135 Service Manual PDF

Service - Manual
BW 135 AD-5 / BW 138 AD-5

BW 138 AC-5
S/N 101 650 32 1036 > / S/N 101 650 30 1132 > / S/N 101 650 33 1007 >
S/N 101 650 31 1071 >
Tandem Vibratory Roller

Combination Roller
Catalogue number.
008 922 51 03/2013
Table of Contents
General 5
1.1 Introduction 6
1.2 Safety regulations 7
1.3 General repair instructions 11
1.4 Tightening torques 21
Technical data 25
2.1 Technical data 26
Maintenance 35
3.1 General notes on maintenance 36
3.2 Fuels and lubricants 37
3.3 Table of fuels and lubricants 40
3.4 Running-in instructions 42
3.5 Maintenance table 43
Overall view of machine 47
4.1 Overview 48
Electrics 53
5.1 Battery service 54
5.2 Starting with jump wires 55
5.3 Main battery switch 55
5.4 Generator repair 56
5.5 Repair of starter 61
5.6 Instrument cluster (A15), overview 67
5.7 Seat contact switch 69
5.8 Switching the vibration on 70
5.9 Switching on the pressure sprinkler system 71
5.10 Level sensor in diesel tank (R03) 71
5.11 Water in fuel filter, sensor B124 (optional) 72
5.12 Charge control lamp and operating hour meter 73
5.13 Engine oil pressure monitoring 73
5.14 Coolant temperature monitoring 74
5.15 Glow plugs, R81 74
5.16 Engine solenoid, Y13 75
5.17 Inductive proximity switch, B63 77
5.18 Angle sensor on travel control lever, B39 78
5.19 Central electrics 80
5.20 Fuse assignment 84
5.21 Control elements 87
5.22 Machine related electrics 89
Engine 97
6.1 Kubota diesel engine 99
6.2 Check the engine oil level 103
6.3 Change engine oil and oil filter cartridge 104
6.4 Checking the coolant level 105
6.5 Change the coolant 106
6.6 Check the anti-freeze concentration and the condition of the coolant 107
6.7 Checking radiator hoses and hose clamps 107
008 922 51 BOMAG 1

Table of Contents
6.8 Cleaning radiator and hydraulic oil cooler 108

6.9 Checking the V-belt, tightening, if necessary replacing the V-belt 109
6.10 Check, clean the air filter, replace if necessary 109
6.11 Check the air intake lines 111
6.12 Check, clean the water separator 112
6.13 Change the fuel filter 112
6.14 Check fuel lines and clamps 113
6.15 Replacing the fuel lines 114
6.16 Checking the engine mounts 114
6.17 Checking the engine oil pressure 115
6.18 Checking the thermostat in disassembled state 115
6.19 Check the injection valves 116
6.20 Checking the start of commencement 118
6.21 Checking the fuel injection pump 120
6.22 Checking the compression 121
6.23 Checking and adjusting the valve clearance 121
6.24 Engine problems 123
Hydraulics 125
7.1 Hydraulic circuit 126
7.2 Travel pump, A10VG45 HW 128
7.3 Drum drive motor MK05 135
7.4 Wheel motor MSE02 138
7.5 External gear motors 141
7.6 External gear pumps 142
7.7 Pump assembly 144
7.8 Travel circuit 146
7.9 Towing 152
7.10 Vibration circuit 154
7.11 Steering circuit 157
7.12 Checking the hydraulic oil level 159
7.13 Change hydraulic oil and breather filter 160
7.14 Checking the hydraulic oil filter element 161
7.15 Changing the hydraulic oil filter 162
Tests and adjustments 163
8.1 Special tools, tests and adjustments 164
8.2 Checking the rotation speeds 168
8.3 Pressure tests in the travel circuit 170
8.4 Checking / adjusting the neutral positions of the travel pump 172
8.5 Pressure test in the vibration circuit 175
8.6 Checking the leakage rate of the vibration motor 176
8.7 Pressure test in steering circuit 177
Trouble shooting 179
9.1 Perform trouble shooting 180
9.2 Engine problems 181
9.3 Troubleshooting axial piston pumps 183
9.4 Fault detection via instrument cluster, A15 186
9.5 The machine does not drive 186
9.6 Insufficient travel power 188
2 BOMAG 008 922 51

Table of Contents
Flushing and bleeding 191

10.1 Special tools for flushing 192
10.2 Flushing - general 197
10.3 Flushing schematic for front drum drive 199
10.4 Flushing the front drum drive 200
10.5 Flushing schematic for rear drum drive system 204
10.6 Flushing the rear drum drive 205
10.7 Flushing schematic, rear wheel drive motors 209
10.8 Flushing the rear wheel drive 210
10.9 Flushing schematic for vibration drive on AD-machines 214
10.10 Flushing the vibration circuit 215
10.11 Bleeding the travel circuit 217
Drum 219
11.1 Reparaturübersicht Bandage 220
11.2 Removing and installing the drum 222
11.3 Dismantling the drum 225
11.4 Assembling the drum 231
Oscillating articulated joint 239
12.1 Repair overview oscillating articulated joint 240
12.2 Repairing the oscillating articulated joint 242
Suppliers documentation 249
13.1 Travel pump 251
13.2 Travel motor 309
13.3 Wheel drive 399
13.4 Steering valve 475
Circuit diagrams 491
14.1 Hydraulic diagram 114 493
14.2 Wiring diagram 134 507
008 922 51 BOMAG 3

Table of Contents
4 BOMAG 008 922 51

1 General
008 922 51 BOMAG 5

1.1 Introduction
1.1 Introduction
This manual addresses the professionally qualified

personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.
Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
4 Fundamental electrics
Use only 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 an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
! Danger
These safety regulations must be read and ap-

plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
6 BOMAG 008 922 51

Safety regulations 1.2
Important notes Block the articulated joint with the articulation lock.
1.2 Safety regulations
l
l Use protective clothes like hard hat, safety boots

These safety regulations must be read and ap-
and gloves.
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident l Keep unauthorized persons away from the machine
prevention instructions and the safety regulations during repair work.
in the operating and maintenance instructions l Tools, lifting gear, lifting tackle, supports and other
must be additionally observed.
auxiliary equipment must be fully functional and in
Repair work shall only performed by appropriately safe condition.
trained personnel or by the after sales service of l Use only safe and approved lifting gear of sufficient
BOMAG. load bearing capacity to remove and install parts or
components from and to the machine.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants, l Do not use easily inflammable or harmful substanc-
cleaning agents and solvent as well as gases and es, such as gasoline or paint thinners for cleaning.
chemicals are subject to legal regulations, which l Do not smoke or use open fire and avoid sparks
are intended to provide a minimum on safety. It is when cleaning or repairing a tank.
obviously your own responsibility to know and
adhere to these regulations.
l When performing welding work strictly comply with
the respective welding instructions.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan- Transport work with cranes and lifting
gers to persons, property and the environment. tackle
i Note i Note
Paragraphs marked like this contain technical infor- Cranes must only be operated by instructed persons
mation for the optimal economical use of the machine. who had been trained in handling cranes.
l Follow the operating instructions of the manufactur-
Caution
! er when working with cranes.
Paragraphs marked like this highlight possible l Follow the operating instructions of the operator
dangers for machines or parts of the machine. when working with cranes.
l Always comply with the applicable accident preven-
Danger
!
tion instructions when working with cranes and lift-
ing tackle.
Paragraphs marked like this highlight possible
dangers for persons.
Precautions and codes of conduct for
welding work
Environment
Welding work must only be carried out by properly
Paragraphs marked like this point out practices
trained personnel.
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Danger
!
Observe the regulations for the protection of the
environment. Electric shock!
Sparks, fire hazard, burning of skin!
General Infrared or ultraviolet radiation (arc), flashing of
l
For repair and maintenance work move the ma- eyes!
chine on a firm base and shut it down. Health hazard caused by welding work on highly
l
Always secure the machine against unintended roll- alloyed work pieces, metal coatings, paint coat-
ing. ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
l Secure the engine reliably against unintentional
starting.
l Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
l Mark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
l Ensure good conductivity between ground cable
the dashboard. and workpiece, avoid joints and bearings.
008 922 51 BOMAG 7

l Start the extraction fan before starting work and Operation of high-voltage systems
guide with the progressing work as required.
l Always isolate the burner when laying it down (re- i Note
move possible electrode residues).
The rules and statutory regulations valid in the corre-
l Protect cables from being damaged, use cables sponding do apply in addition to the notes given here.
with insulated couplings.
l Ensure sufficient fire protection, keep a fire extin- !Caution
guisher at hand. The high-voltage system must only be operated
l Welding work in areas where there is a risk of fire or and serviced by qualified and authorized person-
explosion, must only be carried out with welding nel.
permission.
Before starting operation the operator must check
l Remove any combustible materials from the weld- the proper condition of the system.
ing area or cover such items appropriately.
l Name a fire watch during and after welding work. !Danger
l Place welding rod holders and inert gas welding Possibility of injury or even death caused by elec-
guns only on properly insulated bases. tric shock:
l Place the inert gas bottles in a safe place and se- l if persons come into contact with live parts,
cure them against falling over. l in case of faulty insulation of live parts,
l
Use a protective screen or hand shield with welding l
inadequate, unsuitable insulation,
filter, wear welding gloves and clothes. l
if melted parts flake off in case of short circuits.
l
Switch the welding unit off before connecting weld-
ing cables. Old oils
l
Check electrode holders and electric cables at reg- Prolonged and repetitive contact with mineral oils will
ular intervals. remove the natural greases from the skin and causes
Behaviour in case of faults dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
l
In case of faults on the welding unit switch of the which could cause skin cancer. Appropriate skin pro-
welding unit immediately and have it repaired by ex- tection agents and washing facilities must therefore
pert personnel. be provided.
l
In case of failure of the extraction system switch the l
Wear protective clothes and safety gloves, if possi-
system off and have it repaired by expert personnel. ble.
Maintenance; waste disposal l
If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
l
Replace damaged insulating jaws and welding rod
full face visor; a facility suitable for rinsing the eyes
holders immediately.
should also be available.
l
Replace the welding wire reels only in de-energized l
Avoid longer and repetitive contacts with oils. In
state.
case of open incisions and injuries seek medical ad-
What to do in case of accidents; First Aid vice immediately.
l
Keep calm. l
Apply protective cream before starting work, so that
oil can be easier removed from the skin.
l Call first air helpers.
l
Wash affected skin areas with water and soap (skin
l
Report the accident.
cleansers and nail brushes will help). Lanolin con-
l
In case of an electric accident: Interrupt the power taining agents will replace natural skin oils that were
supply and remove the injured person from the lost.
electric circuit. If breathing and heart have stopped l
Do not use gasoline, kerosene, diesel, thinner or
apply reactivation measures and call for an emer-
solvents to wash the skin.
gency doctor.
l
Do not put oil soaked cloths into your pockets.
l Avoid clothes getting soiled by oil.
l
Overalls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
l
If possible degrease components before handling.
8 BOMAG 008 922 51

Safety regulations 1.2
Environment l Fire extinguishers charged with FOAM, CO2 GAS
It is strictly prohibited to drain off oil into the soil, or POWDER must be available wherever fuel is
the sewer system or into natural waters. Old oil stored, filled in, drained off, or where work on fuel
must be disposed of according to applicable envi- systems is performed.
ronmental regulations. If in doubt you should con- l The vehicle battery must always be disconnected,
sult your local authorities. BEFORE work in the fuel system is started. Do not
disconnect the battery while working on the fuel
Hydraulics system. Sparks could cause explosion of the fuel
fumes.
l Always relieve the pressure in the hydraulic system
before disconnecting any lines. Hydraulic oil escap-
l Wherever fuel is stored, filled, drained off or where
ing under pressure can penetrate the skin and work on fuel systems is carried out, all potential ig-
cause severe injury. nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
l Always make sure that all screw fittings have been against possible contact with running out fuel.
tightened properly and that hoses and pipes are in
mint condition before pressurizing the system
again.
Hot fuels
Please apply the following measures before draining
l Hydraulic oil leaking out of a small opening can
of fuel to prepare for repair work:
hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When l Allow the fuel to cool down, to prevent any contact
injured by hydraulic oil escaping under pressure with a hot fluid.
consult a physician immediately, as otherwise this l
Vent the system, by removing the filler cap in a well
may cause severe infections. ventilated area. Screw the filler cap back on, until
l Do not step in front of or behind the drums, wheels the tank is finally emptied.
or crawler tracks when performing adjustment work
in the hydraulic system while the engine is running. Synthetic rubber
Block drums, wheels or crawler tracks with wedges.
Many O-rings, hoses, etc. are made of synthetic ma-
Reattach all guards and safety installations after terial, a so-called fluorocarbon elastomer. Under nor-
all work has been completed. mal operating conditions this material is safe and does
not impose any danger to health.
Environment However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
It is strictly prohibited to drain off oil into the soil,
caustic hydrofluoric acid, which can cause severe
the sewer system or into natural waters. Oil oil
burns in contact with skin.
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con- l
If the material is in such a state it must only be
sult your local authorities. touched with special protective gloves. The protec-
tive gloves must be disposed of according to appli-
Fuels cable environmental regulations immediately after
use.
l
If the material has contacted the skin despite these
!Danger
measures, take off the soiled clothes and seek
Repair work shall only performed by appropriately medical advice immediately. In the meantime cool
trained personnel or by the after sales service of and wash the affected area of skin over a sufficient
BOMAG. time with cold water or lime water.
Follow the valid accident prevention instructions when
handling fuels. Poisonous substances
The following notes refer to general safety precau- Some of the fluids and substances used are toxic and
tions for danger free handling of fuel. must under no circumstances be consumed.
Fuel vapours not only are easily inflammable, but also Skin contact, especially with open wounds, must be
highly explosive inside closed rooms and toxic; dilu- avoided.
tion with air creates an easily inflammable mixture. These fluids and substances are, amongst others,
The vapours are heavier than air and therefore sink anti-freeze agents, hydraulic oils, fuels, washing addi-
down to the ground. Inside a workshop they may eas- tives, refrigerants, lubricants and various bonding
ily become distributed by draft. Even the smallest por- agents.
tion of spilled fuel is therefore potentially dangerous.
008 922 51 BOMAG 9

