x 05756425 "L" + 793-501

5 2 x 05756425 "L" + 05756420 + 793-501

7 05756422
8 4 x 05756423 "L" + 05756419 + 793-501

12 18 x 05756436 "R" + 05756419 + 793-501 12 Flachsicherung DIN 72581-C30 / 057 510

99

13 Flachsicherung DIN 72581-C15 / 057 510

98

14 Flachsicherung DIN 72581-C20 / 057 511

00

15 Flachsicherung DIN 72581-C15 / 057 510

98

16 Flachsicherung DIN 72581-C15 / 057 510

98

17 Flachsicherung DIN 72581-C15 / 057 510

98

19 Flachsicherung DIN 72581-C10 / 057 510

97

20 Flachsicherung DIN 72581-C10 / 057 510

97

21 Flachsicherung DIN 72581-C15 / 057 510

98

22 Flachsicherung DIN 72581-C10 / 057 510

97

23 Flachsicherung DIN 72581-C15 / 057 510

98

24 Flachsicherung DIN 72581-C10 / 057 510

97

25 Flachsicherung DIN 72581-C10 / 057 510

97

26 Flachsicherung DIN 72581-C15 / 057 510

98

27 Flachsicherung DIN 72581-C10 / 057 510

97

28 Flachsicherung DIN 72581-C15 / 057 510

98

Optional1 : Projektgruppe : Walzenzüge-4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Absicherung D-4 Version 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.

17.11.2005 07:47:59 Seite 1

008 911 49 BOMAG 941

17.1 Wiring diagram
WAGO smart DESIGNER 4.1

30 2 x 05756436 "R" + 793-501

32 05756435
33 05756417

Optional1 : Projektgruppe : Walzenzüge-4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Absicherung D-4 Version 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.

17.11.2005 07:47:59 Seite 2

942 BOMAG 008 911 49

Wiring diagram 17.1
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge-4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Absicherung D-4 Version 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.

17.11.2005 07:48:52 Seite 3

008 911 49 BOMAG 943

17.1 Wiring diagram
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge-4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Absicherung D-4 Version 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.

17.11.2005 07:48:52 Seite 4

944 BOMAG 008 911 49

Wiring diagram 17.1
WAGO smart DESIGNER 4.1

1 05756417

2 2 x 05756540 "R" + 793-501 + 05756536

4 2 x 05756540 "R" + 793-501

6 3 x 05756539 "R" + 793-501

9 05756537
10 4 x 05756538 "R" + 793-501

14 05756537
15 3 x 05756538 "R" + 793-501

18 05756537
19 3 x 05756540 "R" + 793-501

22 05756535 "R" + 793-501

23 05756537
24 5 x 05756540 "R" + 793-501

29 05756537
30 2 x 05756538 "R" + 793-501

32 2 x 05756539 "R" + 793-501

34 05756537
35 4 x 05756538 "R" + 793-501

39 05756537
40 4 x 05756540 "R" + 793-501

44 2 x 05756539 "R" + 793-501

46 05756537
47 05756540 "R" + 793-501
48 05756535 "R" + 793-501

Optional1 : Projektgruppe : Walzenzüge-4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Kabelbäume D Version 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.

17.11.2005 07:51:17 Seite 1

008 911 49 BOMAG 945

17.1 Wiring diagram
WAGO smart DESIGNER 4.1

49 05756537
50 2 x 05756538 "R" + 793-501

52 05756537
53 4 x 05756540 "R" + 793-501

57 05756539 "R" + 793-501

58 05756537
59 4 x 05756540 "R" + 793-501

63 05756537
64 05756540 "R" + 793-501
65 05756535 "R" + 793-501

66 05756537
67 05756540 "R" + 793-501
68 05756535 "R" + 793-501

69 05756537
70 05756538 "R" + 793-501
71 2 x 05756540 "R" + 793-501

73 05756539 "R" + 793-501

74 05756537
75 05756417

Optional1 : Projektgruppe : Walzenzüge-4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Kabelbäume D Version 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.

17.11.2005 07:51:17 Seite 2

946 BOMAG 008 911 49

Wiring diagram 17.1
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge-4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Kabelbäume D Version 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.

17.11.2005 07:51:57 Seite 3

008 911 49 BOMAG 947

17.1 Wiring diagram
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge-4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Kabelbäume D Version 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.

17.11.2005 07:51:57 Seite 4

948 BOMAG 008 911 49

Wiring diagram 17.1
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

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Messtechnik D 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.

16.11.2005 14:51:24 Seite 1

008 911 49 BOMAG 949

17.1 Wiring diagram
WAGO smart DESIGNER 4.1

13 05756539 "R" + 793-501

14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501

17 05756540 "R" + 793-501

18 05756537
19 05756417

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Messtechnik D 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.

16.11.2005 14:51:24 Seite 2

950 BOMAG 008 911 49

Wiring diagram 17.1
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Messtechnik D 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.

16.11.2005 14:51:51 Seite 3

008 911 49 BOMAG 951

17.1 Wiring diagram
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Messtechnik D 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.

16.11.2005 14:51:51 Seite 4

952 BOMAG 008 911 49

Wiring diagram 17.1
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.

16.11.2005 14:48:22 Seite 1

008 911 49 BOMAG 953

17.1 Wiring diagram
WAGO smart DESIGNER 4.1

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.

16.11.2005 14:48:52 Seite 2

954 BOMAG 008 911 49

 X74 X75
X55
X56 X76 X53 X54

008 911 49
Wiring diagram

X5
X21
X11 X12
X59 X13
X58 X42
X20
X46 X14

X18 X77
X17 X6 X7
X22 X19 X4 X3
X8
X48 X49 X10
X36 X60
X37 X1 X61
X38 X2
X9
X44

BOMAG
X61
X77 X9
X21
X74 X75
X59
X76
X42 X11 X12 X8
X10
X46 X13
X56
X53
X20
X18
X5 X17 X14
X19 X55 X6 X7
X54

X58
X4 X3
X36 X1
X37 X44 X2
X38 X60

X48 X49
X22

Gez.: 19.10.2005 Seite: 1 von: 1

Name: Vogt
Steckerübersicht BW 177...219 D-4/D-40 page: 1 from: 1
582 702 09
17.1

955
Gepr.: 19.10.2005 Ers. f.: Blatt Nr.: 301
Name: Seis Connector overview BW 177...219 D-4/D-40 Replaces: Sheet No.: 301
17.1 Wiring diagram

956 BOMAG 008 911 49

 17.2 Wiring diagram

008 911 49 BOMAG 957

17.2 Wiring diagram

Serial number for wiring diagram 582 702 29 not yet available at the printing deadline.

958 BOMAG 008 911 49

Inhaltsverzeichnis: BW 177..219 D−4/D−40

008 911 49
table of contents: BW 177..219 D−4/D−40
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
Wiring diagram

001 582 702 29 Stromlaufplan Circuit Diagram

002 582 702 29 Versorgung, Starten, Motordrehzahl supply, starting unit, engine−speed
003 582 702 29 Motor−Heizflansch, Signalhorn, Kraftstoffvorwärmung engine heating−flange cont., warning horn, fuel pre−heater
004 582 702 29 Bremse, Rückfahrwarneinr., Überwachung brake, back up alarm, monitoring
005 582 702 29 Anzeigen indicators
006 582 702 29 Fahrstufen, Sitzkontaktsch., Vibration speed−ranges, seat−switch, vibr.
007 582 702 29 ZA Messtechnik option measurement equipm.
008 582 702 29 BOMAG Compaction Management BCM BOMAG Compaction Management BCM
009 582 702 29 ZA Beleuchtung und StvZO opt. illumination and StvZO
010 582 702 29 ZA Kabine, Beleuchtung, Radio, Tachograph opt. cabin, headlights, radio, tachograph
011 582 702 29 ZA Kabinenheizung, Klimaanlage, Zusatzheizung opt. cabin−heater, air conditioning, add. heater
012 582 702 29 Diebstahlschutzsystem D−4, D−40, DHC−4, DH−40 anti − theft system
101 582 702 29 Bauteilliste component listing

BOMAG
03.01.2007
001 001
Vogt Stromlaufplan 582 702 29
03.01.2007
17.2

959
circuit diagram 001
Seis
 960
30 7:1
K30
10:2
15:54
17.2

2:10 K11 30
X1
X1:15E 2:10
17E
87 87a
1

X1:9
F13 1

X1:10
F105
30A
2 20A
X1:15A 2 K11/87 3:1

X1
X37:A
17A X1

X36:B
S00 30 X1:30E

X36:A
30 27E
B+
2:11 K35 1
2:16 F14 1 F39
15A 15A

4qmm
Startschalter 87a 87 2 2
starting switch 15 54 58 19 17 50a
X1 X1 X1:30A
15:54 27A
2:13 80 K32:86
X1 10:2
79 S120 11 23
30 F14:2
6:9
K114
nur ohne Sitzkontaktschalter
without switch seat−contact

X37:B 2:14 S01:21

X1:3 X1:4 6:9
V01
3:2 87a 87

switch engine speed

30 12 24

Schalter Motordrehzl
2 1 K11:86 K05 X1:151
4:5
7:5

30(3)

main fuse
125mA
4:3

Hauptsicherung
K14 21 11 31 ?