Engine l The installation and use of non-genuine spare parts

or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
Danger
!
machine and thereby impair the active and/or pas-
Do not work on the fuel system while the engine is sive driving safety. The manufacturer explicitly ex-
running. (Danger to life!) cludes any liability for damage caused by the use of
non-original parts or accessories.
Once the engine has stopped wait approx. 1 min-
utes for the system to depressurize. The systems l Unauthorized changes to the machine are prohibit-
are under high pressure. (Danger to life!) ed for safety reasons.
Keep out of the danger zone during the initial test l
Do not perform any cleaning work while the engine
rung. Danger caused by high pressure in case of is running.
leaks. (Danger to life!) l If tests on the articulated joint need to be performed
When performing work on the fuel system make with the engine running, do not stand in the articu-
sure that the engine cannot be started uninten- lation area of the machine (danger of crushing!).
tionally during repair work. (Danger to life!) l If tests must be performed with the engine running
l Maintenance and cleaning work on the engine must do not touch rotating parts of the engine (danger of
only be performed with the engine stopped and injury!).
cooled down. Make sure that the electric system is l Always ensure an adequate supply of fresh air
switched off and sufficiently secured against being
when starting in closed rooms. Exhaust gases are
switched on again (e.g. pull off ignition key, attach a
highly dangerous!
warning label).
l
Refuel only with the engine shut down. Ensure strict
l Observe the accident prevention regulations for
cleanliness and do not spill any fuel.
electric systems (e.g. -VDE-0100/-0101/-0104/-
0105 Electric precautions against dangerous con- l
Always ensure an adequate supply of fresh air
tact voltages). when refuelling in closed rooms.
l Cover all electric components properly before wet l
Dispose of used filters in accordance with applica-
cleaning. ble environmental regulations.
l
When performing repair and maintenance work col-
Battery lect oils and fuels in suitable containers and dispose
l Always wear goggles and protective clothing to of in compliance with applicable environmental reg-
service or clean batteries! Battery acid can cause ulations.
severe injury by cauterization when coming in con- l
Do not heat up oils higher than 160 °C because they
tact with skin. may ignite.
l Work only well ventilated rooms (formation of oxy- l
Wipe off spilled or overflown oil using suitable
hydrogen gas). cleaning means and dispose of in accordance with
l Do not lean over the battery while it is under load, applicable environmental regulations.
being charged or tested (danger of explosion). l Dispose of old batteries according to applicable en-
l Keep ignition sources away from the battery. Burn- vironmental regulations.
ing cigarettes, flames or sparks can cause explo-
sion of the battery
l
There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
l Use battery chargers etc. only in strict compliance engine and hydraulic system to cool down to a suf-
with the operating instructions. ficient level.
l After an accident with acid flush the skin with a suf- l Do not exceed the max. permissible tire pressure.
ficient amount of 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.
Special safety regulations

l Use only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.
10 BOMAG 008 922 51

General repair instructions 1.3
General Electrics
1.3 General repair instructions
l
Before removing or disassembling parts, assem- General
blies, components or hoses mark these parts for
easier assembly. Due to the fast technical development electric and
electronic vehicle systems become more intelligent
l Before assembling and installing parts, assemblies and more comprehensive day by day, and can hardly
or components oil or grease all movable parts or be dispensed with in hydraulic and mechanical vehicle
surfaces as required and in compliance with the systems.
compatibility of materials.
Diagnostics according to plan
Well structured trouble shooting procedures can save
time and money.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l In approx. 10 % of the examined cases the prob-
lems were caused by control units.
l In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Knowledge in basic electrics is re-
quired for this purpose. If a fault was diagnosed
without having pulled the plug of the control unit or
inspected the wiring, this should be done before
changing any parts.
l
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l
Always use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
l
Do not disconnect or connect battery or generator
while the engine is running.
l
Do not operate the main battery switch under load.
l
Do not use jump leads after the battery has been re-
moved.
l Sensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
l
It is not permitted to pull plugs off while the voltage
supply is switched on (terminal 15 "ON")! Switch the
voltage supply "OFF" first and pull out the plug.
l Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!
008 922 51 BOMAG 11

l Plug-in connectors on control units are only dust Battery

and water tight if the mating connector is plugged
on! Control units must be protected against spray Rules for the handling of batteries
water, until the mating connector is finally plugged When removing a battery always disconnect the mi-
on! nus pole before the plus pole. When installing the bat-
l Unauthorized opening of control electronics (Micro- tery connect the minus pole after the plus pole to avoid
controller MC), modifications or repairs in the wiring short circuits.
can cause severe malfunctions. Fasten the terminal clamps with a little force as possi-
l
Do not use any radio equipment or mobile phones ble.
in the vehicle cab without a proper aerial or in the vi- Always keep battery poles and terminal clams clean to
cinity of the control electronics! avoid high transition resistances when starting and
the related development of heat.
Electrics and welding
Make sure the battery is properly fastened in the vehi-
cle.
!Caution
Before starting welding work you should discon-
nect the negative battery pole or interrupt the
electric circuit with the main battery switch, dis-
connect the generator and pull the plugs off all
control units in order to protect the electrical sys-
tem of the machine.
l Disconnect the minus pole of the battery or interrupt
the electric circuit with the main battery switch.
l Isolate the generator and all control units from the
electric circuit.
l Always fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location.
l When choosing the location for the earth clamp
make sure that the welding current will not pass
through joints or bearings.
12 BOMAG 008 922 51

Generator Starter motor
Before removing the generator you must disconnect So-called jump starting (using an additional external
the ground cable from the minus pole of the battery battery) without the battery connected is dangerous.
while the ignition is switched off. Do not disconnect When disconnecting the cables from the poles high in-
the generator while the engine is running, because ductivities (arcs, voltage peaks) may occur and de-
this may cause extremely high voltage peaks in the stroy the electrical installation.
vehicle wiring system ("Load Dump"), which could For purposes like e.g. purging the fuel systems, start-
possibly damage control units, radios or other elec- ers may be operated for maximum 1 minute without
tronic equipment. interruption. Then you should wait for at least 30 min-
When disassembling the battery cable, the B+-nut un- utes (cooling down) until trying again. During the 1
derneath on the generator side may also be loosened. minute starting period this process should not be inter-
This nut must in this case be retightened. rupted.
When connecting e.g. the battery cable to the terminal Starter motors must not be cleaned with high pressure
of the generator you must make sure that the polarity steam cleaning equipment.
is correct (generator B+ to the + pole of the battery). The contacts on starter terminals 30, 45, 50 must be
Mixing up the polarities by mistake causes short cir- protected against unintended shorting (jump protec-
cuit and damage to the rectifier elements - the gener- tion).
ator will be out of function.
When replacing the starter the ring gear on the engine
The generator can only be operated with the battery flywheel must be checked for damage and its number
connected. Under special conditions emergency op- of teeth - if necessary replace the ring gear.
eration without battery is permitted, the lifetime of the
generator is in such cases especially limited. Always disconnect the battery before starting assem-
bly work in the starter area of the engine or on the
Plus and minus cables must be disconnected during starter itself.
rapid charging of the battery or electric welding on the
vehicle.
When cleaning the generator with a steam or water jet
make sure not to direct the steam or water jet directly
on or into the generator openings or ball bearings. Af-
ter cleaning the generator should be operated for
about 1 - 2 minutes to remove any deposits of water
from the generator.
008 922 51 BOMAG 13

Hydraulic system l Perform measurements at operating temperature of

the hydraulic oil (approx. 40 ¯C).
!Caution
l After changing a component perform a high and
charge pressure test, if necessary check the speed
Repair work on hydraulic elements shall only per-
of the exciter shaft.
formed by appropriately trained personnel or by
the after sales service of BOMAG. l The operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
Please note ing drum. On hard ground place the drums on a suit-
able base and check the drum pressure. Do not
i Note activate the vibration on a hard, concreted base,
danger of bearing damage.
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system. l After the completion of all tests perform a test run
and then check all connections and fittings for leaks
l Connections and screw fittings, filler neck covers
with the engine still stopped and the hydraulic sys-
and their immediate surrounding areas must be
tem depressurized.
cleaned before removal.
l Before loosening hoses, pipe lines etc. relieve all Before commissioning
pressure from the system. l Fill the housings of hydraulic pumps and motors
l During repair work keep all openings closed with with hydraulic oil. Use only hydraulic oils according
clean plastic plugs and caps. to the specification in the maintenance instructions.
l Never run pumps, motors and engines without oil or
l
After changing a component flush the hydraulic sys-
hydraulic oil. tem as described in the flushing instructions.
l When cleaning hydraulic components take care not Taking into operation
to damage any fine machine surfaces. l
Bleed the hydraulic circuits.
l Chemical and rubber soluble cleansing agents may l
Start up the hydraulic system without load.
only be used to clean metal parts. Do not let such
substances come in contact with rubber parts.
l
Check the hydraulic oil level in the tank, if neces-
sary top up with hydraulic oil as specified in the op-
l Rinse of cleaned parts thoroughly, dry them with erating and maintenance instructions or drain oil off
compressed air and apply anti-corrosion oil immedi- into a suitable container.
ately. Do not install parts that show traces of corro-
sion. After taking into operation
l Avoid the formation of rust on fine machined caused l
Check fittings and flanges for leaks.
by hand sweat. l
After each repair check all adjustment data, system
l Use new O-rings or seal rings for reassembly. pressures, rotational speeds and nominal values in
l Use only hydraulic oil as sliding agent when reas- the hydraulic system, adjust if necessary.
sembling. Do not use any grease! l
Do not adjust pressure relief valves and control
l Use only the specified pressure gauges. Risk of valves to values above their specified values.
damaging the pressure gauges under too high pres-
sure.
l Check the hydraulic oil level before and after the
work.
l Fill in only clean oil as specified in the maintenance
instructions.
l Check the hydraulic system for leaks, if necessary
find and rectify the cause.
l Before taking new hydraulic components into oper-
ation fill these with hydraulic oil as specified in the
operating and maintenance instructions.
l After changing a hydraulic component thoroughly
flush, refill and bleed the complete hydraulic sys-
tem.
14 BOMAG 008 922 51

Fuel hoses Gaskets and mating surfaces
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets.
l Before assembling a new seal or gasket make sure
that the sealing surface is free of pitting, flutes, cor-
rosion or other damage.
l Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Assemble seals and gaskets only with sealing com-
pound, grease or oil, if this is specifically specified
Fig. 1 in the repair instructions.
l If necessary remove any old sealing compound be-
! Caution fore assembling. For this purpose do not use any
tools that could damage the sealing surfaces.
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi- l Sealing compound must be applied thin and evenly
ton hose. If a fuel hose has come loose one must on the corresponding surfaces; take care that the
make absolutely sure that the internal Viton layer compound does not enter into oil galleries or blind
has not been separated from the reinforced outer threaded bores.
layer. In case of a separation the hose needs to be l
Examine the contact faces for scratches and burrs,
replaced. remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components.
l
Blow out lines, ducts and gaps with compressed air,
replace any O-rings and seals that have been dis-
lodged by the compressed air.
Assembly of radial seals
Fig. 2
l
Lubricate the sealing lips (2) (Fig. 2) with clean
grease; in case of double seals fill the space be-
tween the sealing lips with a generous amount of
grease.
l
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve (1 (Fig. 2)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-
008 922 51 BOMAG 15

able, you should use a plastic tube or adhesive tape Feather keys and keyways
to prevent the sealing lip from being damaged.
l Lubricate the outer rim (arrow 3 (Fig. 2)) of the seal Caution
!
and press it flat on the housing seat.
Feather keys may only be reused if they are free of
damage.
Fig. 3
l
Press or knock the seal into the housing, until it is
flush with the housing surface.
i Note
Fig. 4
If possible, use a "bell" (1 (Fig. 3)), to make sure that
the seal will not skew. In some cases it may be ad-
l Clean and thoroughly examine the feather key.
visable to assemble the seal into the housing first, be- l Deburr and thoroughly clean the edges of the key-
fore sliding it over the shaft. Under no circumstances way with a fine file before reassembling.
should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.
16 BOMAG 008 922 51

Ball and roller bearings l Check shaft and bearing housing for discolouration
or other signs of movement between ball or roller
bearing and seats.
!Caution
l Make sure that shaft and housing are free of burrs
Ball and roller bearings may only be reused if they
before assembling the ball or roller bearing.
are free of damage and do not show any signs of
wear. l Always mark the individual parts of separable ball or
roller bearings (e.g. taper roller bearings) to enable
correct reassembling. Never assemble the rollers to
an outer race that has already been used, replace
the complete ball or roller bearing instead.
Fig. 6
!Caution
When assembling the ball or roller 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).
Fig. 5
l If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l
Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l
Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l
Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.
008 922 51 BOMAG 17

Screws and nuts Strength classes, metric screws

The strength classes (from 3.6 to 12.9) are specified
Tightening torque
for all strength classes from a nominal diameter of
5mm. The corresponding identification can be found
!Caution where allowed for by the shape of the screw.
Tighten nuts or screws with the tightening tor-
ques specified in the following tables of tighten-
ing torques. 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 generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
specified tightening torque you should first relieve
Fig. 7 Identification of screws
by a quarter turn and then tighten to the correct
torque. Example: A screw is identified with 12.9.
l Before tightening you should lightly oil the thread, in The first number corresponds with 1/100 of the nomi-
order to ensure low friction movement. The same nal tensile strength (minimum tensile strength) in N/
applies for self-locking nuts. mm2.
l Make sure that no oil or grease will enter into blind l
The nominal tensile strength is 12 X 100 N/mm2 =
tapped bores. The hydraulic power generated when
1200 N/mm2.
turning in the screw could cause breakage of the ef-
fected part. 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.
18 BOMAG 008 922 51

Strength classes of metric nuts Identification in clock system
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. 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.
Fig. 8 Identification of nuts l
The strength class is identified by a dash (b).
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).
008 922 51 BOMAG 19

Identification of UNF-threads Cotter pins
Fig. 11
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.
Fig. 10
Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 10).
Nuts
An uninterrupted series of stamped in circles parallel
to the axis of the nut on a hexagon area (2).
Studs and brake rods

At the outmost end a short end of the component is re-
duced to its core diameter (1).
20 BOMAG 008 922 51