heating−flange
K61 87 87a

Sicherung Heizflansch
3:5 86 1 K61 30 S01
87(4) 86
F48 2 F00 2 R10 2:5 22 12 32 ?
82 OHM K35
87 87a NOT−AUS
85 2 K05/87

125A
125A
1 1 3:2 85 Emerg.−Stop
X1:53

BOMAG
4:13 X1:152
K61/85
7:2 2:5 B+ X1 X1 X1 X1 30
X1:60 K22
X1 D+ MESX 7 8 58 59
1 4:9
G03 + G01 + X1 2x2.5qmm 87 87a
65 X38:A 2

nur bei Klimaanlage

B+ X1
− − D+ V47 X1
3.9A

81 54

only acc.to air conditioning

G02

125mA
50A / 10A
30 50 1
3.8A

86 AW
AUX

86 86 86 Y01 2 + HW 1

167A
K09 Y13
B− W M01 K114 Y120
1 1 K36 K11 M
S30 1 70A/1A − 2

31−1
R19 85
85 85 85 −
2 X1 X1 X1

nur bei BW 219D−4 und D−40 USA Version, sonst Option

only at BW 219 D−4 and D−40 USA version, otherwise option
X1:55 X1:56
2 W 5:2 62 63 55

Option
option
X1:66 X1:168

31 31 3:1
2:8 4:4 11:7 2:18 2:16 2:13

Trennschalter Batterie
break switch battery
Heizflansch Batterie Batterie Generator Starter Startmehrmenge Hubmagnet Drehzahl Kraftstoffabschaltug
heating−flange battery battery generator starter start boost fuel sol. engine speed fuel shut off

03.01.2007
1 1

008 911 49
Wiring diagram

Vogt Versorgung, Starten, Motordrehzahl 582 702 29

03.01.2007
Seis supply, starting unit, engine−speed 002
 2:20 K11/87 K11/87 4:1

4:19 X1 X1
GLÜH 28E 37E
2:10 K11:86 X1 1 1

008 911 49
F23 F124
52
10A 25A
2:13 K05/87 X1 2 2
X1 X1
78
28A 37A
X1
Wiring diagram

75

X1:155

13 23
5 2 7 1 S03

14 24
A13
X1 X1
3 4 6 97 98

Anbau im Motorbereich
X1 X1

assembled in engine−area
101 102

Modul Heizflanschsteuerung
modul heating−flange−control
1

Taster Signalhorn
X1:217

push but. warning horn

BOMAG
K14

2
2

V21
V22

4.2A
4.2A

1
1

Relais Heizflansch
Nur bei BW 219 D−4 und D−40 USA Version, sonst Option
only at BW 219 D−4 and D−40 USA version, otherwise option

relais heating−flange
B11 1 B11 1 1

Anbau im Motorbereich
R79

assembled in engine−area
2
1 2 2 2
nicht bei D−40/BW211D−4 ohne SN1
not at D−40/BW211D−4 ohne SN1
Option Winterpaket
option winter package

B113
2

X1 X1 X1 X1
57 64 99 100 X1:218

2:20 31 31 4:1

2:2
Kühlmitteltemperatur Signalhorn Signalhorn Kraftstoffvorwärmung
collant temperature warning horn warning horn fuel pre−heater

03.01.2007
1 1 582 702 29
Vogt Motor−Heizflansch, Signalhorn, Kraftstoffvorwärmung
03.01.2007
17.2

961
Seis engine heating−flange cont., warning horn, fuel pre−heater 003
 962
3:20 K11/87 K11/87 6:1
Zentralstecker Sammelanzeige (Ansicht von hinten)
X1 X1:31E mainplug monitoring module (view from backside)
29E
17.2

9 8 7 6 5 4 3 2 1
1 1
F25 F24
10A 10A
2 2 X5:1−20
Sammelanzeige 201918 1716151413 121110
X1
X1:31A monitoring module
29A 6 Vorglühen
F24:2 GLÜH
F24:2 5:1 A15 3:5
Warnbl.
7 BL−W
9:16
X1 15/54 Blinker rechts
20 FUEL 19 BL−R
HOURS 9:17
X1:156 86 OUT2 Blinker links
9 18 BL−L
F25:2 9:17
6:2 OUT1 Sitz
1 12 A68/6
6:9
Bel.
8 4
X12 X13 9:5
1 1 BEL 10 3

geöffnet in 0
Position (Bremse ein)
BR/BN 30 BR/BN
30 2 14 11 13 15 17 16 5

D+
K48 K26

GND
B13 B14
4:2 4:6

Bremse

6:9
6:9

Luftfilter
87a 87 87a 87

Tankanzeige
BL/BU SW/BK BL/BU SW/BK
Motoröldruck

Öltemperatur

30

Hydraulikölfilter

D+
Wasserabscheider

K36 X1 X1 X1
B06:1

2:7
Kühlmittelfüllstand

69 87 76

Initiator Farhebel"0
87a 87

Initiator Vorw. und Null

X1 X1 X1 X1
X12 3 X12 2 X13 3 X13 2 110 71 X1:77 X1:72 111 112
X1 X1 X1 X1 X1
106 67 X1:74 73 X1:68 107 108
5:6

BOMAG
K48:87A 4:13 X1:147 K26/87A

proximity switch travel lever "0"−position

6:9

proximity switch forwards and "0"−position

K48/86 11
6:9
X1:148 S01 X1

K61/85
2:18 109 2:6
12 SITZWARN.
6:9
X1:61 B30:2

X1:150 X1 X1 X1
105
X1:153 114 90 K48:87A X8 1 X8 2
7:2 4:3
X10

300mA
X1:113 BRAKE MESX 2 X21:1
Sensor

X1 or B21 3 B03 3 2 1 B06 1 B55 B124

2.5A
125mA
X9 89 +
86 86 Y04 86 1 86 R03
K48 K05 1 K26 K22 P P _t P Q
H14+ + bl 4 4 B30 2 −
− P

H07
85 85 2 85 X9 85 X10 X21:2
2 3 X1:117 X1:57

125mA
125mA
X1:149 X1 X1:82 X1:117
X1:117 129 X1:117
3:20 31 31 5:1

4:3 2:11 4:8 2:18 nicht bei D−40

not at D−40 nicht bei D−40/BW177 D−4
not at D−40/BW177 D−4

Magnetventil Bremse Rückfahrwarnsummer Warnsummer Störung Tankgeber Luftfilter Motoröldruck Sensor Wasserabschei
solenoid valve brake buzzer back up alarm buzzer failure sender fuel
air cleaner engine oil pressure sens. water separator
Hydraulikölfilter Öltemperatur Kühlmittelstand
hydraulik oil cleaner oil temperature coolant stock level

03.01.2007
1 1

008 911 49
Wiring diagram

Vogt Bremse, Rückfahrwarneinr., Überwachung 582 702 29

03.01.2007
Seis brake, back up alarm, monitoring 004
 4:11 F24:2 F24:2

X1:225

008 911 49
X1:187
Wiring diagram

br

X1
92

X22:1
X1:191

Voltmeter
volt meter
Drehzahlmesser
RPM meter
Hydrauliköltemperatur
hydraulic oil temperature
Kühlmitteltemperatur
collant temperature
gg

X1:189
+

+
15/54
Lern
Test
OUT+

+ + + + br
+ ws X22:4
P05 P04
P12 V P03 n P02 P14 B16 Modul Geschw. A05
modul speedometer
speedometer

−
− G − G − G − bei BW177 sw − X22:3 − −

Frequenzanzeige
frequency meter
in

bei BW213 bl
sw
Geschwindigkeitsanz.

X1:192 X1
OUT−

bei BW177 bl
bei BW213 sw

Aufnehmer Vibration
transducer vibration
93

X22:2
in X1:188
15/54
OUT+
OUT−
ZA Geschwindigkeitsanzeige
bl option speedometer
X1:70 X1:227 X1:226 A06 Elektronik
transducer
W
2:6 − 1 3 4
X1:223

BOMAG
X1:171

+
X1:173
1 BW 177−179 D−4/40 −−−− B60 dir. DIR MESX 7:2

B30:2
BW 177−179 DHC−4/DH−40 −−−−
R04 speed SPEED MESX 7:2
2 BW 211−216 D−4/40 PIN 1: −
X1:172
BW 213−214 DHC−4/DH−40 PIN 1: − − SPEED TAC 10:6

4:15
BW 216 DHC−4 PIN 3: +
BW 219 D−4 PIN 3: +

X1:82 X1:228 X1:190

X1:174

4:20 31 31 6:1

Hydrauliköltemperatur Sensor Achse

hydr.oil temp. sender axle

ZA Frequenzanzeige nur bei ZA Messtechnik, Geschw.−Anzeige und Tachograph

option frequency meter only at opt. measurement−equ., speedometer and tachograph

03.01.2007
1 1 582 702 29
Vogt Anzeigen
03.01.2007
17.2

963
Seis indicators 005
964
4:20 K11/87 K11/87 9:1
D+
4:13
B06:1 X1:32E
4:17
17.2

4:3 K48/86 F03 1

15A 2

X1:32A

F14:2
2:20
Nur mit Sitzkontaktschalter
only with switch seat−contact

nur D−40/BW177D−4 Standard D−Maschinen/D−40 USA

only D−40/BW177D−4 Standard D−maschines/D−40 USA

Fahren
Öldruck
D+
F25:2 1 12 13 14 30 56
4:8
K04
31
A68 Modul Sitzschalter/Vibration
module seatswitch/vibration