Tightening torques 1.4
The values specified in the table apply for screws:
1.4 Tightening torques
l black oiled
l with surface protection A4C
l with surface protection DACROMET
i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with metric unified thread*
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
* Coefficient of friction  tot. = 0,14
Tightening torques for screws with metric unified fine thread*
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
008 922 51 BOMAG 21

Tightening torques for screws treated with anti-seizure paste OKS 240* (copper paste)
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
* Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques for wheel nuts (fine thread) * **
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
** These values result in a 90% utilization of the yield point
22 BOMAG 008 922 51

Tightening torques 1.4
The values specified in the table apply for screws:
l black oiled
l with surface protection A4C
l with surface protection DACROMET
i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, * UNC Unified Coarse Thread Series, American Unified
Coarse Thread
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
Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread
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
008 922 51 BOMAG 23

Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread
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
24 BOMAG 008 922 51

2 Technical data
008 922 51 BOMAG 25

2.1 Technical data
2.1 Technical data
26 BOMAG 008 922 51

Technical data 2.1
The following noise and vibration data acc. to
- EC Machine Regulation edition 2006/42/EC
- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC
- Vibration Protection Regulation 2002/44/EC
were determined during conditions typical for this type of equipment and by application of harmonized
standards.
During operation these values may vary because of the existing operating conditions.
Noise value
Sound pressure level on the place of the operator:
LpA = 84 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:

LWA = 104 dB(A), determined acc. to ISO 3744 and EN 500
! Danger
Wear your personal noise protection means (ear defenders) before starting operation.
Vibration value
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is  0.5 m/s2.
Hand-arm vibration values

The weighted effective acceleration value determined according to EN 500/ISO 5349 is  2.5 m/s2.
008 922 51 BOMAG 27

2.1 Technical data
Fig. 12
BW 135 AD-5
Dimen- A B C D H H2 K L O S W
sions
(mm) 1900 1390 700 900 1900 2700 340 2840 44 16 1300
(in) 74.8 54.7 27.6 35.4 74.8 106.3 13.4 111.8 1.7 0.6 51.2
BW 135 AD-5
Weights
Operating weight with ROPS 3850 kg 8488 lbs
(CECE)
Mean axle load (CECE) 1925 kg 4244 lbs
Mean static linear load (CECE) 14.8 kg/cm 83 pli
Max. operating weight 4600 kg 10141 lbs
Dimensions
Length with precision spreader* 3687 mm 145.2 in
Travel characteristics
Travel speed 0 - 10 km/h 0 - 6.2 mph
Working speed with vibration 0 - 10 km/h 0 - 6.2 mph
Max. gradability without/with vibra- 40/30 % 40/30 %
tion (soil dependent)
Drive
Engine manufacturer Kubota Kubota
Type V 2203 V 2203
Exhaust classification Europe (97/ Classification 3a Classification 3a
68/EU)
Exhaust classification U.S. EPA in- TIER 4i TIER 4i
clusive CALIFORNIA NONROAD CI
ENGINES
Cooling Water Water
Number of cylinders 4 4
28 BOMAG 008 922 51

Technical data 2.1
BW 135 AD-5
Rated power ISO 14396 33.3 KW 33.3 KW

Rated power SAE J 1995 45.3 hp 45.3 hp
Rated speed 2600 min-1 2600 rpm
Fixed engine speed (1) 2300 min-1 2300 rpm
Electrical equipment 12 V 12 V
Drive system hydrostatic hydrostatic
Driven drum front + rear front + rear
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrostatic hydrostatic
Steering angle +/- 32 ° +/- 32 °
Oscillation angle +/- 10 ° +/- 10 °
Inner track radius 2665 mm 104.9 in
Crab walk / lateral offsetting 0 - 50 mm 0 - 2.0 in
Exciter system
Vibrating drum front + rear front + rear
Frequency (1) 42 Hz 2520 vpm
Amplitude 0.5 mm 0.02 in
Centrifugal force (1) 27 kN 6070 lbf
Water sprinkler system

Type of sprinkling Pressure Pressure
Filling capacities
Fuel (diesel) approx. 55.0 litres approx. 14.5 gal us
Water approx. 310.0 li- approx. 81.9 gal us
tres
* Optional equipment
i Note
The right for technical modifications remains reserved
008 922 51 BOMAG 29

2.1 Technical data
Fig. 13
BW 138 AD-5
sions
in mm 1900 1470 700 900 1900 2700 340 2840 44 18 1380
in in 74.8 57.9 27.6 35.4 74.8 106.3 13.4 111.8 1.7 0.7 54.3
* BW 138 AD-5
Weights
Operating weight with ROPS (CECE) kg (lbs) 4250 (9370)
Mean axle load (CECE) kg (lbs) 2125 (4685)
Mean static linear load (CECE) kg/cm (pli) 15,4 (86)
Max. operating weight kg (lbs) 5000 (11023)
Dimensions
Length with precision spreader** mm (in) 3687 (145.2)
Max. working speed with vibration km/h (mph) 5 (3.1)
Max. travel speed km/h (mph) 10 (6.2)
Max. gradability without/with vibration % 40/30
(soil dependent)
Drive
Engine manufacturer Kubota
Type V 2203
Cooling Water
Number of cylinders 4
Rated power ISO 14396 kW 33.3
Rated power SAE J 1995 hp 45.3
Fixed engine speed (1) min-1 2600
Fixed engine speed (2) min-1 2300
Electrical equipment V 12
Drive system hydrostatic
30 BOMAG 008 922 51

Technical data 2.1
*
BW 138 AD-5
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering/oscillation angle +/-° 32/10
Inner track radius mm (in) 2616 (103.0)
Crab walk / lateral offsetting mm (in) 50 (2.0)
Vibration system
Vibrating drum front + rear
Drive system hydrostatic
Frequency (1) Hz (vpm) 52 (3120)
Frequency (2) Hz (vpm) 42 (2520)
Amplitude mm (in) 0,50 (0.02)
Centrifugal force (1) kN (lbf) 49 (11016)
Centrifugal force (2) kN (lbf) 32 (7194)

Type Pressure
Filling capacities
Fuel (diesel) l (gal us) approx. 55 (14.5)
Water l (gal us) approx. 310 (81.9)
Hydraulic oil l (gal us) approx. 32 (8.5)
Engine oil l (gal us) approx. 9.5 (2.5)
Coolant l (gal us) approx. 7 (1.8)
* The right for technical modifications remains reserved
** Optional equipment
008 922 51 BOMAG 31

2.1 Technical data
Fig. 14
BW 138 AC-5
sions
(mm) 1900 1470 700 900 1900 2700 340 2840 44 18 1380
(in) 74.8 57.9 27.6 35.4 74.8 106.3 13.4 111.8 1.7 0.7 54.3
BW 138 AC-5
Weights
Operating weight with ROPS (CECE) 4100 kg 9039 lbs
Axle load, drum (CECE) 2050 kg 4519 lbs
Static linear load front (CECE) 14.9 kg/cm 83 pli
Axle load, wheels (CECE) 2050 kg 4519 lbs
Wheel load (CECE) 512 kg 1129 kg
Max. operating weight 4500 kg 9921 lbs
Travel speed 0 - 10 km/h 0 - 6.2 mph
Working speed with vibration 0 - 10 km/h 0 - 6.2 mph
Max. gradability without/with vibra- 40/30 % 40/30 %
tion (soil dependent)
Drive
Engine manufacturer Kubota Kubota
Type V 2203 V 2203
Exhaust classification Europe (97/68/ Classification 3a Classification 3a
EU)
Exhaust classification U.S. EPA in- TIER 4i TIER 4i
clusive CALIFORNIA NONROAD CI
ENGINES
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 14396 33.3 KW 33.3 KW
Rated power SAE J 1995 45.3 hp 45.3 hp
Rated speed 2600 min-1 2600 rpm
32 BOMAG 008 922 51

Technical data 2.1
BW 138 AC-5

Electrical equipment 12 V 12 V
Driven drum front front
Wheels driven 4 4
Tires
Tire size 10.5/80-16 10.5/80-16
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrostatic hydrostatic
Steering angle +/- 32 ° +/- 32 °
Oscillation angle +/- 10 ° +/- 10 °
Inner track radius 2616 mm 103.0 in
Crab walk / lateral offsetting 0 - 50 mm 0 - 2.0 in
Exciter system
Vibrating drum front front
Amplitude 0.5 mm 0.02 in

Type of sprinkling Pressure Pressure
Filling capacities
Fuel (diesel) approx. 55.0 litres approx. 14.5 gal us
Water approx. 260.0 li- approx. 68.7 gal us
tres
Emulsion approx. 50.0 litres approx. 13.2 gal us
i Note
The right for technical modifications remains reserved
008 922 51 BOMAG 33

2.1 Technical data
Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 1100 - 1400
High idle speed rpm 2700 - 2800
Valve clearance intake/exhaust mm 0.20 ± 0.02
Injection valves opening pressure bar 140
Starter power kW 1.4
Travel pump
Manufacturer Bosch-Rexroth
Type A10VG45 HWD1
System Axial piston/swash plate
Max. displacement cm3/U 45
Pressure override valve bar Pressure override set to 380 bar absolute, differential
pressure 355 bar
High pressure limitation High pressure relief valve with bypass, fixed to a differ-
ential pressure of 380 bar
Travel pressure against block: 370 to 410
Charge pressure bar Low pressure relief valve, set to 25 bar
Charge pressure in high idle bar 20 to 27
Charge pressure in low idle bar 15 to 26
Travel motor AD
Manufacturer Poclain
Type MK 05
System Radial piston
Displacement cm3/U 670
Perm. leak oil rate l/min 1.5
Wheel motor AC
Manufacturer Poclain
Type MSE 02
System Radial piston
Perm. leak oil rate l/min 1.5
Vibration motor
System Gear motor
Steering/charge/vibration pump
System Gear pump
Displacement cm3/U 8/14
Steering pressure against block bar 165 to 185
Vibration start-up pressure bar 100 to 130
Start-up pressure both drums bar 190 to 200
Operating pressure, soil dependent bar 30 to 50
Operating pressure, soil dependent, bar 50 to 80
both drums:
Steering valve
Manufacturer Eaton
System Rotary spool valve
34 BOMAG 008 922 51

3 Maintenance
008 922 51 BOMAG 35

3.1 General notes on maintenance
3.1 General notes on maintenance l The fuel drum must rest for a longer period of time
before drawing off fuel.
Always comply with the appropriate safety regulations l Fuel residues in the drum are not suitable for the en-
when performing maintenance work.
gine.
Thorough maintenance of the machine guarantees far
longer safe functioning of the machine and prolongs
Notes on the performance of the engine
the lifetime of important components. The effort need-
ed for this work is only little compared with the prob- On diesel engines both combustion air and fuel injec-
lems that may arise when not observing this rule. tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
The terms right/left correspond with travel direction
gas quality of the engine.
forward.
If your engine has to work permanently in "thin air" (at
l Always clean machine and engine thoroughly be- higher altitudes) and under full load, you should con-
fore starting maintenance work.
sult our customer service or the customer service of
l Do not touch hot engine parts. the engine manufacturer.
l For maintenance work stand the machine on level
ground. Notes on the cooling system
l Always remove the main battery switch for all main- Prepare and check coolant with highest care, since
tenance work. otherwise the engine may be damaged by corrosion,
cavitation and freezing.
l Perform maintenance work only with the engine
shut down. The coolant is prepared by mixing a cooling system
protection agent (ethylene glycol) into the coolant.
l
Relieve hydraulic pressures before working on hy-
draulic lines. Mixing with cooling system protection agent is neces-
sary in all climatic zones. It prevents corrosion, lowers
l
Before working on electric parts of the machine dis- the freezing point and raises the boiling point of the
connect the battery and cover it with insulation ma- coolant.
terial.
l
When working in the area of the articulated joint at- Notes on the hydraulic system
tach the articulation lock (transport lock).
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that no
Environment dirt or other contaminating substances can enter into
During maintenance work catch all oils and fuels the system. Small particles can produce flutes in
and do not let them seep into the ground or into valves, cause pumps to seize, clog nozzles and pilot
the sewage system. Dispose of oils and fuels en- bores, thereby making expensive repairs inevitable.
vironmentally. l
If, during the daily inspection of the oil level the hy-
Keep used filters in a separate waste container draulic oil level is found to have dropped, check all
and dispose of environmentally. lines, hoses and components for leaks.
Catch biodegradable oils separately.

l Seal external leaks immediately. If necessary in-
form the responsible customer service.
Notes on the fuel system l
Do not store drums with hydraulic oil outdoors, or at
least under a cover. Water can be drawn in through
The lifetime of the diesel engine depends to a great
the bunghole when the weather changes.
extent on the cleanliness of the fuel.
l We recommend to use our filling and filtering unit
l Keep fuel free of contaminants and water, since this
with fine filter to fill the system. This ensures finest
will damage the injection elements of the engine.
filtration of the hydraulic oil, prolongs the lifetime of
l Drums with inside zinc lining are not suitable to the hydraulic oil filter and protects the hydraulic sys-
store fuel. tem.
l When choosing the storage place for fuel make l
Clean fittings, filler covers and the area around such
sure that spilled fuel will not harm the environment. parts before disassembly to avoid entering of dirt.
l
Do not let the hose stir up the slurry at the bottom of l Do not leave the tank opening unnecessarily open,
the drum. but cover it so that nothing can fall in.
36 BOMAG 008 922 51

Fuels and lubricants 3.2
3.2 Fuels and lubricants
Engine oil
Quality
Lubrication oils are classified according to their performance and quality class. Oils according to other compa-
rable specifications may be used.
If low sulphur fuel ( 0.05%) is used, you must only use engine oils of API*-classification CF, CF-4, CG-4, CH-4
and CI-4.
For operation of an engine with high sulphur fuels it is recommended to use an engine oil of classification CF or
higher with a total base number of at least 10.
! Caution
Engine oils of classification CJ-4 must not be used!
Oil viscosity
Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating location
of the engine is of utmost importance when choosing the viscosity class (SAE-class) .
Optimal operating conditions can be achieved by using the following oil viscosity chart as a reference.
Ambient temperature Viscosity
SAE 30
> 25 °C (77 °F) SAE 10W-30
SAE 15W-40
SAE 20
0 °C to 25 °C (32 °F to 77 °F) SAE 10W-30
SAE 15W-40
< 0 °C (32 °F) SAE 10W