S 56b
modul vibration
Modul Vibration

13 4 6 9 11 15 5
S42 1234 2
S42

1 5 7 3 S01:21
14 2:20 X1:158 X1:157
Fahrstufensch.
switch speed ranges K26/87A

switch speed ranges

Nur ohne Sitzkontaktschalter
without switch seat−contact

4:8 X14 X11

Schalter Fahrstufen
2
1
B 1 X1:159
V09 X1 14
S13
88
23 13
A68/6 3 S35
S58
4:19 13

BOMAG
X1:143 X1:144 X1:162 X1:143 SITZWARN. 4
4:10 24 14

2
1
V05 X1:161 X1:160
V02 V03
2 1 1 2
GA MESX
7:2
KA MESX
Taster Vibration
pushbutton vibration

X1:141 X1:137 X1:142 X1:141 7:2

X1:116 X1:115
switch seat−contact
Sitzkontaktschalter

1.23A
1.23A
1.23A
X6 X7
Y31 Y30 Y30 Y31 X14 X11 1 1
1 1 1 1 Y07 Y08
3.33A
3.33A

A 2
10:7 KA
10:6 GA

a b
2 2 2 2
X6 X7
2 2
X1:124 X1:138 X1:124 X1:124
X1:149
X1:154
X1:149
X1:149

31
X1:118

5:20 31 7:1

Schalter Vibration klein/groß

nur BW216+219D−4 switch vibration small/big ampl.
only BW216+219D−4
Stufenumsch. hinten Stufenumschaltung vorn Stufenumschaltung hinten Vibration vorne groß
switching axle switching drum switching axle vibration big ampl.
Vibration vorne klein
Stufenumschaltung vorn
switching drum vibration small ampl.

03.01.2007
1 1

008 911 49
Wiring diagram

Vogt Fahrstufen, Sitzkontaktsch., Vibration 582 702 29

03.01.2007
Seis speed−ranges, seat−switch, vibr. 006
 Beschleunigungssensoren Beschleunigungssensoren Drucker Anzeige BMFSA Display Messtechnik BOP
acc. sensor front acc. sensor rear printer Display BMFSA display measurem. BOP

GND
2:20 30 30 9:1
Pot 30
K11/87
9:20 Pot 15

008 911 49
X2:66 X2:70 X2:47 X2:48 X2:49
X1:145 X42:1 X42:2 X42:3
X2:71
Wiring diagram

X46:B X46:A X46:E

X1:33E X1:35E 31
+ −
1 1 S01
F148 F146 2:18 X2:56 X2:53 X2:60 X2:57
10A 15A
2 2 32
X48:2 X48:1 X49:2 X49:1 P33
X1:33A X1:35A X1:146

X4:C
X4:E

X4:D
P16
B62 B62 F1 F2

+/sw
+/sw
nur bei BEM
only at BEM

F148:2 X1:34E −/gg −/gg

8:15
CAN+ CAN−
nur bei BTM+/BTM prof
only at BTM+/BTM prof

F84 1 X46:D X46:F

10A 15g/bl 15g/bl

X74:3
X74:5
X74:4
2 X42:4 X42:5
X2:57 X1:34A P11

20g/br
20g/br
nur bei BTM prof
X48:3 X48:4 X49:3 X49:4

only at BTM prof

X74:1 X74:2
X2:50 X2:51
X2:54 X2:55 X2:58 X2:59 X4:A X4:B R20
1 2
60OHM
X2:64 X2:65

Pot. 15
Leistung
Elektronik
AGND MESX

Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
CAN1+
CAN1−

RxD TxD

BOMAG
X44:1

X44:7
X44:5
X44:4

X44:31

X44:56
X44:57
X44:59
X44:60
X44:30

X44:58
X44:29
X44:27
X44:26

X44:28
X44:54
A83
Messtechnik−Rechner

X44:38
X44:15
X44:35
X44:14
X44:36
X44:37
X44:41
X44:25
X44:53
X44:33

measurement calc. unit

X44:3

X44:55
X44:65
X44:66
X44:67
X44:68

GA MESX CAN3+ CAN3−

6:17

GPS
GND
GND
EVIB

6:17 KA MESX CAN3− 8:15

SPEED MESX X1:85
5:17
DIR MESX X2:49 X2:52 + CAN3+
5:17 BEL MESX STVZO 8:15
9:7 X2:79 P07 E
VIB
4:5 BRAKE MESX BEL MESX 9:4
−
D+ MESX
2:6 Anschluß ohne StvZO Bel. X2:63 X2:66 X1:82
connection without StvZO

31 31 8:1
6:20

EVIB−Meter
EVIB−meter
nur bei BEM
only at BEM

03.01.2007
1 1 582 702 29
Vogt ZA Messtechnik
03.01.2007
17.2

965
Seis option measurement equipm. 007
966
17.2

F148:2
7:2

CAN3−
7:18

7:18 CAN3+

CAN3+ CAN3−
1 R242
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

X76:2
P15
X4:F

X2:63

BCM 05

nur bei BCM

only at BCM

7:20 31 31 9:1

03.01.2007
1 1

008 911 49
Wiring diagram

Vogt BOMAG Compaction Management BCM 582 702 29

03.01.2007
Seis BOMAG Compaction Management BCM 008
 6:20 K11/87 K11/87 7:2
7:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
F11 F18 F07 F08
15A 10A 15A 15A

008 911 49
30
X1:18A K06 X1:19A X1:25A
X1:26A
9:4 X1:305
X1:83

X1:301
Schalter StvZO 87 87a
switch, StvZO
Wiring diagram

13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO L0R Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:306
X1:307

X3:4 X3:5 with cabin 30 49L 49R

STV1

X1:302
10:17 A02
STV2
10:17
X1:23E X1:24E
K16 30 31 82 L R
9:9 F09 F10
15A 15A
87 87a X1:23A X1:24A

4:11 BL−L X1:91

4:19
13 BEL BEL MESX STVZO BL−R
4:19
7:8
X1:96
S53 14

switch, working head lights

Schalter Arbeitsbeleuchtung

BOMAG
X1:308

X1:304

X1:303
13 23
01
01
X1:84 S14

X1:311

lights without StvZO

X1:313

Anschluß Arbeitsschein−
werfer ohne StvZO
connection working head
BEL MESX Warnblinkschalter 14 24
7:8 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.

X61:3 X1:320

X59:5 X1:310
X60:3 X1:319
X59:3 X1:312

X58:5 X1:309
X58:3
X61:1 X1:322

X60:1 X1:321
X59:2 X1:314

X58:2

BL−W

0,125A
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 4:19 E08 1 E09 1 E10 1 E11 1

0,125A
+
2 2 86 2 2 2 2 86 2 2 2 2 H06 2 2 2 2
K06 K16

4,6A
4,6A
4,6A
4,6A

−
X61:2

X59:6

X58:6
X60:2

85 85
X3:1

X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6

4,6A
4,6A
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A

X1:323 X60:4
X1:324 X61:4
X1:315
X1:316

X1:323
X1:324

8:20 10:1
31
9:10 Schlußleuchte links 9:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
Anschluß Arbeitsscheinwerfer
Scheinwerfer rechts parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
head light RH Parkleuchte rechts Blinkleuchte HL
parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schlußleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH

03.01.2007
1 1 582 702 29
Vogt ZA Beleuchtung und StvZO
03.01.2007
17.2

967
Seis opt. illumination and StvZO 009
 968
F42:H 11:14 F41:5 11:14
X3:6
2:11 K30 2:11 K32:87 11:2
X3:7
17.2

K32:86 K32 30 STV2

X3:8 9:13
2:20 10:2 9:13 STV1
87 87a E F
G H A B C

X3:3
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3
5 6
F42 11:8
F130 10:9 F130 F130 11:7
10:14

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
10:16 E29 E70
− − − − 1
87 87a 2 2 2 1
31 S21 5 4 S20 5 4
Radio
radio

Steckdose Fahrerst.
3,8A
3,8A
1 Tachographenmodul

socket operator platform

E71 1 module, tachograph
XS
+ R80 A2+A3
X3:17
4,6A
4,6A
4,6A
4,6A

2 4 6 A1 XS
Nachtleuchte
− 5:17 P09 +

indicator
X55:1
X56:1

X55:3
X56:3
12V 2 1

X55:4
X56:4
night illumination
SPEED TAC A16 1 B3 E27 1 E28 1 E23 1 E25

Kontrolleuchte
Innenleuchte
inside light, cabin
socket cabin

−
12V
Steckdose Kabine

+ 7,8,9 2 B4 2 2 2 2
A01 5 3 C3

A5+A6

BOMAG
S45 TK −

Heizung Heckscheibe
4 1

heating rear screen

A51

Schalter Innenleuche
switches interior lights
3
5A

86 S86 + 3 2 5 + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31

X3:16
X3:15
− −
3 min

− M07 − M06 4

KA
85

GA
2,9A
ZA

Nur bei Geländer/Rops/SD

4,7A

X55:2 X56:2 option

Abfallverzögert

only at hand−rail/Rops/sun−roof
6:17
6:16
11:11
Relais Kabine Türkontaktschalter Frequenzmodul Tachograph KABINE 31
relais cabin door switch module, frequency tachograph Schalter Nachtleuchte
switch, night illumination

X3:1
X3:2
Schalterbel.
switch illum.