SAE 10W-30
SAE 15W-40
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.
API: CF, CF-4, CG-4,CH-4 and CI-4: 250 operating hours
Caution
!
When using fuels with a sulphur content higher than 0.5% the oil change intervals must be halved.
Fuels
Quality
Cetan index number: The recommended minimum index number for the Cetan value is 45. A Cetan index
number higher than 50 should preferably be used, especially at ambient temperatures below -20°C (-4 °F) and
when working at altitudes of 1500 m (4921 ft) and more.
Diesel fuel specifications: With respect to the percentage (ppm) of sulphur the fuel used in the engine must com-
ply with all relevant exhaust emission regulations in the are of use of the engine.
It is highly recommended to use a fuel with a sulphur content of less than 0,10% (1000 ppm).
* American Petroleum Institute
008 922 51 BOMAG 37

3.2 Fuels and lubricants
When using a diesel fuel with a high sulphur content of 0.50% (5000 ppm) to 1.0% (10.000 ppm), the engine oil
change intervals must be halved.
Caution
!
Do not use any fuels with a sulphur content of more than 1,0% (10000ppm).
It is recommended to use diesel fuel that complies with the specifications EN590 or ASTM D975.
Diesel fuel with the designation no. 2-D is a destillate fuel with low volatility, which is especially suitable for in-
dustrial engines and heavy-duty commercial vehicles (SAE J313 JUN87).
Since KUBOTA diesel engines with a rated power of less than 56 kW (75 HP) comply with the exhaust emission
standard of EPA*-stage 4, the use of low or ultra-low sulphur fuel is mandatory for these engines, if the engines
are operated within the validity area of the EPA standard. As an alternative to no. 2-D you may also use diesel
fuel no. 2-D S15; with ambient temperatures below -10°C (+14 °F) the diesel fuel no. 1-D S15 should be used
for no. 1-D.
Fuel should always be replenished in due time.
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.
Coolant
Always use a mixture of anti-freeze agent and clean, dehardened water with a mixing ratio of 1:1.
Under particularly extreme temperature conditions you should consult our customer service concerning the anti-
freeze agent to be used.
There are various types of anti-freeze agents available. For this engine you should use ethylene glycol.
Before filling in the coolant mixed with anti-freeze agent the radiator must be flushed with clean water. This pro-
cedure should be repeated two to three times to clean the inside of radiator and engine block.
Mixing the anti-freeze agent: Prepare a mixture of 50% anti-freeze agent and 50% low mineral, clean water. Stir
well before filling it into the radiator. The method for mixing water and anti-freeze agent depends on the brand
of the anti-freeze agent. In this respect see standard SAE J1034 and also the standard SAE J814c.
Add anti-freeze agent: If the coolant level drops because of evaporation,only clean water is to be used for top-
ping up. In case of leakages you must always fill in anti-freeze agents of the same brand and the same mixing
ratio.
Caution
!
Do not mix different coolants and additives of any other kind.

Do not use any radiator cleaning agent after the anti-freeze agent has been mixed in. The anti-freeze agent also
contains a corrosion protection agent. If this mixes with cleaning agent it may cause the development of sludge,
which could damage the cooling system.
Anti-freeze concentration
50% = -37 °C (-35 °F)
Environment
Coolant must be disposed of environmentally.
* United States Environmental Protection Agency
38 BOMAG 008 922 51

Fuels and lubricants 3.2
Mineral oil based hydraulic oil
The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm2/s at 40 °C
and 8 mm2/s at 100 °C. For topping up or for oil changes use only high-quality hydraulic oil, type HVLP according
to DIN 51524, part 3, or hydraulic oils type HV according to ISO 6743/3. The viscosity index (VI) should be at
least 150 (observe information of manufacturer).
Bio-degradable hydraulic oil

The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Panolin HLP Synth.46 meets all demands of a mineral oil based
hydraulic oil according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46 always use the same oil to top up.
When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manufacturer for details.
! Caution
Check the filter more frequently after this change.
Perform regular oil analyses for content of water and mineral oil.
Replace the hydraulic oil filter element every 500 operating hours.
008 922 51 BOMAG 39

3.3 Table of fuels and lubricants
3.3 Table of fuels and lubricants
Assembly Fuel or lubricant Quantity
Summer Winter Attention!

Observe the
level marks
Motor
- Engine oil Engine oil API: approx. 9.5 li-

CF, CF-4, CG-4, CH-4 or CI-4 tres
(2.5 gal us)
SAE 10W/-40
(-20 °C to +40 °C) (-4 °F to +104 °F)
(BOMAG 009 920 06; 20 l)
SAE 10W-30
(-15 °C to +30 °C) (+5 °F to +86 °F)
SAE 15W-40
(-15 °C to +40 °C) (+5 °F to +104 °F)
SAE 30 SAE 10W

(+5 °C to +30 °C) (-30 °C to -5 °C)
(+41 °F to +86 °F) (-22 °F to +23 °F)
- Fuel Diesel Winter diesel fuel approx. 55 li-

(down to -12 °C) tres
(+10.4 °F) (14.5 gal us)
- Coolant Mixture of water and anti-freeze agent approx. 7 li-

(BOMAG 009 940 08; 20 l) tres
(1.8 gal us)
40 BOMAG 008 922 51

Table of fuels and lubricants 3.3
Assembly Fuel or lubricant Quantity
Summer Winter Attention!

Observe the
level marks
Hydraulic system Hydraulic oil (ISO), HLP 46 approx. 39 li-

(BOMAG 009 930 09; 20 l) tres
or (10.3 gal us)
ester based biodegradable hydraulic oil
Sprinkler system Water Anti-freeze mix- AD: approx.

ture water * 310 l
(81.9 gal us)
AC: approx.
260 l
(68.7 gal us)
- Rubber tire sprin- Emulsion approx. 50 li-

kler system tres
(13.2 gal us)
* Mix water and anti-freeze agent by following the instructions of the manufacturer.
008 922 51 BOMAG 41

3.4 Running-in instructions
3.4 Running-in instructions

The following maintenance work must be per-
formed when running in new machines or over-
hauled engines:
! Caution
Up to approx. 250 operating hours check the en-
gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.
Maintenance after 50 operating hours

l Change engine oil and filter
l Check the engine for leaks
l Retighten the fastening screws on air filter, exhaust
and other attachments.
l Check screw connections on the machine, retighten
as necessary.
42 BOMAG 008 922 51

Maintenance table 3.5
3.5 Maintenance table
No. Maintenance work Note
With all maintenance intervals perform also the work for shorter preced-
ing service intervals.
Every 10 operating hours

5.6 Checking the engine oil level Dipstick mark
5.7 Check the fuel level
5.8 Check the hydraulic oil level Dipstick mark
5.9 Check the hydraulic oil filter element Contamination indica-
tor
5.10 Check the coolant level
5.11 Check the water level
5.12 Check the emulsion level only AC-machines

5.13 Check, clean the air filter, replace if necessary min. 1 x year
5.14 Check fuel lines and clamps

5.15 Check, clean the water separator
5.16 Service the precision spreader
008 922 51 BOMAG 43


5.17 Change engine oil and oil filter cartridge* min. 1 x year
see foot note
5.18 Check, tension, replace the V-belt
5.19 Check the air intake lines
5.20 Clean radiator and hydraulic oil cooler
5.21 Battery service
5.22 Check radiator hoses and hose clamps
5.23 Check the scrapers, adjust if necessary
5.24 Check the parking brake
5.25 Drain the fuel tank sludge
5.26 Change the fuel filter
5.27 Check the anti-freeze concentration and the
condition of the coolant
* Running-in instructions: oil change after 50 operating hours, then every 250 operating hours
When using fuels with a sulphur content higher than 0.5% the oil change intervals must be
halved.
44 BOMAG 008 922 51

Maintenance table 3.5

5.28 Check, adjust the valve clearance on cold engine
Intake and exhaust
valve: 0.20 mm (0.008
in)
5.29 Check the engine mounts
5.30 Check the travel control
5.31 Change hydraulic oil and breather filter* see foot note
at least every 2 years
5.32 Change the hydraulic oil filter1 see foot note
at least every 2 years
5.33 Change the coolant at least every 2 years
5.34 Replacing the fuel lines at least every 2 years

5.35 Check the injection valves only by authorized
service personnel
* Also after repairs in the hydraulic system.
008 922 51 BOMAG 45


5.36 Check the fuel injection pump only by authorized
service personnel
As required
5.37 Check the tire pressure only AC-machines
5.38 Water sprinkler system, maintenance in case
of frost
5.40 Engine conservation
46 BOMAG 008 922 51

4 Overall view of machine
008 922 51 BOMAG 47

4.1 Overview
Front frame
4.1 Overview
Fuel pump
Fuel pre-cleaner
Tandem gear pump Fuel filter
Cooler
Battery
Hydraulic oil tank
Fuel tank Vibration valve Travel pump Charge oil filter

Brake valve High pressure filter
48 BOMAG 008 922 51

Overview 4.1
Rear frame
Power board
Steering cylinder
Steering valve
Oscillating articulated joint
008 922 51 BOMAG 49

4.1 Overview
Sprinkling system AD
Sprinkling pump
Sprinkling pump
50 BOMAG 008 922 51

Overview 4.1
Sprinkling system AC
Emulsion tank
Emulsion pump
Sprinkling pump
Emulsion pump Sprinkling pump
008 922 51 BOMAG 51

4.1 Overview
52 BOMAG 008 922 51

5 Electrics
008 922 51 BOMAG 53

5.1 Battery service
5.1 Battery service
! Danger
Danger of cauterisation ! Danger of explosion!

When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
For recharging remove the plugs from the battery Fig. 15
to avoid the accumulation of highly explosive gas-
es.
l Open the engine hood.
l Clean battery (Fig. 15) and battery compartment.
Environment l Clean battery poles and terminals.
Dispose of the old batteries environmentally. l Retighten the pole clamps.
l Check the fastening of the battery.
i Note
Maintenance free batteries also need care. Mainte-
nance free only means that the fluid level does not
need to be checked. Each battery suffers under self-
discharge, which may, in not checked occasionally,
even cause damage to the battery as a result of ex-
haustive discharge.
The following therefore applies for the service life:

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

sulphate on the plates) are not covered under war-
ranty!
54 BOMAG 008 922 51

Starting with jump wires 5.2
5.2 Starting with jump wires 5.3 Main battery switch
II
650115
Fig. 16 Fig. 17
No. 1 = Main battery switch*
!Caution Position "I" (horizon-
A wrong connection will cause severe damage in tal) = Disconnects the plus pole of the
the electric system. battery from the vehicle electrics
in case of burning cables and fire
l
Only use a 12 Volt battery to bridge the machine. in the engine compartment, pro-
l
When jump starting with an external battery connect tection against unauthorized use,
both plus poles first. during welding work on the ma-
chine. Can be removed.
l
Then connect the ground cable first to the minus
pole of the current supplying battery and then to en- Position "II" (90°
gine or chassis ground, as far away from the battery down) = Operating position, engine can be
as possible(Fig. 16). started.
l
Start as described under 'Starting the engine'.
l
Once the engine is running switch on a powerful
i Note
consumer (working light, etc.). BOMAG TELEMATIC** remains active even with the
main battery switched pulled out.
!Caution
If no powerful consumer is switched on voltage
peaks may occur when separating the connecting
cables between the batteries, which could dam-
age electrical components.
l
After starting disconnect the negative poles (ground
cable) first and the positive poles after.
l
Switch off the consumer.
** Optional equipment
008 922 51 BOMAG 55

5.4 Generator repair
Fig. 1
1 V-belt pulley l Disassemble the holding plate (5).

2 Drive bearing plate l Use a press and a suitable device to press the bear-
3 Stator ing (4) out of the drive bearing plate (2).
4 Bearing
l To protect the rotor against damage clamp it lightly
in vice and extract the bearing (7) with a puller.
5 Holding plate
6 Rotor Assembly
7 Bearing
8 Rear bearing plate i Note
9 Rectifier V-belt pulley tightening torque 58.4 to 78.9 Nm.
10 IC-regulator
11 Brush holder
12 Rear covering
Dismantling
l Remove the V-belt pulley (1).
l Remove the rear covering (12).
l Disassemble the brush holder (11).
l
Disassemble the IC-regulator (10).
l
Unscrew the four stator cable fastening screws.
l
Take off the rectifier (9).
l
Take off the rear bearing plate (8).
l Press the rotor (6) out of the drive bearing plate (2).
56 BOMAG 008 922 51

Generator repair 5.4
Bearing Stator
Fig. 2 Fig. 3
l Check whether the bearing rotates without obstruc- l Use the resistance range of the continuity tester to
tion. measure the resistance between the individual lines
l Replace the bearing if it does not rotate properly. of the stator winding.
l If the measuring value does not comply with the fac-
tory specification, replace the stator.
l
Use the resistance range of the continuity tester to
check the continuity between the individual stator
windings and the core.
l
Replace the stator if no infinite value is indicated.
i Note
Factory specification for resistance: Less than 1 OHM.
008 922 51 BOMAG 57

Rotor Slipring
Fig. 4 Fig. 5
l Measure the resistance between the sliprings. l Check the slipring for score marks.
l If the resistance does not comply with the factory l If score marks are found rework the slipring with
specification, replace the rotor. emery cloth or on a lathe.
l Use the resistance range of the continuity tester to l Measure the outer diameter of the slipring with a
check the continuity between slipring and core. vernier caliper.
l
Replace the rotor if no infinite value is indicated. l
Replace if the measuring value is below the permis-
sible limit.
i Note
Factory specification for resistance: 2.9 OHM. i Note
Outer slipring diameter: 14.4 mm.
Permissible limit: 14.0 mm.
58 BOMAG 008 922 51

Generator repair 5.4
Wear on carbon brushes Rectifier
Fig. 6 Fig. 7
l Measure the brush length with a vernier caliper. l Use the resistance range of the continuity tester to
l Replace if the measuring value is below the permis- check the continuity between the individual rectifier
sible limit. diodes.
l Make sure that the brush is light moving.
l The rectifier is in good working order when the rec-
tifier diode conducts to one direction and block in
l A defective carbon brush must be replaced.
the other direction.
i Note
Brush: 10.0 mm.
Fig. 8
008 922 51 BOMAG 59