9:20 31 31 11:1

10:6 Wascher hinten Wascher vorn 10:2 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

03.01.2007
1 1

008 911 49
Wiring diagram

Vogt ZA Kabine, Beleuchtung, Radio, Tachograph 582 702 29

03.01.2007
Seis opt. cabin, headlights, radio, tachograph 010
 10:20 K32:87 10:19 F41:5
Potential 15 aus Kabine
F42:H
10:4

F31 D F40 A F15 B

BOX2 BOX2
20A 20A 5A
4 10:17 F130 1 2

008 911 49
Potential 15 aus Kabine
F42
10:9 Potential 30 aus Kabine
Wiring diagram

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
2:8
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
_t 2 2
2

Thermofühler Klimaanlage
inline fuse

BOMAG
X19:2 Inline Sicherung
X20:1 X18:2

X17:1 X1:163
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

Überwachung Kühlmitteldruck
monitoring coolant pressure
M09 M M09 M
Kabinenlüfter 2 2
br br −
X20:2
X69:2 X77:2
Option
option

Y15 1 2
X17:4 V04 X1:168
2 1 10:19

3,5A
X1:164 KABINE 31
10:20 31 31 12:1

Kabinenlüfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit

Frischluft Lüfter
blower fresch air

03.01.2007
1 1 582 702 29
Seis ZA Kabinenheizung, Klimaanlage, Zusatzheizung
03.01.2007
17.2

969
Seis opt. cabin−heater, air conditioning, add. heater 011
970
17.2

A67 1 2 3
Keyboard
keyboard
4 5 6

7 8 9

ANN 0 VAL

A66
Steuereinheit
control unit

BOMAG
+
H80
−

ZA
option

03.01.2007
1 1

008 911 49
Wiring diagram

Vogt Diebstahlschutzsystem D−4, D−40, DHC−4, DH−40 582 702 29

03.01.2007
Seis MV009 anti − theft system 012
 Name Bl. Pf. Benennung title TYP
A02
Wiring diagram
A05
A06
009
005
005
17
17
10
Blinkgeber
Elektronik Geschwindigkeitsanzeige
Elektronik Frequenzanzeige vorne
flasher
Electronic system, speedometer
electronic frequency−meter, front
MODUL
MODUL
17.2
A12 010 5 Radio Radio
A13 003 3 Steuergeraet Heizung Control unit, heating
A15 004 16 Ueberwachungsmodul monitoring module
A16 010 7 Elektronik Tachograph Electronic system, tachograph
A51 010 6 Platine Frequenzanzeige Circuit board,frequenzy meter
A66 012 9 Elektronik Steuereinheit Electronic control unit
A67 012 15 Eingabeeinheit Keyboard
A68 006 10 Modul Sitzkontakt Modul seat contact MAX. 0,12A
A72 011 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A83 007 6 Elektronik Messtechnik electronic measurement−equipment
A87 008 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
Seis
03.01.2007
Vogt
03.01.2007

B03 004 15 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B06 004 17 Druckschalter Motoroel Pressure switch, engine oil
B11 003 9 Signalhorn Warning horn MAX.5A
B11 003 11 Signalhorn Warning horn MAX.5A
B13 004 2 Naeherungsinitiator Fahrhebel links Proximity switch, travel lever, lh.
B14 004 6 Naeherungsinitiator Fahrhebel rechts Proximity switch, travel lever, rh.
B16 005 9 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 004 14 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B30 004 16 Temperaturschalter Motoroel Temperature switch, engine oil
B51 010 5 Lautsprecher Radio Speaker radio
B51 010 6 Lautsprecher Radio Speaker radio
B55 004 17 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B60 005 14 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 007 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 007 8 Beschleunigungsaufnehmer Acceleration sensor
B62 007 10 Beschleunigungsaufnehmer Acceleration sensor
B103 011 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 011 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B113 003 3 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B124 004 19 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 011 10 Temperaturschalter Heizung Temperature switch, heating

E08 009 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 009 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 009 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 009 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 009 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 009 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
component listing

E14 009 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A

E15 009 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
Bauteilliste

E16 009 2 Scheinwerfer links Head light, lh. MAX. 4,6A

E17 009 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E23 009 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 010 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 009 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 010 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 009 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 010 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 009 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 010 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 010 4 Innenleuchte Kabine Inside light, cabin 1,75A
E30 011 15 Heizgeraet Heating unit
E32 010 19 Kennleuchte Warning light 5A
E70 010 15 Nachtleuchte Night lamp 0,83A
E71 010 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 010 16 Beleuchtung Bedienschalter illum. Switches

F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A

F03 006 18 Sicherung Vibration Fuse, vibration MAX. 1,23A
F07 009 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 009 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 009 6 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 009 8 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 009 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F14 002 18 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 15A
F15 011 19 Sicherung Heizgeraet Fuse, heating unit BOX2
F18 009 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 009 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 009 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 003 9 Sicherung Signalhorn Fuse, warning horn 10A
F24 004 10 Sicherung Ueberwachungsmodul Fuse, monitoring module 10A
F25 004 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F31 011 3 Sicherung Kabinenluefter Fuse, cabin ventilator
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 011 15 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
F41 010 19 Sicherung Rundumkennleuchte Fuse, rotary beacon
1

F42 010 4 Sicherung Kabineninnenleuchte Fuse, inside light cab

F43 010 10 Sicherung Wischermotor hinten Fuse, wipermotor rear
F44 010 13 Sicherung Wischermotor vorn Fuse, wipermotor front
F48 002 3 Sicherung Gluehanlage Fuse, glow plug system 125A
F68 002 6 Sicherung Potential 30 Fuse, potential 30 5A
7

F84 007 5 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F97 011 13 Sicherung Frischluftluefter fuse, blower fresh air 3A
FM4 007 11 Platinensicherung Multifuse
F105 002 16 Sicherung Motordrehzahl Fuse, motor speed 20A
582 702 29

F124 003 14 Sicherung Kraftstoffvorwärmung Fuse, fuel pre−heating 25A

F130 010 15 Sicherung Nachtleuchte Fuse, night lamp
F143 010 2 Sicherung Heckscheibenheizung fuse rear screen heating unit
F144 010 20 Sicherung Kabinensteckdose Fuse cabin−socket
F146 007 4 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30)
101

F148 007 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15)

008 911
G01 49 002 4 Batterie BOMAG
Battery 103A 971
 Name Bl. Pf. Benennung title TYP

17.2 G02
G03
002 5
002 3
Generator
Batterie
Generator
Battery Wiring
103A diagram

H06 009 15 Meldeleuchte Warnblinker Indicator light, hazard light

H07 004 10 Warnsummer Betriebsstoerung Warning buzzer, breakdown MAX. 0,12A
H14 004 8 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX. 0,12A
H80 012 15 Meldeleuchte Wegfahrsperre Indicator light, anti−theft device LED

K04 006 18 Schrittrelais Vibration Toggle relay, vibration MAX. 1,23A

K05 004 3 Relais Startstrom Relay, starting current BOSCHW
K06 009 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW
K14 003 5 Relais Vorgluehen Relay, glow plug system BOSCHL
Seis
03.01.2007
Vogt
03.01.2007

K16 009 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K22 004 9 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K26 004 6 Relais Rueckfahrwarneinrichtung Relay, back up alarm BOSCHW
K32 010 2 Relais Kabine Relay, cabin BOSCHW
K35 002 16 Relais Selbsthaltung Relay, holding contact BOSCHW
K36 002 7 Relais Bremskontrolle Relay, brake control BOSCHW
K48 004 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K61 002 5 Relais Ladekontrolle Relay, charge control BOSCHW
K114 002 14 Relais Motordrehzahl Relay, engine rpm BOSCHW
K141 010 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW

M01 002 11 Starter Starter 2.3 KW

M04 010 13 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 010 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 010 14 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 010 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 011 3 Kabinenluefter Cabin ventilator
M09 011 4 Kabinenluefter Cabin ventilator
M17 011 13 Zusatzluefter Additional blower

P02 005 5 Temperaturanzeige Hydraulikoel Temperature gauge, hydraulic oil

P03 005 3 Drehzahlmesser Rpm meter
P04 005 19 Geschwindigkeitsanzeige Speedometer
P05 005 11 Frequenzanzeige vorne Frequency meter, front
P07 007 15 Omegameter Omegameter
P09 010 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 007 14 Drucker Printer
P12 005 2 Voltmeter Volt meter
P14 005 6 Anzeige Kuehlmitteltemperatur Temperature gauge, coolant
component listing

P15 008 16 BCM 03 Bildschirm BCM 03 terminal

P16 007 16 Diagnose, Variomatic Diagnostics, varimatic
Bauteilliste

P33 007 18 Opus 21 Opus 21

R03 004 12 Geber Tankanzeige Sender, level gauge

R04 005 4 Geber Hydraulikoeltemperatur Sender, hydraulic oil temp.
R10 002 6 Parallelwiderstand Parallel resistor 82 OHM
R19 002 2 Heizflansch heater flange 167A
R20 007 17 Widerstand Resistor 60OHM
R24 008 15 Widerstand Resistor 60 OHM
R79 003 14 Kraftstoffvorwärmung fuel pre−heater 250W
R80 010 2 Heizung Heckscheibe heating rear screen