Regulator
Fig. 9
l Use the resistance range of the continuity tester to
check the continuity between terminal B (2) and ter-
minal F (1) on the IC-regulator.
l The IC-regulator is in good working order when it
conducts current to one direction, but not in the oth-
er direction.
60 BOMAG 008 922 51

Repair of starter 5.5
Fig. 1
1 Through bolt l Separate the armature (5) from the starter frame
2 Brush (4).
3 Terminal nut C
l Disassemble the housing (13).
4 Starter frame
l Disassemble intermediate gear (7) and freewheel
(6).
5 Armature
l Remove the magnetic switch cover (9).
6 Freewheel
l Disassemble the piston (11).
7 Intermediate gear
8 Housing cover
Caution
!
9 Brush holder
Do not damage carbon bushes or collector.
10 Magnetic switch cover
11 Piston Assembly
12 Terminal nut B l Apply some grease to intermediate gear and free-
13 Housing wheel. Tightening torque for terminal nut (12): 5.88
to 11.8 Nm
Dismantling
l Unscrew the terminal nut (3) and take off the con-
necting cable.
l Disassemble the two through bolts (1).
l
Take off the motor.
l
Disassemble the housing cover (8).
l
Compress the spring and take the carbon brush off
the brush holder.
l
Disassemble the brush holder (9).
008 922 51 BOMAG 61

5.5 Repair of starter
Freewheel Collector and mica capacitor
Fig. 2
l Check the pinion, replace the complete freewheel if Fig. 3
signs of wear or damage are found. l Check the contact surface of the collector for wear
l Make sure that the pinion rotates freely in the free- and rework it with sanding paper if it is slightly worn.
wheeling direction and does not slip in starting di-
rection.
l If the pinion slips or does not rotate to both direc-
tions, replace the freewheel assembly.
i Note
Do not wash the grease in the freewheel out with
chemicals or oils.
Fig. 4
l Measure the outer diameter of the collector at sev-
eral points with an outside micrometer.
l If the smallest outside diameter is below the permis-
sible limit, the rotor must be replaced.
i Note
Factory specification, collector outside diameter:
30.0 mm.
Fig. 5
l
If the difference between the outer diameter meas-
uring values exceeds the permissible limit have the
62 BOMAG 008 922 51

collector reworked to the factory specifications on a Wear on carbon brushes
lathe.
i Note
Factory specification, difference of outer diameter
measurements: Less than 0.02 mm.
Fig. 7
l If the contact area of the carbon brush is dirty or
dusty, clean it with emery cloth.
l Measure the brush length (A) with a vernier caliper.
l If the length is shorter than the permissible limit, the
brush holder must be replaced.
Fig. 6
1 Segment i Note
2 Counterdraft Factory specification, brush length: 16.0 mm.
3 Collector Permissible limit: 10.5 mm.
a) correct
b) not correct
l
Measure the counterdraft on the collector.
l
If the counterdraft falls short of the lower limit value,
correct it with a saw blade and bevel the segment
edges.
i Note
Factory specification, collector counterdraft: 0.5 to 0.8
mm
008 922 51 BOMAG 63

Brush holder Armature coil
Fig. 9
Fig. 8 l Use the resistance range of the continuity tester to
l Use a continuity tester to check the continuity be- check the continuity between collector and arma-
tween brush holder and holder carrier. ture coil.
l If continuity is found replace the brush holder. l If continuity is found replace the armature.
Fig. 10
l
Use the resistance range of the continuity tester to
check the continuity between the collector seg-
ments.
l
If no continuity is found replace the armature.
64 BOMAG 008 922 51

Field coil Trouble shooting "Starter"
i Note
The most frequent fault is definitely a fully discharged
battery.
If the starter rotates too slowly, either the brushes
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric
contacts or a soiled ground connection causing ex-
tremely high voltage losses in the overall starter sys-
tem are the cause of problems.
If the starter only emits a clicking sound,- either
Fig. 11 the magnetic switch is defect / soiled (dismantle and
1 Replace the clean))- the main contacts on the magnetic switch are
worn off / soiled (scrape off carefully with a file and
2 Brush
clean)- the starter motor is defective / soiled (remove
3 Stator armature and clean), cover cleaned, moveable parts
l Use the continuity tester to check the continuity be- with grease.
tween line (1) and brush (2). Frequently a jammed return mechanism is the reason
l If no continuity is found replace the stator frame. for a starter failure.
Occasionally worn contacts are found on the magnetic
return switch
Defects on the actual starter motor including pinion
and carbon brushes are very rare.
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system
can only work when many conditions are fulfilled at
the same time.
l Immobilizer deactivated?
l Ignition switch OK?
l Travel lever in correct position?
Fig. 12 l Emergency stop not actuated?
l
Use the continuity tester to check the continuity be- l Battery sufficiently charged?
tween brush (2) and stator (3).
l Battery poles OK?
l
If continuity is found replace the stator frame.
l Main battery fuse OK?
l Main battery switch closed?
l Main starter cable (terminal 30) OK?
l Starter control cable (terminal 50) OK, voltage
drop?
l Ground cable OK?
l Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l the experience of the specialist
l the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.
008 922 51 BOMAG 65

Testing and measuring the starter Continuity test for the magnetic switch
Function control with the starter removed
Caution
!
Fasten the starter to make sure that it will not

come loose during the test.
Fig. 15
l
Use a continuity tester to check for continuity be-
tween terminal (1) and terminal (29 while holding
the pin depressed.
l Replace the magnetic switch if no continuity is de-
tected.
Fig. 13
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).
i Note
If the motor does not start, the starter is defective. Re-
pair or replace the starter.
Checking the magnetic switch
Fig. 14
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).
i Note
If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.
66 BOMAG 008 922 51

Instrument cluster (A15), overview 5.6
5.6 Instrument cluster (A15), overview
Self test
When applying operating voltage to PIN26 (UB) and PIN25 (GND) the display runs a self-test of the LEDs (2
sec.).
Fig. 1
Fuel gauge
00 Ohm = Tank full
30 Ohm = Tank 1/2
65 Ohm = Tank empty
If no level switch is connected or the cable is broken, no fuel level will be displayed
Shut-down function
Pos. Monitoring function Reaction of control Reaction of warning Reaction of engine

lamp horn shut-down
a Seat contact On On, backup alarm addi- see chapter "Seat con-
tionally active tact switch"
c Engine oil pressure On After 5 seconds After 10 seconds
e Excessive engine tem- On After 5 seconds After 2 minutes
perature
h Water in fuel filter On After 5 seconds After 2 minutes
008 922 51 BOMAG 67

5.6 Instrument cluster (A15), overview
Digital inputs
Input Performance Comment

DigIn1, PIN4 LOW-active (GND) Input pre-heating
DigIn2, PIN5 HIGH-active (+UB) Input brake
DigIn3, PIN8 HIGH-active (+UB) Input day/night control
DigIn4, PIN9 LOW-active (GND) Input engine temperature
DigIn5, PIN10 LOW-active (GND) Input seat contact
DigIn6, PIN11 HIGH-active (+UB) Input charge control
DigIn7, PIN12 LOW-active (GND) Input engine oil pressure
DigIn8, PIN13 HIGH-active (+UB) Input indicator / hazard light
DigIn9, PIN14 LOW-active (GND) Input vibration button
DigIn10, PIN15 HIGH-active (+UB) Input sensor "Water in fuel"
DigIn11, PIN16 HIGH-active (+UB) Input vibration switch IVC (Manual /
Auto)
DigIn12, PIN17 HIGH-active (+UB) Input option USA (V9)
Analog inputs1 analog input

Should a defect occur on the two analog inputs (input rotation angle sensor B39, Pin 2) or the input (interval
switch A01, Pin 3), the fault indicator lamp (red, h) will start flashing (Fig. 1).

AnalogIn1, PIN1 0…100 OHM Input level switch, 0…65 OHM
AnalogIn2, PIN2 0…25mA Input rotation angle sensor travel le-
ver, 4…20mA
AnalogIn3, PIN3 0…+UB Input 6-stage switch for sprinkling
system
Digital outputs

DigOut1, PIN18 IOOut = 150mA Output relay K190 (solenoid for
holding winding)
DigOut2, PIN19 IOOut = 150mA Output relay K22 (solenoid for pick-
up winding)
DigOut3, PIN20 IOOut = 4mA Output brake valve Y04
DigOut4, PIN21 IOOut = 150m Output vibration K43
DigOut5, PIN22 IOOut = 4mA Output warning buzzer
DigOut6, PIN23 IOOut = 400mA Output backup alarm
DigOut7, PIN24 IOOut = 150mA Outlet sprinkling system (K79)
68 BOMAG 008 922 51

Seat contact switch 5.7
5.7 Seat contact switch
The seat contact control is controlled by the instrument cluster (A15).
Machine standing
Diesel engine running
Seat not occupied
Travel lever in brake lock
Travel lever Engine is shut down

is actuated immediately
Brake is closed
Warning buzzer on
Control lamp (a) lights
Machine travels
Driver seated
Driver stands up Engine is

shut down
after 2 seconds
Warning buzzer on
Control lamp (a) lights
Driver sits down Engine starts.

and with
engine oil pressure is kinetic energy
still present (Engine solenoid retracts)
008 922 51 BOMAG 69

5.8 Switching the vibration on
5.8 Switching the vibration on
i Note
Vibration can only be switched on when the engine is
running.
Fig. 2 Instrument cluster, A15
Fig. 1
Manual vibration pre-selection, position left (Fig.

1)
The push button (S13 in travel lever, optionally S12)
switches ground to the instrument cluster (A15, termi-
nal X6:14). The instrument cluster ((Fig. 2) 1) in turn
switches the relay coil (K43) via terminal (X6:21) and
thus the vibration on or off.
Automatic mode, position right

When the travel lever is moved forward or backwards,
the speed of the machine is detected by the position
of the angle sensor (B39) (Fig. 3).
At speeds of < 1 km/h and > 6 km/h the relay coil (K43)
is switched to floating condition by the instrument
cluster.
Fig. 3 Angle sensor, B39
70 BOMAG 008 922 51

Switching on the pressure sprinkler system 5.9
5.9 Switching on the pressure 5.10 Level sensor in diesel tank
sprinkler system (R03)
Fig. 1 Interval switch, A01
Step On-time Off-time Cycle peri-

(sec.) (sec.) od (sec.) Fig. 1 R03
0 0 15 15 The fluid of the level to be measured carries a float,
1 3 12 15 which lowers or rises with the fluid level. Contact
2 6 9 15 springs mounted on the float thereby slide along two
3 9 6 15 resistor wires arranged parallel to the movement of
4 12 3 15 the float and generate a resistance value, which is
5 15 0 15 proportionate to the fluid filling level. The correspond-
The interval switch (A01, voltage divider) (Fig. 1) ap- ing resistance value is measured by an electric meter
plies different voltages to terminal (A15 instrument and displayed as fluid level value.
cluster, X6:3).
Depending on the switching position /(A01) the instru-
ment cluster (Fig. 2) switches the relay coil (K79) and
thus the sprinkling pump (M02) on and off, via terminal
(X6:24).
Sprinkling is switched off when the travel levr remains
longer than 15 seconds in neutral position.
Fig. 2 A15
j = Fuel level gauge
00 Ohm = Tank full
30 Ohm = Tank 1/2
65 Ohm = Tank empty
If no level switch is connected or the cable is broken,
no fuel level will be displayed
Fig. 2 Instrument cluster, A15
008 922 51 BOMAG 71

5.11 Water in fuel filter, sensor B124 (optional)
5.11 Water in fuel filter, sensor

B124 (optional)
2
2
2
Fig. 2 A15
The control lamp (h, red) (Fig. 2) lights if the sensor
(B124) detects water, the engine is shut down after 2
1 1 minutes.
The warning buzzer sounds after 5 seconds.
Fig. 1 Fuel filter sensor

With water in the filter the sensor will switch to ground.
72 BOMAG 008 922 51

Charge control lamp and operating hour meter 5.12
5.12 Charge control lamp and oper- 5.13 Engine oil pressure monitor-
ating hour meter ing
Fig. 1 Generator
Charge control lamp

If the battery is not being charged, a ground signal is Fig. 1 Oil pressure switch
applied to generator terminal "L" (Fig. 1). 1 Oil pressure switch, B06
Current flows from the instrument cluster (A15)
through the charge control lamp (Pin11) to generator
terminal "L". The charge control lamp d (Fig. 2) lights
up.
Fig. 2 Instrument cluster

The control lamp (c, red) (Fig. 2) flashes if the engine
oil pressure is too low (<0.5 bar), the engine is shut
down after 10 seconds.
Fig. 2 A15
Operating hour meter
If UB (12 Volt) is applied to generator terminal "L", the
operating hour meter j counts the operating time.
008 922 51 BOMAG 73

5.14 Coolant temperature monitoring
5.14 Coolant temperature monitor- 5.15 Glow plugs, R81

ing During the preheating process the glow plugs are en-
ergized through terminals (17 and 19) on the ignition
switch.
During the starting process the glow plugs are ener-
gized through terminals (17, 19 and 50) on the ignition
switch.
Fig. 1 Temperature switch

1 Temperature switch, B53

The pre-heating control lamp b (Fig. 3) lights for 10
seconds. The LED goes out if running of the engine is
detected during this time.
Measuring the spark plug voltage
Fig. 2
The control lamp (e, red) (Fig. 2) flashes if the coolant
temperature is too high (>115 °C), the engine is shut
down after 2 minutes.
Fig. 4
Nominal value: Battery voltage

l Turn the ignition switch to "Preheating" and check
the voltage between cable terminal and engine
block with a continuity tester.
74 BOMAG 008 922 51