S00 002 10 Startschalter Starter switch

S01 002 18 Schalter NOT AUS Switch, emergency off
S03 003 9 Taster Signalhorn Push button, warning horn
S13 006 13 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 009 15 Warnblinkschalter Switch, hazard light
S15 009 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 010 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 010 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 011 19 Schalter Kabinenheizung Switch, cabin heating
S30 002 3 Batterietrennschalter Switch, battery disconnect
S35 006 15 Vibrationsschalter klein/gross Switch, vibration low/high
S37 009 18 Schalter Blinker Switch, indicator
S38 010 19 Schalter Kennleuchte Switch, warning light
S42 006 3 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S42 006 7 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S44 011 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 010 4 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 009 4 Schalter Arbeitsbeleuchtung Switch, working lights
S58 006 13 Schalter Aetherstartanlage Push button, ether starting unit
S86 010 4 Schalter Tuer, links Switch door, lh.
S120 002 14 Schalter Motordrehzahl Switch, engine speed
S158 010 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 010 16 Schalter Heckscheibenheizung switch rear screen heating unit

V01 002 6 Diode Diode 4UF004

V02 006 6 Diode Diode MAX. 1,23A
2

V03 006 7 Diode Diode MAX. 1,23A

V04 011 8 Diode Diode FE5B
V05 006 10 Diode Diode MAX. 0,12A
V06 011 9 Diode Diode
V09 006 10 Diode Diode MAX. 0,12A
7

V21 003 10 Diode Diode

V22 003 11 Diode Diode
V47 002 15 Diode (A7) Diode (A7) FE5B
582 702 29

X1:1 002 5 WAGO,E−Kasten WAGO,E−BOX

X1:2 009 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:3 002 9 WAGO,E−Kasten WAGO,E−BOX
X1:4 002 10 WAGO,E−Kasten WAGO,E−BOX
X1:7 002 11 WAGO,E−Kasten WAGO,E−BOX
102

X1:8 002 12 WAGO,E−Kasten WAGO,E−BOX

X1:9 002 4 WAGO,E−Kasten WAGO,E−BOX
972 X1:10 002 4 WAGO,E−Kasten BOMAG
WAGO,E−BOX 008 911 49
 Name Bl. Pf. Benennung title TYP
X1:52
Wiring diagram
X1:53
X1:54
003
002
002
2
12
18
WAGO,E−Kasten
WAGO,E−Kasten
WAGO,E−Kasten
WAGO,E−BOX
WAGO,E−BOX
WAGO,E−BOX
17.2
X1:55 002 10 WAGO,E−Kasten WAGO,E−BOX
X1:55 002 18 WAGO,E−Kasten WAGO,E−BOX
X1:56 002 15 WAGO,E−Kasten WAGO,E−BOX
X1:57 003 3 WAGO,E−Kasten WAGO,E−BOX
X1:57 004 15 WAGO,E−Kasten WAGO,E−BOX
X1:58 002 16 WAGO,E−Kasten WAGO,E−BOX
X1:59 002 16 WAGO,E−Kasten WAGO,E−BOX
X1:60 002 16 WAGO,E−Kasten WAGO,E−BOX
X1:61 004 15 WAGO,E−Kasten WAGO,E−BOX
X1:62 002 16 WAGO,E−Kasten WAGO,E−BOX
X1:63 002 16 WAGO,E−Kasten WAGO,E−BOX
Seis
03.01.2007
Vogt
03.01.2007

X1:64 003 3 WAGO,E−Kasten WAGO,E−BOX

X1:64 012 12 WAGO,E−Kasten WAGO,E−BOX
X1:65 002 5 WAGO,E−Kasten WAGO,E−BOX
X1:66 002 6 WAGO,E−Kasten WAGO,E−BOX
X1:67 004 15 WAGO,E−Kasten WAGO,E−BOX
X1:68 004 17 WAGO,E−Kasten WAGO,E−BOX
X1:69 004 13 WAGO,E−KASTEN WAGO, E−box
X1:70 005 3 WAGO,E−Kasten WAGO,E−BOX
X1:71 004 15 WAGO,E−KASTEN WAGO, E−box
X1:72 004 17 WAGO,E−Kasten WAGO,E−BOX
X1:73 004 17 WAGO,E−Kasten WAGO,E−BOX
X1:74 004 16 WAGO,E−Kasten WAGO,E−BOX
X1:75 003 4 WAGO,E−Kasten WAGO,E−BOX
X1:76 004 17 WAGO,E−KASTEN WAGO, E−box
X1:77 004 16 WAGO,E−KASTEN WAGO, E−box
X1:78 003 4 WAGO,E−Kasten WAGO,E−BOX
X1:79 002 10 WAGO,E−Kasten WAGO,E−BOX
X1:80 002 14 WAGO,E−Kasten WAGO,E−BOX
X1:81 002 14 WAGO,E−Kasten WAGO,E−BOX
X1:82 004 11 WAGO,E−Kasten WAGO,E−BOX
X1:82 005 4 WAGO,E−Kasten WAGO,E−BOX
X1:82 007 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:83 009 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:84 009 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:85 007 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:86 004 10 WAGO,E−Kasten WAGO,E−BOX
X1:87 004 13 WAGO,E−KASTEN WAGO, E−box
X1:88 006 11 WAGO,E−Kasten WAGO,E−BOX
X1:89 004 10 WAGO,E−Kasten WAGO,E−BOX
component listing

X1:90 004 9 WAGO,E−Kasten WAGO,E−BOX

X1:91 009 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:92 005 19 WAGO,E−Kasten WAGO,E−BOX

X1:93 005 19 WAGO,E−Kasten WAGO,E−BOX
X1:96 009 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:97 003 9 WAGO,E−Kasten WAGO,E−BOX
X1:98 003 10 WAGO,E−Kasten WAGO,E−BOX
X1:99 003 10 WAGO,E−Kasten WAGO,E−BOX
X1:100 003 11 WAGO,E−Kasten WAGO,E−BOX
X1:101 003 9 WAGO,E−Kasten WAGO,E−BOX
X1:102 003 10 WAGO,E−Kasten WAGO,E−BOX
X1:105 004 12 WAGO,E−Kasten WAGO,E−BOX
X1:106 004 14 WAGO,E−Kasten WAGO,E−BOX
X1:107 004 19 WAGO,E−Kasten WAGO,E−BOX
X1:108 004 20 WAGO,E−Kasten WAGO,E−BOX
X1:109 004 12 WAGO,E−KASTEN WAGO, E−box
X1:110 004 14 WAGO,E−KASTEN WAGO, E−box
X1:111 004 19 WAGO,E−Kasten WAGO,E−BOX
X1:112 004 20 WAGO,E−Kasten WAGO,E−BOX
X1:113 004 5 WAGO,E−Kasten WAGO,E−BOX
X1:114 004 8 WAGO,E−Kasten WAGO,E−BOX
X1:115 006 16 WAGO,E−Kasten WAGO,E−BOX
X1:116 006 14 WAGO,E−Kasten WAGO,E−BOX
X1:117 004 5 WAGO,E−Kasten WAGO,E−BOX
X1:117 004 8 WAGO,E−Kasten WAGO,E−BOX
X1:117 004 12 WAGO,E−Kasten WAGO,E−BOX
X1:117 004 14 WAGO,E−Kasten WAGO,E−BOX
X1:118 006 14 WAGO,E−Kasten WAGO,E−BOX
X1:124 006 3 WAGO,E−Kasten WAGO,E−BOX
X1:124 006 6 WAGO,E−Kasten WAGO,E−BOX
X1:124 006 8 WAGO,E−Kasten WAGO,E−BOX
X1:129 004 6 WAGO,E−Kasten WAGO,E−BOX
X1:137 006 4 WAGO,E−Kasten WAGO,E−BOX
X1:138 006 4 WAGO,E−Kasten WAGO,E−BOX
X1:141 006 3 WAGO,E−Kasten WAGO,E−BOX
X1:141 006 8 WAGO,E−Kasten WAGO,E−BOX
X1:142 006 6 WAGO,E−Kasten WAGO,E−BOX
X1:143 006 3 WAGO,E−Kasten WAGO,E−BOX
X1:143 006 8 WAGO,E−Kasten WAGO,E−BOX
3

X1:144 006 6 WAGO,E−Kasten WAGO,E−BOX

X1:145 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:146 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:147 004 5 WAGO,E−Kasten WAGO,E−BOX
X1:148 004 2 WAGO,E−Kasten WAGO,E−BOX
7

X1:149 004 1 WAGO,E−Kasten WAGO,E−BOX

X1:149 006 12 WAGO,E−Kasten WAGO,E−BOX
X1:149 006 13 WAGO,E−Kasten WAGO,E−BOX
X1:149 006 19 WAGO,E−Kasten WAGO,E−BOX
582 702 29

X1:150 004 5 WAGO,E−Kasten WAGO,E−BOX

X1:151 002 18 WAGO,E−Kasten WAGO,E−BOX
X1:152 002 18 WAGO,E−Kasten WAGO,E−BOX
X1:153 004 6 WAGO,E−Kasten WAGO,E−BOX
X1:154 006 13 WAGO,E−Kasten WAGO,E−BOX
103

X1:155 003 9 WAGO,E−Kasten WAGO,E−BOX

X1:156 004 2 WAGO,E−Kasten WAGO,E−BOX
008 911
X1:15749 006 13 WAGO,E−Kasten BOMAG
WAGO,E−BOX 973
 Name Bl. Pf. Benennung title TYP

17.2 X1:158
X1:159
X1:15A
006
006
002
13
16
10
WAGO,E−Kasten
WAGO,E−Kasten
WAGO,E−Kasten
WAGO,E−BOX
WAGO,E−BOX
WAGO,E−BOX
Wiring diagram
X1:15E 002 10 WAGO,E−Kasten WAGO,E−BOX
X1:160 006 16 WAGO,E−Kasten WAGO,E−BOX
X1:161 006 14 WAGO,E−Kasten WAGO,E−BOX
X1:162 006 7 WAGO,E−Kasten WAGO,E−BOX
X1:163 011 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:164 011 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:165 011 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:166 011 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:167 011 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:168 002 8 WAGO,E−Kasten WAGO,E−BOX
X1:168 011 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
Seis
03.01.2007
Vogt
03.01.2007

X1:169 011 7 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:16A 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:16E 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:170 011 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:171 005 14 WAGO,E−Kasten WAGO,E−BOX
X1:172 005 15 WAGO,E−Kasten WAGO,E−BOX
X1:173 005 15 WAGO,E−Kasten WAGO,E−BOX
X1:174 005 14 WAGO,E−Kasten WAGO,E−BOX
X1:17A 002 16 WAGO,E−Kasten WAGO,E−BOX
X1:17E 002 16 WAGO,E−Kasten WAGO,E−BOX
X1:187 005 9 WAGO,E−Kasten WAGO,E−BOX
X1:188 005 10 WAGO,E−Kasten WAGO,E−BOX
X1:189 005 10 WAGO,E−Kasten WAGO,E−BOX
X1:18A 009 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:18E 009 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:190 005 9 WAGO,E−Kasten WAGO,E−BOX
X1:191 005 11 WAGO,E−Kasten WAGO,E−BOX
X1:192 005 11 WAGO,E−Kasten WAGO,E−BOX
X1:19A 009 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:19E 009 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:217 003 14 WAGO,E−Kasten WAGO,E−BOX
X1:218 003 14 WAGO,E−Kasten WAGO,E−BOX
X1:21A 009 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:21E 009 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:223 005 4 WAGO,E−Kasten WAGO,E−BOX
X1:225 005 6 WAGO,E−Kasten WAGO,E−BOX
X1:226 005 6 WAGO,E−Kasten WAGO,E−BOX
X1:227 005 4 WAGO,E−Kasten WAGO,E−BOX
X1:228 005 7 WAGO,E−Kasten WAGO,E−BOX
component listing

X1:22A 009 12 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:22E 009 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
Bauteilliste

X1:23A 009 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:23E 009 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:24A 009 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:24E 009 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:25A 009 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:25E 009 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:26A 009 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:26E 009 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:27A 002 18 WAGO,E−Kasten WAGO,E−BOX
X1:27E 002 18 WAGO,E−Kasten WAGO,E−BOX
X1:28A 003 9 WAGO,E−Kasten WAGO,E−BOX
X1:28E 003 9 WAGO,E−Kasten WAGO,E−BOX
X1:29A 004 2 WAGO,E−Kasten WAGO,E−BOX
X1:29E 004 2 WAGO,E−Kasten WAGO,E−BOX
X1:301 009 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:302 009 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:303 009 9 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:304 009 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:305 009 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:306 009 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:307 009 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:308 009 15 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:309 009 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:30A 002 19 WAGO,E−Kasten WAGO,E−BOX
X1:30E 002 19 WAGO,E−Kasten WAGO,E−BOX
X1:310 009 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:311 009 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:312 009 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:313 009 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:314 009 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:315 009 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:315 009 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:315 009 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:316 009 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:316 009 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:316 009 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:319 009 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
4

X1:31A 004 10 WAGO,E−Kasten WAGO,E−BOX

X1:31E 004 10 WAGO,E−Kasten WAGO,E−BOX
X1:320 009 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:321 009 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:322 009 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
7

X1:323 009 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:323 009 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:324 009 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:324 009 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
582 702 29

X1:32A 006 18 WAGO,E−Kasten WAGO,E−BOX

X1:32E 006 18 WAGO,E−Kasten WAGO,E−BOX
X1:33A 007 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:33E 007 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:34A 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
104

X1:34E 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX

X1:35A 007 4 WAGO ZENTRALELEKTRIK WAGO E−BOX
974 X1:35E 007 4 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 008 911 49
 Name Bl. Pf. Benennung title TYP
X1:37A
Wiring diagram
X1:37E
X2:47
003
003
007
14
14
18
WAGO,E−Kasten
WAGO,E−Kasten
WAGO−MESSTECHNIK
WAGO,E−BOX
WAGO,E−BOX
Wago−measurement equip.
17.2
X2:48 007 19 WAGO−MESSTECHNIK Wago−measurement equip.
X2:49 007 12 WAGO−MESSTECHNIK Wago−measurement equip.
X2:49 007 19 WAGO−MESSTECHNIK Wago−measurement equip.
X2:50 007 17 WAGO−MESSTECHNIK Wago−measurement equip.
X2:51 007 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:52 007 13 WAGO−MESSTECHNIK Wago−measurement equip.
X2:53 007 8 WAGO−MESSTECHNIK Wago−measurement equip.
X2:54 007 7 WAGO−MESSTECHNIK Wago−measurement equip.
X2:55 007 8 WAGO−MESSTECHNIK Wago−measurement equip.
X2:56 007 7 WAGO−MESSTECHNIK Wago−measurement equip.
X2:57 007 2 WAGO−MESSTECHNIK Wago−measurement equip.
Seis
03.01.2007
Vogt
03.01.2007

X2:57 007 10 WAGO−MESSTECHNIK Wago−measurement equip.

X2:58 007 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:59 007 10 WAGO−MESSTECHNIK Wago−measurement equip.
X2:60 007 9 WAGO−MESSTECHNIK Wago−measurement equip.
X2:61 008 15 WAGO−MESSTECHNIK Wago−measurement equip.
X2:62 008 16 WAGO−MESSTECHNIK Wago−measurement equip.
X2:63 007 13 WAGO−MESSTECHNIK Wago−measurement equip.
X2:63 008 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:64 007 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:65 007 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:66 007 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:66 007 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:67 007 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:68 007 12 WAGO−MESSTECHNIK Wago−measurement equip.
X2:69 007 12 WAGO−MESSTECHNIK Wago−measurement equip.
X2:70 007 15 WAGO−MESSTECHNIK Wago−measurement equip.
X2:70 008 18 WAGO−MESSTECHNIK Wago−measurement equip.
X2:71 007 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:77 007 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:78 007 11 WAGO−MESSTECHNIK Wago−measurement equip.
X2:79 007 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X3:1 009 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 010 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:2 010 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:3 010 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:4 009 10 STECKER ROPS/SD conn. ROPS/SR
X3:5 009 12 STECKER ROPS/SD conn. ROPS/SR
X3:6 010 2 STECKER KABINE/ROPS conn. cabin/ROPS
X3:7 010 2 STECKER KABINE/ROPS conn. cabin/ROPS
component listing

X3:8 010 2 STECKER KABINE/ROPS conn. cabin/ROPS

X3:9 011 3 STECKER KABINE/ROPS conn. cabin/ROPS
Bauteilliste

X3:10 011 3 STECKER KABINE/ROPS conn. cabin/ROPS

X3:11 011 4 STECKER KABINE/ROPS conn. cabin/ROPS
X3:12 011 4 STECKER KABINE/ROPS conn. cabin/ROPS
X3:13 011 7 STECKER KABINE/ROPS conn. cabin/ROPS
X3:14 011 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:15 010 7 STECKER KABINE/ROPS conn. cabin/ROPS
X3:16 010 6 STECKER KABINE/ROPS conn. cabin/ROPS
X3:17 010 6 STECKER KABINE/ROPS conn. cabin/ROPS
X4:A 007 14 KABINENST. MESST. con. measurem.equipm.
X4:B 007 14 KABINENST. MESST. con. measurem.equipm.
X4:C 007 14 KABINENST. MESST. con. measurem.equipm.
X4:D 007 14 KABINENST. MESST. con. measurem.equipm.
X4:E 007 15 KABINENST. MESST. con. measurem.equipm.
X4:F 008 18 KABINENST. MESST. con. measurem.equipm.
X4:G 008 18 KABINENST. MESST. con. measurem.equipm.
X4:M 008 16 KABINENST. MESST. con. measurem.equipm.
X4:N 008 15 KABINENST. MESST. con. measurem.equipm.
X6:1 006 14 DEUTSCH DEUTSCH connector
X6:2 006 14 DEUTSCH DEUTSCH connector
X7:1 006 16 DEUTSCH DEUTSCH connector
X7:2 006 16 DEUTSCH DEUTSCH connector
X8:1 004 19 DEUTSCH DEUTSCH connector
X8:2 004 20 DEUTSCH DEUTSCH connector
X9:1 004 8 DEUTSCH DEUTSCH connector
X9:2 004 8 DEUTSCH DEUTSCH connector
XS 010 1 Steckdose Socket
XS 010 20 Steckdose Socket
X10:2 004 12 AMP SUPERSEAL AMP connector
X10:3 004 12 AMP SUPERSEAL AMP connector
X11:1 006 13 DEUTSCH DEUTSCH connector
X11:2 006 13 DEUTSCH DEUTSCH connector
X12:1 004 2 DEUTSCH DEUTSCH connector
X12:2 004 2 DEUTSCH DEUTSCH connector
X12:3 004 1 DEUTSCH DEUTSCH connector
X13:1 004 6 DEUTSCH DEUTSCH connector
X13:2 004 6 DEUTSCH DEUTSCH connector
X13:3 004 6 DEUTSCH DEUTSCH connector
5

X14:A 006 13 DEUTSCH DEUTSCH connector

X14:B 006 13 DEUTSCH DEUTSCH connector
X17:1 011 3 STECKER LÜFTER HKL conn. blower
X17:2 011 3 STECKER LÜFTER HKL conn. blower
X17:3 011 4 STECKER LÜFTER HKL conn. blower
7

X17:4 011 5 STECKER LÜFTER HKL conn. blower

X18:1 011 10 STECKER THERMOFÜHLER conn. sender temp.
X18:2 011 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 011 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
582 702 29

X19:2 011 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.