Engine solenoid, Y13 5.16
Continuity test 5.16 Engine solenoid, Y13
Fig. 5
l Remove the glow plug.
l Use a continuity tester to measure the resistance
between glow plug connection and glow plug body.
l If the measured value does not correspond with the
factory specification, the glow plug is defective.
Fig. 1 Engine solenoid
i Note
The machine is equipped with a solenoid which works
Factory specification for resistance approx. 0.9 . according to the principle "ENERGIZED TO RUN".
This solenoid has the advantage, that the engine will
be immediately shut down, if the electric system fails.
A disadvantage is the quite costly design of the sole-
noid with two coils.
Fig. 2 Engine solenoid
Nominal currents of windings:

Pickup winding (AW) 32 A
Holding winding (HW) 0.8 A
Function
During the start process the pick-up winding (PW) is
supplied with potential (30) through relay (K22). Once
the engine oil pressure is reached, the holding wind-
ing is supplied with voltage.
After the engine has started, the voltage (potential 30)
to the pick-up winding is interrupted again.
Testing the function

l Start the engine for a moment.
008 922 51 BOMAG 75

5.16 Engine solenoid, Y13
i Note i Note
During the starting process the pin is retracted and it When switching the switch (4) on the pin is retracted
extends again when the ignition is switched off. and it moves out again when the switch (4) is switched
off.
Testing the shut-off solenoid
l
Switch the switch (3) on first and switch (4) after -the
pin is retracted into the body of the solenoid and re-
mains in this position when switch (4) is switched
Ground supply off.
Fig. 3
1 Plug
2 Battery
3 Switch for holding winding (HW)
4 Switch for pick-up winding (PW)
Danger
!
Danger of burning!
The shut-down solenoid gets very hot during the Fig. 4
stating process.
! Caution
For inspection do not apply current to the pick-up
winding for longer than two seconds.
i Note
Terminal for pick-up winding, resistance approx. 0.38
OHM.
Terminal for holding winding, resistance approx. 16
OHM.
l
Connect bridging cables between terminal (PW) of
the pick-up winding and switch (4), as well as be-
tween switch (4) and battery plus.
l
Connect bridging cables between terminal (HW) of
the holding winding and switch (3), as well as be-
tween switch (3) and battery plus.
l Connect the bridging cable (ground supply).
l
Switch the switch (4) on and off.
76 BOMAG 008 922 51

Inductive proximity switch, B63 5.17
5.17 Inductive proximity switch,
B63
The following functions are influenced by the proximity
switch:
l Diesel engine start enable (relay, K05)
l Engine solenoid Y13, pick-up winding (relay, K22)
l
Closing of brake, time delayed via instrument clus-
ter.
l Teaching of the travel lever zero position of the an-
gle sensor, B39.
l Sprinkler system, water off after 15 seconds, if trav-
el lever is in 0-position.
Fig. 3
The proximity switch (B63) works with a normally
open contact. The switching gap is 4 mm, the max.
electrical load is 300 mA.
The LED (Fig. 3) lights up, when the initiator has de-
tected metal in its stray field.
Fig. 1 Proximity switch, B63
Working principle
Fig. 2
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.
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.
008 922 51 BOMAG 77

5.18 Angle sensor on travel control lever, B39
5.18 Angle sensor on travel control Situation without external magnetic field
lever, B39
The following functions are influenced by the sensor:
l Automatic vibration ON/OFF
l Sprinkler system, water off after 30 seconds, if trav-
el lever is in 0-position.
l
Backup protection
l Checking the travel lever neutral position.
Fig. 2
I = Current in semi-conductor of Hall-IC
W = Semi-conductor as current conductor in Hall-IC
Current passes through the semi-conductor W in the
Hall-IC. Since there is no other magnetic force, the
electrons pass evenly through the semi-conductor.
There is no measureable Hall voltage (UHall = 0 V).
Situation with external magnetic field
Fig. 1 Angle sensor on travel control lever
Sensor with current output

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.
Fig. 3
The advantage of the Hall sensor lies in the fact that,
Current passes through the semi-conductor W in the
in contrast to the potentiometer, there is no dragging
Hall-IC. Since there is the effect of an external mag-
contact and thus no wear by abrasion.
netic field, the electrons are deflected to the left. There
The Hall sensor generates an electric voltage, the Hall is an excess of electrons on the left and a lack of elec-
voltage. The necessary electric and magnetic proc- trons on the right. Hall voltage (UHall > 0 V) can be
esses take place in a very confined space inside the measured on the side surfaces.
Hall-IC. Since a vast variety of electronic elements
work together in highly complicated circuitries inside
the Hall-IC, the Hall sensor needs an external power
supply, which is not possible through the vehicle
mains supply or the associated control unit.
The Hall effect is based on the phenomenon that elec-
trons are deflected to one side when they pass
through a magnetic field that acts from the outside. In
this case an excess of electrons is created on the side
used by the electrons, because the negative electrical
potential of the flowing electrons predominates. On
the opposite side the electrically positive potential of
the stationary atomic cores is predominant, after the
associated electrons were forced to the opposite side.
A semi-conductor is used as current conductor.
78 BOMAG 008 922 51

Angle sensor on travel control lever, B39 5.18
Fig. 4 Connection diagram

The angle sensor has 3 electric connections (Fig. 4).
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.
008 922 51 BOMAG 79

5.19 Central electrics

Optimal access, unfoldable, integrated in the steering column.
Fig. 1
80 BOMAG 008 922 51

Central electrics 5.19
Power board for high-current applications
Fig. 1
Power elements implemented in the board by means of pressing technology, ensure permanent connections,
which meet highest quality demands throughout the entire life cycle of the product and thus are a major contri-
bution to product reliability.
A powerful electric press fit is made by pressing a press pin through the contacted hole in a printed circuit board
- within the course of a cold welding process - whereby a gas tight electrical connection is achieved.
Advantages:
l Particularly quick connection with the wiring loom of the vehicle
l Possibility of combining high-current and signal lines
l
Highest possible avoidance of connecting and wiring faults
l Gain in space due to the possibility of compact design (e.g. by placement from both sides) as well as weight
reduction
l 100% electric testing
l
Increased reliability and prolonged lifetime of the overall system
l Clear display of switching states by means of LEDs (simple diagnostics).
008 922 51 BOMAG 81

Fig. 2
1 LEDs for switching functions
2 LEDs for relays
3 Test base for fuses
Switching function 15= Potential 15
Switching function B53= Engine oil temperature switch
Switching function S06= Seat contact switch
Switching function Y04= Solenoid valve for brake
Switching function Y54= Solenoid valve, rear vibration
Switching function Y55= Solenoid valve, front vibration
i Note
LEDs relay light when Ubat is applied to the relay coils.
LEDs switching functions light when Ubat is applied to tthe switching outputs.
A02 = Flasher unit
H07 = Warning buzzer for malfunctions
82 BOMAG 008 922 51

Central electrics 5.19
K05 = Relfor start current
K11 = Relay potential 30 to 15
K13 = Relay for warning horn
K22 = Relay for engine solenoid
K43 = Relay for vibration
K78 = Relay for emulsion pump
K79 = Relay for sprinkling pump
K117 = Relay for edge cutter
K190 = Relay for holding winding
K203 = Relay for additional headlights
K212 = Timer relay for rear drum vibration
R09 = Dropping resistor for generator excitation
X29 = Glow plugs
X30 = Potential 30 (battery)
GND = Potential 31 (ground)
Test base to check the conductivity of plug-in fuses
Fig. 3 Pictogram:
i Note
The printed circuit board is a equipped with a fuse test socket (Fuse Test). When plugging in an intact fuse the
LED lights up.
008 922 51 BOMAG 83

5.20 Fuse assignment
! Danger
Fire hazard!
Do not use fuses with higher ampere ratings and do not bridge fuses.
Central electrics
462100
Fig. 4
l
Unscrew the fastening screw (Fig. 4) and fold out the central electrics against the end stop.
i Note
The printed circuit board is a equipped with a fuse test socket (Fuse Test). When plugging in an intact fuse an
LED lights up.
Fig. 5
Fuse Amperage Designation
F241 15 A Optional headlights
F274 10 A Precision spreader / hydraulic breaker
F119 10 A Motor
F153 10 A Potential 15
84 BOMAG 008 922 51

Fuse assignment 5.20
F23 10 A Warning horn
F06 5A Interval switch for pressure sprinkling sys-

tem
F11 15 A Headlights, left
F12 15 A Headlights, right
F156 15 A Lighting
F08 15 A Direction indicators and working head lights
F07 15 A Hazard light system
F03 10 A Vibration
F139 30 A Engine solenoid
F275 5A Economizer
F48 40 A Preheating system
F10 10 A Parking and tail light, right
F09 10 A Parking and tail light, left
F157 30 A Starter
F45 10 A Edge cutter
F37 10 A Sprinkling pump
F05 10 A 12 V socket
F276 10 A Pump for emulsion sprinkling system
F04 7.5 A Instruments
JP1 5A Vibration also with travel lever in position"II"
Main fuse for battery

The main fuse for the battery is located inside the engine compartment.
008 922 51 BOMAG 85

650110
Fig. 6
F00 80 A Main fuse for battery
86 BOMAG 008 922 51

Control elements 5.21
5.21 Control elements
Fig. 7
008 922 51 BOMAG 87

5.21 Control elements
1 S53 Rotary switch for working lights

2 S15 Rotary switch for lighting
3 S14 Rotary switch for hazard light system a
4 S38 Rotary switch for flashing beacon
5 S08 Rotary switch, vibration pre-selection b
6 S36 Rotary switch for vibration, drum pre-selection
7 A01 Interval switch pressurized sprinkling system
8 S37 Rotary switch for direction indicators
9 S01 Emergency stop switch
10 S25 Rotary switch seat heating
11 S316 Rotary switch pre-selection of button assign-
880168
ment in travel lever
Fig. 8
12 A103 Economizer display
a, S12 = Button vibration on/off
13 A15 Instrument cluster
b, S03 = Button for warning horn
14 S00 Start switch
15 XS 12V-socket
16 Travel lever with buttons for vibration S13, warning
horn S03 and edge cutter S82 a c
17 Double travel lever with buttons for vibration S12
and warning horn S03 b d
18 Throttle lever
880166
Fig. 9
a, S13 = Button vibration on/off
b, S03 = Button for warning horn
c, S82 = Button, edge cutter* up
d, S82 = Button edge cutter* down
Fig. 10
Foot switch, S164
88 BOMAG 008 922 51

Machine related electrics 5.22
5.22 Machine related electrics
1 Battery cable (+) - starter

2 Ground cable, rear frame
3 Ground cable, front frame
4 Ground cable Powerboard
5 Ground cable - driver's stand
6 Battery cable (ground)
008 922 51 BOMAG 89

1 Wiring loom engine & lighting

2 Wiring loom screen
90 BOMAG 008 922 51

1 Wiring loom, rear frame

2 Wiring loom screen
008 922 51 BOMAG 91

1 Wiring loom Telematic
92 BOMAG 008 922 51

1 Wiring loom, flashing beacon
008 922 51 BOMAG 93

1 Battery cable (-) disconnecting switch
94 BOMAG 008 922 51

1 Wiring loom double travel lever
008 922 51 BOMAG 95

96 BOMAG 008 922 51

6 Engine
008 922 51 BOMAG 97

Fuel pump
Fuel filter
Tank
Fuel pre-cleaner
98 BOMAG 008 922 51

Kubota diesel engine 6.1
6.1 Kubota diesel engine 9 Water drain tap
10 Cover of the oil filler opening
The tandem vibratory rollers of series BW 135-5 to
138-5 are powered by a water cooled Kubota diesel 11 Exhaust manifold
engine type D902-E3. 12 Alternator
13 Starter
14 Oil dipstick
15 Oil pressure switch
16 Flywheel
17 Oil drain plug
18 Oil sump
19 Engine hook
Fig. 1
Fig. 3
Fig. 2
1 Intake manifold
Fig. 4
2 Speed control lever
The cylinder sequence is No. 1, No. 2, No. 3 and No.
3 Engine stop 4, starting from the timing gear side.
4 Injection pump
5 Fuel pump
6 Fan
7 V-belt pulley
8 Oil filter element
008 922 51 BOMAG 99

6.1 Kubota diesel engine
Engine block Piston
Semi-floating valve cover
Fig. 6
Fig. 5 The piston is coated with molybdenum sulphide. This
1 Valve cover allows you to reduce the tolerance between piston
2 Rubber seal and cylinder, which has the effect of reducing the en-
gine noise.
A installed rubber seal ensures a distance of approx.
0.5 mm (0.02 inch) between valve cover and cylinder The molybdenum sulphide has a similar solid lubricant
head. This reduces the development of noise on the effect as graphite or Teflon. This material prevents
cylinder head. wear, even if only little lubrication oil is available.
100 BOMAG 008 922 51

Kubota diesel engine 6.1
Cooling system Fuel system
Cooling system with lower by-pass flow Governor
The 03-M-series is equipped with a system with lower
by-pass flow to improve the cooling power.
Fig. 7 By-pass line closed

If the coolant temperature in the engine is low, the
thermostat (1) remains closed. THis way coolant can
flow through the by-pass line and thus around the en- Fig. 9
gine. The governor automatically controls the fuel quantity
fed to the engine by means of load changes. This en-
sures a constant engine speed. This engine is
equipped with a governor for all engine speeds, which
controls the centrifugal force of the steel ball weight
(1). The centrifugal force, which compensates the ten-
sion of the governor springs 1 (7) and 2 (8) is generat-
ed by the rotation of the fuel control shaft (5).
1 Steel ball
2 Governor sleeve
3 Steel ball
4 Governor ball housing
5 Fuel control shaft
6 Governor lever
Fig. 8 By-pass line open 7 Governor spring 1
If the temperature exceeds the limiting value for open- 8 Governor spring 2
ing the thermostat valve, the thermostat (1) is opened 9 Fork lever 2
completely. Hot coolant no longer flows through the 10 Fork lever 1
by-pass line into the engine, but flows completely
11 Fork lever axle
through the radiator. For the radiator it is therefore
much easier to reduce the coolant temperature. 12 Fork lever bracket
008 922 51 BOMAG 101