X20:1 011 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:2 011 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:3 011 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X20:4 011 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
105

X21:1 004 17 STECKER KÜHLMITTEL connector coolant sensor

X21:2 004 17 STECKER KÜHLMITTEL connector coolant sensor
008 911
X22:1 49 005 9 ST. VIBRATIONSAUFNEHM BOMAG
connector vibration sensor 975
 Name Bl. Pf. Benennung title TYP

17.2 X22:2
X22:3
X22:4
005
005
005
9
10
10
ST. VIBRATIONSAUFNEHM
ST. VIBRATIONSAUFNEHM
ST. VIBRATIONSAUFNEHM
connector vibration sensor
connector vibration sensor
connector vibration sensor
Wiring diagram
X36:A 002 4 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 4 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 10 ST. ZÜNDSCHLOß E−KAST connector ignition switch
X37:B 002 11 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 11 ST.STARTER E−KASTEN connector starter e−box
X42:1 007 18 STECKER ADAPTER BOP conector adapter BOP
X42:2 007 19 STECKER ADAPTER BOP conector adapter BOP
X42:3 007 19 STECKER ADAPTER BOP conector adapter BOP
X42:4 007 18 STECKER ADAPTER BOP conector adapter BOP
X42:5 007 18 STECKER ADAPTER BOP conector adapter BOP
X44:1 007 13 MESX STECKER MESX Stecker
Seis
03.01.2007
Vogt
03.01.2007

X44:3 007 15 MESX STECKER MESX Stecker

X44:4 007 14 MESX STECKER MESX Stecker
X44:5 007 14 MESX STECKER MESX Stecker
X44:7 007 10 MESX STECKER MESX Stecker
X44:9 007 12 MESX STECKER MESX Stecker
X44:14 007 5 MESX STECKER MESX Stecker
X44:15 007 5 MESX STECKER MESX Stecker
X44:23 007 11 MESX STECKER MESX Stecker
X44:25 007 10 MESX STECKER MESX Stecker
X44:26 007 18 MESX STECKER MESX Stecker
X44:27 007 17 MESX STECKER MESX Stecker
X44:28 007 2 MESX STECKER MESX Stecker
X44:29 007 7 MESX STECKER MESX Stecker
X44:30 007 9 MESX STECKER MESX Stecker
X44:31 007 8 MESX STECKER MESX Stecker
X44:32 007 6 MESX STECKER MESX Stecker
X44:33 007 18 MESX STECKER MESX Stecker
X44:35 007 5 MESX STECKER MESX Stecker
X44:36 007 6 MESX STECKER MESX Stecker
X44:37 007 7 MESX STECKER MESX Stecker
X44:38 007 4 MESX STECKER MESX Stecker
X44:41 007 7 MESX STECKER MESX Stecker
X44:53 007 17 MESX STECKER MESX Stecker
X44:54 007 5 MESX STECKER MESX Stecker
X44:55 007 13 MESX STECKER MESX Stecker
X44:56 007 4 MESX STECKER MESX Stecker
X44:57 007 4 MESX STECKER MESX Stecker
X44:58 007 4 MESX STECKER MESX Stecker
X44:59 007 5 MESX STECKER MESX Stecker
component listing

X44:60 007 5 MESX STECKER MESX Stecker

X44:65 007 13 MESX STECKER MESX Stecker
Bauteilliste

X44:66 007 13 MESX STECKER MESX Stecker

X44:67 007 14 MESX STECKER MESX Stecker
X44:68 007 14 MESX STECKER MESX Stecker
X46:A 007 19 STECKER BOP Connector BOP
X46:B 007 18 STECKER BOP Connector BOP
X46:D 007 18 STECKER BOP Connector BOP
X46:E 007 19 STECKER BOP Connector BOP
X46:F 007 18 STECKER BOP Connector BOP
X47:A 007 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 007 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:C 007 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X48:1 007 8 STECKER AUFN. VORNE conn. sender front
X48:2 007 7 STECKER AUFN. VORNE conn. sender front
X48:3 007 7 STECKER AUFN. VORNE conn. sender front
X48:4 007 8 STECKER AUFN. VORNE conn. sender front
X49:1 007 10 STECKER AUFN. HINTEN conn. sender rear
X49:2 007 9 STECKER AUFN. HINTEN conn. sender rear
X49:3 007 9 STECKER AUFN. HINTEN conn. sender rear
X49:4 007 10 STECKER AUFN. HINTEN conn. sender rear
X53:B 011 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 011 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 011 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:L 011 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 011 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 011 11 STECKER HEIZSTEUERUNG conn. heating controller
X54:2 011 11 STECKER HEIZSTEUERUNG conn. heating controller
X54:3 011 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:4 011 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:6 011 7 STECKER HEIZSTEUERUNG conn. heating controller
X54:11 011 10 STECKER HEIZSTEUERUNG conn. heating controller
X54:12 011 11 STECKER HEIZSTEUERUNG conn. heating controller
X55:1 010 11 STECKER WISCHER HINTE connector wiper rear
X55:2 010 10 STECKER WISCHER HINTE connector wiper rear
X55:3 010 10 STECKER WISCHER HINTE connector wiper rear
X55:4 010 10 STECKER WISCHER HINTE connector wiper rear
X56:1 010 14 STECKER WISCHER VORNE conn. wiper front
X56:2 010 13 STECKER WISCHER VORNE conn. wiper front
6

X56:3 010 13 STECKER WISCHER VORNE conn. wiper front

X56:4 010 13 STECKER WISCHER VORNE conn. wiper front
X58:2 009 17 STECKER STVZO VL Con. STVZO FL
X58:3 009 7 STECKER STVZO VL Con. STVZO FL
X58:5 009 2 STECKER STVZO VL Con. STVZO FL
7

X58:6 009 2 STECKER STVZO VL Con. STVZO FL

X58:6 009 7 STECKER STVZO VL Con. STVZO FL
X58:6 009 17 STECKER STVZO VL Con. STVZO FL
X59:2 009 19 STECKER STVZO VR Con. STVZO FR
582 702 29

X59:3 009 7 STECKER STVZO VR Con. STVZO FR

X59:5 009 2 STECKER STVZO VR Con. STVZO FR
X59:6 009 2 STECKER STVZO VR Con. STVZO FR
X59:6 009 7 STECKER STVZO VR Con. STVZO FR
X59:6 009 19 STECKER STVZO VR Con. STVZO FR
106

X60:1 009 18 STECKER STVZO HL Con. STVZO BL

X60:2 009 18 STECKER STVZO HL Con. STVZO BL
976 X60:3 009 6 STECKER STVZO HL BOMAG
Con. STVZO BL 008 911 49
 Name Bl. Pf. Benennung title TYP
X60:4
Wiring diagram
X61:1
X61:2
009
009
009
6
19
19
STECKER STVZO HL
STECKER STVZO HR
STECKER STVZO HR
Con. STVZO BL
Con. STVZO BR
Con. STVZO BR
17.2
X61:3 009 8 STECKER STVZO HR Con. STVZO BR
X61:4 009 8 STECKER STVZO HR Con. STVZO BR
X65:1 012 5 KEYBOARD Keyboard
X65:2 012 5 KEYBOARD Keyboard
X65:3 012 5 KEYBOARD Keyboard
X65:4 012 5 KEYBOARD Keyboard
X65:5 012 5 KEYBOARD Keyboard
X65:7 012 5 KEYBOARD Keyboard
X65:8 012 12 KEYBOARD Keyboard
X65:9 012 5 KEYBOARD Keyboard
X65:10 012 5 KEYBOARD Keyboard
Seis
03.01.2007
Vogt
03.01.2007