6.1 Kubota diesel engine
Smoke reduction system When starting the engine in this condition, more fuel
This smoke reduction system has the function of re- than actually needed to start at normal operating tem-
ducing the development of smoke during starting at peratures is injected, which causes the generation of
normal operating temperatures as well as during sud- smoke.
den acceleration. Since this adaptation is made be- When starting the engine at normal operating temper-
fore the setting of the fuel limitation, the adaptation ature the thermostat of the smoke reduction system is
can in practice only be made on an engine test bench. activated and excessive fuel injection is subsequently
prevented.
In case of sudden acceleration at normal operating
temperatures the lever works as a damper and the
rack of the fuel injection pump moves slightly towards
the the direction of increased fuel injection quantity.
This reduces the development of smoke during accel-
eration.
At low operating temperature
Fig. 10
1 Injection pump assembly
2 Idle speed limiter
3 Shut-down solenoid guide
4 Plunger piston
5 Smoke reduction system
6 Shut-down solenoid
The smoke reduction system is attached to the gear-
box housing, instead of the manual shut-down lever.
When disassembling the fuel injection pump in partic-
ular, the procedure described in the workshop manual
must be strictly followed.
At normal operating temperature

Fig. 12
Starting at low temperatures is ensured, because the
smoke reduction system is deactivated when starting
in a cold environment, and the starter spring pushes
the rack of the fuel injection pump into the position of
maximum injected fuel quantity.
Fig. 11
When starting the engine, the starter spring pushes
the rack of the fuel injection pump into a position in
which the injection quantity
is at maximum level.
102 BOMAG 008 922 51

Check the engine oil level 6.2
Pressure oil lubrication 6.2 Check the engine oil level
The Kubota engines are equipped with pressurized
circulation lubrication Oil pressure and oil flow quanti-
! Caution
ty secure engine lubrication and, to a considerable ex-
tend, also the cooling of the engine. The machine must be in horizontal position. When
the engine is warm, shut it down and check the oil
level after five minutes. With a cold engine the oil
level can be checked immediately.
For quality of oil refer to the "table of fuels and lu-
bricants".
Fig. 2
l
Pull the dipstick (Fig. 2) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
l
Pull the dipstick back out.
The oil level must always be between the "MIN"- and
"MAX"-marks.
l
If the oil level is too low top up oil immediately.
Fig. 1 Lubrication oil schematic l
If the oil level is too high, determine the cause and
1 Rocker arm drain the oil off.
2 Valves
3 Governor shaft
4 Intermediate gear
5 Crankshaft
6 Oil pump
7 Suction screen
8 Oil sump
9 Oil filter
10 Conrod
11 Piston
12 Camshaft
13 Plunger
14 Push rod
15 Rocker arm shaft
16 Oil pressure switch
008 922 51 BOMAG 103

6.3 Change engine oil and oil filter cartridge
6.3 Change engine oil and oil filter

cartridge
Danger
!
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil filter.
Caution
!
The oil change at 250 operating hours refers to the

OIL 650131
use of fuels with a sulphur content of less than Fig. 4

0.5%. When using fuels with a sulphur content of l Unscrew the drain plug (Fig. 4) and catch running
more than 0.5% the oil change intervals must be
out oil.
halved.
l Turn the oil drain plug back in with a new seal ring.
Drain the engine oil only when the engine is warm.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
Environment
Catch running out oil and dispose of environmen-
tally together with the oil filter cartridge.
650102
Fig. 5
l Unscrew the filter cartridge (Fig. 5) using an appro-
priate filter wrench.
l
Clean the sealing face on the filter carrier from any
dirt.
Fig. 3
l
Unscrew the oil filler plug (Fig. 3).
Fig. 6
l
Slightly oil the rubber seal on the new filter cartridge
(Fig. 6).
l Turn the new filter cartridge on by hand, until the
seal contacts.
l Tighten the filter element for another half turn.
104 BOMAG 008 922 51

Checking the coolant level 6.4
6.4 Checking the coolant level
! Danger
Danger of scalding!
Open the cap on the coolant compensation tank
only when the engine is cold.
! Caution
If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and
engine for leaks.
Fig. 7
For quality of coolant refer to the chapter on "fuels
l Fill in new engine oil (Fig. 7). and lubricants".
l Tighten the oil filler cap properly.
650101
Fig. 9
Fig. 8 l
Check the coolant level in the compensation tank
l
After a short test run check the oil level once again (Fig. 9).
(Fig. 8), if necessary top up to the top mark (MAX). l
To top up unscrew the filler cap and fill in coolant up
to the MAX-mark.
008 922 51 BOMAG 105

6.5 Change the coolant
6.5 Change the coolant
! Danger
Danger of scalding!
Change the coolant only when the engine is cold.
Do not remove the radiator cap when the engine is
still hot.
Always wear gloves when handling anti-freeze
agent.
650106
Caution
! Fig. 11
Always screw the radiator cap tightly back on l
Unscrew the coolant drain plug (Fig. 11).
(second detent).
l
Drain the coolant completely off and collect it.
Always fill the engine cooling system with an anti-
freeze mixture (corrosion protection).
l Close the drain plug again.
Do not use more than 50% anti-freeze.

l
Check the condition of radiator hoses, if necessary
replace all radiator hoses.
Do not mix different coolants and additives of any
other kind. If necessary flush the cooling system l
Fill in coolant until the level reaches the bottom
2-3 times with clear water. edge of the filler socket.
For quality and quantity of coolant refer to the "ta-
ble of fuels and lubricants".
Environment
Catch running out coolant and dispose of environ-
mentally.
650107
Fig. 12
l Fill in coolant up to the MAX mark (Fig. 12).
l
Reattach the radiator cap and the cap of the com-
pensation tank.
l Start the diesel engine and run it warm to operating
temperature.
Fig. 10 l Let the engine cool down and check the coolant lev-
l Remove the radiator cap (Fig. 10). el again, if necessary top up in the compensation
tank.
106 BOMAG 008 922 51

Check the anti-freeze concentration and the condition of the 6.6
6.6 Check the anti-freeze concen- 6.7 Checking radiator hoses and
tration and the condition of the hose clamps
coolant
Danger
!
Danger
! Danger of burning!
Danger of scalding! Perform inspection work only after the engine has
cooled down and with the engine stopped.
Check the anti-freeze concentration only when the
engine is cold.
! Caution
!Caution If a radiator hose is swollen, hardened or cracked,
both hose and hose clamp must be replaced im-
In order to avoid damage to the engine (e.g. by
corrosion, cavitation and freezing), particular at- mediately.
tention must be paid to the inspection of the cool-
ant.
For coolant quality refer to the "table of fuels and
lubricants".
Do not mix different coolants and additives, see
section "Fuels and Lubricants - Coolant".
If the coolant is contaminated by corrosion resi-
dues or other suspended matter, flush the cooling
system, see section "Changing the coolant".
Environment
650132
Catch coolant and dispose of environmentally.
Fig. 14
l
Check the condition and tight fit of all radiator hoses
and hose clamps (Fig. 14).
650108
Fig. 13
l
Remove the cap (Fig. 13) from the coolant compen-
sation tank and check the anti-freeze concentration
with a conventional tester.
l Check the condition of the coolant.
l Screw the cap back on.
008 922 51 BOMAG 107

6.8 Cleaning radiator and hydraulic oil cooler
6.8 Cleaning radiator and hydrau- Cleaning with cold cleansing agent
lic oil cooler
Caution
!
Protect electrical equipment such as generator,

Danger
!
regulator and starter against the direct water jet.
Danger of injury!
l Spray engine and cooler with a suitable cleansing
Perform cleaning work only after the engine has agent (e.g. cold cleanser), let it soak in for a while
cooled down and with the engine stopped. and spray it off with a strong water jet.
l Reassemble the fan grille.
Caution
!
l Run the engine warm for a while to avoid corrosion.
Do not damage any cooling fins on the cooler core
when cleaning.
Dirt on fan blades and radiator reduce the cooling
effect. Dirt deposits in these areas are substantial-
ly supported by oil and fuel on these surfaces. For
this reason you should always seal any oil or fuel
leaks in the vicinity of the cooling fan or the radi-
ator and clean the cooling surfaces after.
Fig. 15
l
Open the engine hood.
l
Remove the fan grille (Fig. 15).
l
Blow the radiator out with compressed air.
650133
Fig. 16
l Blow the cooler (Fig. 16) out with compressed air.
108 BOMAG 008 922 51

Checking the V-belt, tightening, if necessary replacing the V- 6.9
6.9 Checking the V-belt, tighten- 6.10 Check, clean the air filter, re-
ing, if necessary replacing the place if necessary
V-belt
! Caution
Danger
! Do not start the engine after having removed the
air filter.
Danger of accident!
If necessary, the air filter may be cleaned up to six
Perform this work only with the engine shut down.
times. After one year at the latest it must be re-
placed together with the safety element.
Checking the V-belt
Cleaning does not make sense if the air filter ele-
ment is covered with a sooty deposit.
Do not use gasoline or hot fluids to clean the filter
element.
After cleaning the air filter must be inspected for
damage using a torch.
Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.
If the air filter is damaged, the safety element must
be replaced as well.
The safety element must not be cleaned.
Fig. 17 i Note
We generally recommend to renew the air filter. A new
l
Inspect the entire circumference of the V-belt (1)
filter element is far less expensive than a possible en-
(Fig. 17) visually for damage and cracks.
gine damage.
l
Replace a damaged or cracked V-belt immediately. l Open the engine hood.
l
Check with thumb pressure whether the V-belt can
be depressed more than 7 to 9 mm (0.28 – 0.35
inch) between the V-belt pulleys (A), retighten if i Note
necessary. Under very dusty conditions you may have to check
the filter service indicator every day.
Tightening the V-belt
l
Slightly slacken the fastening screws (2) (Fig. 17).
l
Press the generator in direction outward using a le-
ver, until the correct V-belt tension is reached.
l Retighten all fastening screws and check the V-belt
tension once again.
Replacing the V-belt

l
Slightly slacken the fastening screws (2) (Fig. 17).
l
Press the generator completely against the engine.
l
Remove the old V-belt.
Fig. 18
l
Fit the new V-belt to the V-belt pulleys.
Service of the dry air filter is due when the red piston
l
Tension the V-belt as previously described. of the filter service indicator (Fig. 18) reaches into the
transparent window.
!Caution
After cleaning the air filter press the reset button
for the red piston on the filter service indicator.
008 922 51 BOMAG 109

6.10 Check, clean the air filter, replace if necessary
Fig. 19 Fig. 22
l Loosen both locking hooks (Fig. 19) on the housing l Examine the air filter with a torch for cracks and
cover and take the cover off. holes in the paper bellows (Fig. 22).
l In case of damage replace the air filter and the safe-
ty element.
Fig. 20
l Pull out the main filter element (Fig. 20) with light
turning movements. Fig. 23
l Clean housing cover and dust discharge valve. l Slide the air filter carefully into the housing (Fig. 23).
Danger
! Caution
!
Danger of injury! The dust discharge valve must point vertically

downwards.
Wear protective clothing (goggles, gloves).
Make sure that the cover locks engage correctly.
l Reassemble the housing cover.
Replacing the safety filter element
Caution
!
The safety element must not be cleaned and

should not be used again after it has been re-
moved.
The safety element must be replaced:

l if the air filter is damaged or has been replaced
Fig. 21
replaced.
l
Blow the air filter (Fig. 21) out with dry compressed
l at the latest after 1 year.
air (max. 2.1 bar (30 psi)) from inside to outside by l if the red piston of the filter service indicator is
moving the gun up and down inside the element, visible again after the air filter has been cleaned.
until it if free of dust.
110 BOMAG 008 922 51

Check the air intake lines 6.11
6.11 Check the air intake lines
! Danger
Danger of burning!
Perform inspection work only after the engine has
! Caution
Take care that no contaminants enter into the air
intake system, since this could damage the en-
gine!
Fig. 24
If an air intake hose is damaged, both hose and
l Remove the housing cover and pull the air filter off. hose clamp must be replaced immediately.
l Pull the safety element (Fig. 24) out by turning it l
Check the condition and tight fit of all air intake lines
lightly. and hose clamps.
l Push in a new safety filter element.
l Insert the air filter and reassemble the housing cov-
er.
008 922 51 BOMAG 111

6.12 Check, clean the water separator
6.12 Check, clean the water separa- 6.13 Change the fuel filter
tor
! Danger
Danger
! Fire hazard!
Fire hazard! When working on the fuel system do not use open
fire, do not smoke.
When working on the fuel system do not use open
fire, do not smoke. Do not spill any fuel.
Do not spill any fuel.
Shut down the engine. ! Danger
Health hazard!
Danger
! Do not inhale any fuel fumes.
Health hazard!
Do not inhale any fuel fumes. Environment
Catch running out fuel, do not let it seep into the
ground.
i Note
The service intervals for the water separator depend Dispose of the used fuel filter environmentally.
on the water content in the fuel and can therefore not
be determined precisely. After taking the engine into Changing the fuel pre-cleaner
operation you should therefore check the water sepa-
rator every day for signs of water.
Environment
Any fuel must be caught and disposed of in an en-
vironmentally friendly manner.
650103
Fig. 26
l Unscrew the hose clamps (Fig. 26) on the fuel pre-
cleaner.
l Pull the fuel filter out of the hoses.
l
Install the new fuel pre-filter and observe the flow di-
rection (arrow).
Fig. 25
l Slacken the drain plug (Fig. 25) for a few turns and
l Fasten the hose clamps.
catch running out fuel / water.
l Tighten the drain plug again and check for leaks, if
necessary replace the seal ring.
112 BOMAG 008 922 51

Check fuel lines and clamps 6.14
Change the fuel filter cartridge 6.14 Check fuel lines and clamps
! Danger
Danger of burning!
Perform inspection work only after the engine has
! Caution
If fuel lines or hose clamps are found to be dam-
aged, the corresponding parts must be immedi-
ately repaired or replaced.
Removed or new fuel lines must be closed with
Fig. 27 clean cloths on both ends, to make sure that no
dirt will enter into the fuel system. Dirt particles
l Slacken and unscrew the fuel filter cartridge (Fig. can destroy the injection pump.
27).
l Clean the sealing face on the filter carrier from any
dirt.
l Apply a thin film of fuel to the seals and screw the
new filter cartridge on hand-tight.
Fig. 28
l
Check the condition and tight fit of all fuel lines (1)
(Fig. 28) and hose clamps (2).
008 922 51 BOMAG 113