X65:11 012 5 KEYBOARD Keyboard

X65:12 012 5 KEYBOARD Keyboard
X68:1 012 15 STECKER LED connector led
X68:2 012 16 STECKER LED connector led
X69:1 011 13 STECKER FRISCHLUFT LÜ connector fresh air blower
X69:2 011 13 STECKER FRISCHLUFT LÜ connector fresh air blower
X74:1 007 14 STECKER DRUCKER con. printer
X74:2 007 14 STECKER DRUCKER con. printer
X74:3 007 14 STECKER DRUCKER con. printer
X74:4 007 15 STECKER DRUCKER con. printer
X74:5 007 14 STECKER DRUCKER con. printer
X75:2 008 16 SUB−D STECKER BCM INT con. SUB−D BCM
X75:7 008 15 SUB−D STECKER BCM INT con. SUB−D BCM
X76:1 008 17 STECKER VERS. BCM con. Power−sup. BCM
X76:2 008 17 STECKER VERS. BCM con. Power−sup. BCM
X77:1 011 15 STECKER PUMPE STANDHE Conn. pump add. heater
X77:2 011 15 STECKER PUMPE STANDHE Conn. pump add. heater

Y01 002 13 Magnetventil Startmehrmenge Solenoid valve, start boost fuel MAX. 3.9A
Y04 004 5 Magnetventil Bremse Solenoid valve, brake MAX. 1,8A
Y07 006 14 D*Prop. Ventil Vibration groß E*prop. Valve vibration high MAX. 2,5A
Y08 006 16 D*Prop. Ventil Vibration groß E*prop. Valve vibration high MAX. 2,5A
Y13 002 18 Hubmagnet Motor Shut off solenoid, engine MAX. 3.8A
Y14 011 15 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 011 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y30 006 4 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front MAX. 1,67A
Y30 006 6 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front MAX. 1,67A
Y31 006 3 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y31 006 8 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
component listing

Y120 002 16 Magnetventil Motordrehzahl hoch Solenoid valve, rpm engine high
Y138 011 10 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
Bauteilliste
77
582 702 29
107

008 911 49 BOMAG 977

978
17.2

X38
X37
X36

BOMAG
Nur bei StvzO
only acc. To StvZO illumination

A02 R10 K05

K11 K16 K06

K36 K22

Nur bei Klimaanlage

K09 K35
only acc. to aircond.

K48

K61

A68 K114

K26

Nur wenn Sitzkontakt angebaut

only acc. if seatswitch is assembled

008 911 49
Wiring diagram

Nur wenn kein Sitzkontakt angebaut Gez.: 03.01.2007 Seite: 1 von: 2

only acc. if no seatswitch is assembled Name: Vogt Übersicht Schaltkasten BW 177...219 D-4/D-40 page: 1 from: 2
582 702 29
K04
Gepr.: 03.01.2007 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box BW 177...219 D-4/D-40 Replaces: Sheet No.: 201
 Nur bei VM8
only acc. To VM8

F1 F2

CAN 1

008 911 49
Wiring diagram

BOMAG
CAN 1 OPUS 21

A83
Messtechnik Steuerung

CAN 3 BCM

Gez.: 03.01.2007 Seite: 2 von: 2

Name: Vogt Übersicht Schaltkasten-Tür BW 177...219 D-4/D-40 page: 2 from: 2
582 702 29
17.2

979
Gepr.: 03.01.2007 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box door BW 177...219 D-4/D-40 Replaces: Sheet No.: 201
17.2 Wiring diagram
WAGO smart DESIGNER 4.1

1 057 564 17

2 057 564 21
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

30 2 x 057 564 36 "R" + 793-501

32 057 564 35
33 057 564 17

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : D-4/40 Artikelnummer lang :
Zeichnung : gezeichnet: : M. Vogt TEE
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Absicherung D-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.

03.01.2007 10:21:43 Seite 1

980 BOMAG 008 911 49

Wiring diagram 17.2
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : D-4/40 Artikelnummer lang :
Zeichnung : gezeichnet: : M. Vogt TEE
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Absicherung D-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.

03.01.2007 10:21:46 Seite 2

008 911 49 BOMAG 981

17.2 Wiring diagram
WAGO smart DESIGNER 4.1

1 057 564 17

2 2 x 057 565 40 "R" + 793-501 + 057 565 36

4 2 x 057 565 40 "R" + 793-501

6 3 x 057 565 39 "R" + 793-501

9 057 565 37
10 4 x 057 565 38 "R" + 793-501

14 057 565 37
15 3 x 057 565 38 "R" + 793-501

18 057 565 37
19 3 x 057 565 40 "R" + 793-501

22 057 565 35 "R" + 793-501

23 057 565 37
24 5 x 057 565 40 "R" + 793-501

29 057 565 37
30 2 x 057 565 38 "R" + 793-501

32 2 x 057 565 39 "R" + 793-501

34 057 565 37
35 4 x 057 565 38 "R" + 793-501

39 057 565 37
40 4 x 057 565 40 "R" + 793-501

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : D-4/40 Artikelnummer lang :
Zeichnung : gezeichnet: : M. Vogt TEE
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Kabelbäume D-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.

03.01.2007 10:10:25 Seite 1

982 BOMAG 008 911 49

Wiring diagram 17.2
WAGO smart DESIGNER 4.1

44 057 565 39 "R" + 793-501

45 057 565 35 "R" + 793-501

46 057 565 37
47 2 x 057 565 40 "R" + 793-501

49 057 565 37
50 057 565 40 "R" + 793-501
51 057 565 38 "R" + 793-501

52 057 565 37
53 4 x 057 565 40 "R" + 793-501

57 057 565 39 "R" + 793-501

58 057 565 37
59 4 x 057 565 40 "R" + 793-501

63 057 565 37
64 057 565 40 "R" + 793-501
65 057 565 35 "R" + 793-501

66 057 565 37
67 057 565 40 "R" + 793-501
68 057 565 35 "R" + 793-501

69 057 565 37
70 057 565 38 "R" + 793-501
71 2 x 057 565 40 "R" + 793-501

73 057 565 38 "R" + 793-501

74 057 565 37
75 4 x 057 565 40 "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
83 057 565 40 "R" + 793-501
84 2 x 057 565 38 "R" + 793-501

86 057 565 39 "R" + 793-501

87 057 565 37
88 057 564 17

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : D-4/40 Artikelnummer lang :
Zeichnung : gezeichnet: : M. Vogt TEE
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Kabelbäume D-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.

03.01.2007 10:10:25 Seite 2

008 911 49 BOMAG 983

17.2 Wiring diagram
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : D-4/40 Artikelnummer lang :
Zeichnung : gezeichnet: : M. Vogt TEE
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Kabelbäume D-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.

03.01.2007 10:11:17 Seite 3

984 BOMAG 008 911 49

Wiring diagram 17.2
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : D-4/40 Artikelnummer lang :
Zeichnung : gezeichnet: : M. Vogt TEE
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Kabelbäume D-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.

03.01.2007 10:11:17 Seite 4

008 911 49 BOMAG 985

17.2 Wiring diagram
WAGO smart DESIGNER 4.1

1 057 564 17

2 2 x 057 565 40 "R" + 793-501 + 057 565 36

4 057 565 39 "R" + 793-501

5 057 565 37
6 057 565 38 "R" + 793-501
7 2 x 057 565 40 "R" + 793-501

9 057 565 38 "R" + 793-501

10 057 565 37
11 2 x 057 565 40 "R" + 793-501

13 057 565 39 "R" + 793-501

14 057 565 37
15 057 565 40 "R" + 793-501
16 057 565 38 "R" + 793-501

17 057 565 40 "R" + 793-501

18 057 565 37
19 057 564 21
20 057 564 25 "L" + 793-501
21 057 564 17

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Messtechnik D Artikelnummer lang :
Zeichnung : gezeichnet: : M. Vogt TEE
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.

04.01.2007 10:51:25 Seite 1

986 BOMAG 008 911 49

Wiring diagram 17.2
WAGO smart DESIGNER 4.1

Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Messtechnik D Artikelnummer lang :
Zeichnung : gezeichnet: : M. Vogt TEE
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.

04.01.2007 10:51:41 Seite 2

008 911 49 BOMAG 987

17.2 Wiring diagram
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

988 BOMAG 008 911 49

Wiring diagram 17.2
WAGO smart DESIGNER 4.1

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 10:28:30 Seite 2

008 911 49 BOMAG 989

990
X74 X75
X55
X56 X76 X53 X54
17.2

X5
X21
X11 X12
X59 X13
X58 X42
X20
X69 X46 X14

X18 X77
X6 X7
X17
X22 X19 X4 X3
X67 X8
X48 X49 X10
X36 X60
X37 X1 X61
X38 X2
X9
X44

BOMAG
X61
X77 X9
X21
X74 X75
X59
X76
X67 X8
X42 X11 X12
X10
X46 X13
X56
X53
X20
X18
X5 X17 X14
X19 X55 X6 X7
X54
X69

X58
X4 X3
X36 X1
X37 X44 X2
X38 X60

X48 X49
X22

008 911 49
Wiring diagram

Gez.: 03.01.2007 Seite: 1 von: 1

Name: Vogt Steckerübersicht BW 177...219 D-4/D-40 page: 1 from: 1
582 702 29
Gepr.: 03.01.2007 Ers. f.: Blatt Nr.: 301
Name: Seis Connector overview BW 177...219 D-4/D-40 Replaces: Sheet No.: 301
 17.3 Hydraulic diagram

008 911 49 BOMAG 991

17.3 Hydraulic diagram

992 BOMAG 008 911 49

Hydraulic diagram 17.3

008 911 49 BOMAG 993

17.3 Hydraulic diagram

994 BOMAG 008 911 49