6.15 Replacing the fuel lines
6.15 Replacing the fuel lines 6.16 Checking the engine mounts
l Check air intake and exhaust manifold fastenings
Danger
! for tight fit.
Fire hazard! l Check sockets and clamps on the air filter for tight
When working on the fuel system do not use open fit and leak tightness.
fire, do not smoke. l Check fastening and tightness of the lubrication oil
Do not spill any fuel. sump.
l Check condition and tight fit of engine mounts.
! Danger
Health hazard!
Do not inhale any fuel fumes.
Caution
!
For safety reasons this work should be performed

every two years.
Hoses consist of rubber or plastic material and
age over the course of time.
Environment
Catch running out fuel, do not let it seep into the
ground.
l Replace all fuel hoses, including their hose clips.
114 BOMAG 008 922 51

Checking the engine oil pressure 6.17
6.17 Checking the engine oil pres- 6.18 Checking the thermostat in
sure 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. 69.5°C to 72.5°C the thermostat is closed. Once
the coolant temperature has reached this tempera-
ture, the thermostat will start to open, at about 85° C it
is fully open. In this condition the full coolant flow is
guided through the radiator.
Fig. 1
l Remove the engine oil pressure switch and install a
measuring adapter.
l
Start the engine. Once operating temperature has
been reached check the oil pressure at idle speed
and at nominal speed.
i Note
Fig. 1
An oil pressure below the permissible limit may have
one of the following causes:
l Measure and write down the measurement "a" on
the thermostat (Fig. 1).
Engine oil level too low
Oil pump defective
i Note
Oil strainer clogged "a" = beginning of stroke at approx. 69.5°C to 72.5°C
Oil filter cartridge clogged (T1)
Excessive oil gap in crankshaft bearings "b" = end of stroke at approx. 85 °C (T2)
Foreign bodies in pressure relief valve
At idle speed: 0.98 bar
At nominal speed: 3 to 4.4 bar
Permissible limiting value at idle speed: 0.5 bar
Permissible limiting value at nominal speed: 2.50

bar
l Retighten the engine oil pressure switch with the
specified torque.
Tightening torque:
15 to 19 Nm 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.
008 922 51 BOMAG 115

6.19 Check the injection valves
The temperature increase should not exceed 1°C/ 6.19 Check the injection valves
min, as otherwise the start of opening will be delayed
accordingly.
! Caution
Ensure strict cleanliness when working on the in-
jection system. Use only clean testing oil acc. to
ISO 4113 or clean diesel fuel to test the injection
valves.
Danger
!
Keep your hands away from the nozzle spray jet.

Fuel will penetrate deeply into the flesh and may
cause blood poisoning.
Nozzle spray pattern
Fig. 3
l Measure and write down the measurement "b" on
the thermostat . (Fig. 3).
l Calculate the stroke.
Stroke = b - a
i Note
Stroke:
BMP8500 and BW80 to BW100-5, at the given tem-
perature (T2) approx. 8 mm.
BW100 to BW138-5, at the given temperature (T2) ap-
prox. 6 mm.
If the measured value is not within the factory specifi-
cation, the thermostat needs to be replaced.
Fig. 1
(a) (Fig. 1) Correct
b) Not correct
l Mount the injection nozzle to a nozzle tester and
check the nozzle spray pattern.
i Note
If the spray pattern is not ok, replace the nozzle ele-
ment.
116 BOMAG 008 922 51

Check the injection valves 6.19
Fuel injection pressure Leak tightness of the nozzle element
Fig. 2 Fig. 4
l Mount the injection valve to the nozzle tester (Fig. l Mount the injection valve to the nozzle tester (Fig.
2). 4).
l
Slowly operate the testing lever to measure the l
Increase the fuel pressure and hold it for 10 sec-
pressure at which fuel starts to emerge from the onds.
nozzle.
Nominal value:
l If this measurement is not compliant with the factory
specifications replace the adjusting shim (1) in the BW80 to BW100-5: 130 bar
nozzle holder in order to adjust the nozzle pressure.
BW100 to BW138-5: 127 bar
Nominal value:
BW80 to BW100-5: 140.0 to 150.0 bar i Note

If a fuel leakage is detected, replace the nozzle ele-
BW100 to BW138-5: 137.3 to 147.0 bar ment.
Fig. 3
i Note
0.025 mm (0.00098 inch) difference in the adjusting
shim thickness 1 (Fig. 3) results in a opening pressure
difference of approx. 6.0 bar.
008 922 51 BOMAG 117

6.20 Checking the start of commencement
Nozzle holder 6.20 Checking the start of com-

mencement
Fig. 1
Fig. 5 l
Remove injection lines and glow plugs.
1 Nozzle holder upper part l
Remove the engine shut-down solenoid.
2 Adjusting shim
l Set the throttle lever to maximum fuel delivery.
3 Compression spring
4 Pressure bolt
5 Spacer block i Note
Turn the flywheel with a screwdriver.
6 Nozzle element
7 Nozzle holder lower part
l
Clamp the lower part of the nozzle holder (7) (Fig.
5) in a vice.
l
Unscrew the nozzle holder (1) and take out the in-
ternal parts.
Tightening torques:
Nozzle holder (upper/lower part): 35 to 39 Nm
Leak oil line retaining nut: 20 to 24 Nm
Nozzle holder assembly: 49 to 68 Nm

Fig. 2
l
Turn the flywheel (see illustration) counter-clock-
wise, until fuel reaches the opening of the pressure
retaining valve for cylinder 1.
l In order to determine the current start of com-
mencement, turn the flywheel further and stop turn-
ing when fuel starts to flow over.
l
Calculate the angle that is shown in the middle of
the window (2). (The flywheel has a 1TC-mark and
four lines, which represent 0.09 rad (5 °) each of the
crankshaft angle from 0.17 rad (10 °) to 0.44 rad (25
°) up to the 1TC-mark.)
l
If the result deviates from the specified start of com-
mencement, the adjustment must be made by re-
moving or adding shims.
118 BOMAG 008 922 51

Checking the start of commencement 6.20
3 Bores: 0.20 mm (0.0079 inch) compensation
shim
4 1 bore: 0.25 mm (0.0098 inch) compensation shim
5 Without bore: 0.30 mm (0.012 inch) compensation
shim
6 2 bores: 0.175 mm (0.00689 inch) compensation
shim
Injection timing:
ask your service
i Note
The sealant is applied to both sides of the compensa-
tion shims. No sealing compound must be used for as-
sembly.No sealing compound is to be used for
Fig. 3
assembly:
Compensation shims are available in the thicknesses
0.175 mm (0.00689 inch) (6), 0.20 mm (0.0079 inch)
(3), 0.25 mm (0.0098 inch) (4) and 0.30 mm (0.012
inch) (5). For the adjustment use a combination of
these shims.
The 0.175 mm (0.00689 inch) compensation shim has
only a thin layer on the bottom side. The 0.175 mm
(0.00689 inch) compensation shim should therefore
not be used as top compensation shim in this combi-
nation (injection pump side). This may otherwise re-
sult in oil leaks.
Enlarging or reducing the compensation shim thick-
ness by 0.05 mm (0.002 inch) adjusts the injection
timing by approx. 0.009 rad (0.5°).
During assembly and replacement make sure that
shims of identical thickness are used.
Fig. 4
Fig. 5
(A) 3 cylinder
(B) 4 cylinder
1 Pressure retaining valve
2 Ignition timing mark
008 922 51 BOMAG 119

6.21 Checking the fuel injection pump
6.21 Checking the fuel injection Fuel leak on the pressure valve
pump
1 Injection pump pressure tester
2 Injection nozzle
3 Protective covering for running out fuel
Fuel leak tightness of the pump element
Fig. 2
l Remove the engine shut-down solenoid.
l Remove injection lines and glow plugs.
l Install the injection pump pressure tester to the in-
jection pump.
l
Install an injection nozzle (2) (Fig. 2) set according
Fig. 1 to factory specifications to the second port of the in-
l
Remove the engine shut-down solenoid. jection pump pressure tester (1).
l
Remove injection lines and glow plugs.
l
Operate the starter to increase the pressure.
l
Mount the injection pump pressure tester to the in-
l
Switch off the starter when fuel emerges from the
jection pump. injection nozzle. Subsequently turn the flywheel by
hand and increase the pressure to approx. 137.3
l
Install an injection nozzle (2) (Fig. 1) set according bar.
to factory specifications to the second port of the in-
jection pump pressure tester (1).
l
Turn the flywheel back by approx. half a turn and
hold it in this position.
l
Set the throttle control lever to max. speed.
l
Measure the time by which the pressure has
l
Operate the starter to crank the engine. dropped from 137.3 to 127.5 bar.
i Note
i Note
If the pump does not reach the permissible limiting If the measured pressure is below the permissible lim-
value replace the pump or have it repaired in a work- iting value replace the pump or have it repaired in a
shop approved by BOMAG. workshop approved by BOMAG.
Nominal value: 137.3 bar Factory specification: 137.3 to 127.5 bar, 10 sec-
onds.
Caution
!
Permissible limit: 137.3 to 127.5 bar, 5 seconds.
Never dismantle the injection pump yourself.
Have repairs solely carried out in workshops ap-
proved by BOMAG.
120 BOMAG 008 922 51

Checking the compression 6.22
6.22 Checking the compression 6.23 Checking and adjusting the
l Run the engine warm and shut it down. valve clearance
l Actuate the emergency stop switch.
!Caution
We recommend to have this work carried out by
trained personnel or our after sales service.
Check and adjust only when the engine is cold.
Cylinder 1 is on the flywheel side.
Adjustment value for intake and exhaust valves: 
0.18 - 0.22 mm (0.007 - 0.009 in)
Fig. 3
l Pull the 2-pin plug-in connector off the shut-down
solenoid to interrupt the fuel supply.
l Disassemble air filter, exhaust muffler and all injec-
tion nozzles.
l
Install a compression tester with nozzle adapter in-
stead of the injection nozzle.
l
Make sure that the shut-down lever is in stop posi- Fig. 4
tion (no injection). l Remove the valve cover (Fig. 4).
l Crank the engine with the starter motor to measure
the compression pressure.
Adjustment Cylinder Intake Exhaust
schematic
i Note 1 x x
Perform this work step on every cylinder. Cylinder 1 in 2 x
l If the measured value is below the permissible lim- TDC 3 x
iting value, apply some oil through the nozzle bore 4
to the cylinder wall. Then measure the compression 1
pressure once again.
Cylinder 1 2 x
l If the compression pressure is below the permissi- overlapping 3 x
ble limiting value, check the top end clearance, the 4 x x
valves and the cylinder head.
l If the compression pressure increases after oil has
been injected, check cylinder wall and piston rings.
i Note
Check the compression with properly adjusted valve
clearance.
Always use a fully charged battery to check the com-
pression.
The deviation between the individual cylinders should
not exceed 10%.
Factory data: 32.4 to 37.2 bar

Fig. 5
Permissible limit: 25.5 bar
l
Set cylinder 1 to TDC (Fig. 5) and check the valve
clearance as per adjustment schematic.
008 922 51 BOMAG 121

6.23 Checking and adjusting the valve clearance
Fig. 6
l A feeler gauge of appropriate thickness (Fig. 6)
must fit with little resistance between rocker arm
and valve.
l If the gap is too narrow or too wide for the feeler
gauge, the valve must be adjusted.
l Turn the crankshaft one revolution (360 °) further.
l Adjust the valve clearance as specified in the ad-
justment diagram.
l Install the cylinder head cover with a new gasket.
i Note
After a short test run check the engine for leaks.
122 BOMAG 008 922 51

Engine problems 6.24
6.24 Engine problems
Fault Possible cause Remedy
No or poor start- Fuel tank empty Fill fuel tank

ing of engine
Fuel filter clogged, in win- Change the fuel filter, use
ter due to paraffin separa- winter fuel
tion
Fuel lines leaking Check all line connections

for leaks and tighten the
fittings, bleed the fuel sys-
tem
Water in the fuel system Cleaning the water sepa-

rator.
Travel lever not in parking Return the travel lever to

brake position parking brake position.
Battery discharged or not Charge the battery, clean

connected, battery power the terminal clamps, tight-
too low en and cover them with
acid-free grease, have
battery tested
Emergency stop push but- Unlock the emergency

ton is locked stop switch
Especially in winter: use of Use the correct engine oil

too viscous engine oil for the ambient tempera-
tures
Engine runs ir- Fuel supply too low, fuel Change the fuel filter,
regularly with system clogged by paraf- check line connections for
poor power fin separation (winter op- leaks and tighten fittings,
eration) us winter fuel under cold
conditions.
Injection valve or injection Have examined by a spe-

pump defective cialist
Air filter dirty Clean the air filter, replace

if necessary.
Excessive play in throttle Adjust the throttle cable,

cable replace if necessary
Engine looses Engine oil level too high Drain the oil down to the
power and top dipstick mark
speed, exces-
sive exhaust Poor quality fuel Use specified fuel
smoke Air filter dirty Clean the air filter, replace
if necessary.
Injection nozzle defective Have examined by a spe-

cialist
008 922 51 BOMAG 123

6.24 Engine problems
Engine over- Radiator heavily soiled Clean the cooling fins

heating, engine
must be shut Coolant level too low Fill up coolant, check for
down immedi- leaks
ately! Injection nozzle defective Have examined by a spe-
cialist
Engine oil level too low Fill up oil down to the top
dipstick mark
V-belt loose or broken Tension or replace the V-

belt
Radiator internally corrod- Replace the radiator, flush

ed the cooling system
Thermostat defective Check the thermostat, re-

place if necessary.
124 BOMAG 008 922 51

7 Hydraulics
008 922 51 BOMAG 125

7.1 Hydraulic circuit
7.1 Hydraulic circuit
Open circuit
Fig. 1 Open circuit

Open in this case means that the suction line of a pump) (Fig. 1) normally is situated below the fluid level, the
surface of which is in open contact with atmospheric pressure. Reliable equalization of pressure between the air
in the hydraulic oil tank and the ambient air ensures problem free suction of the pump.
In an open circuit the hydraulic fluid is fed to the consumer (2 or 3) and also returned to the tank through way
valves.
126 BOMAG 008 922 51

Hydraulic circuit 7.1
Closed circuit
Filter
Cooler (option)
Fig. 2 Closed circuit

One talks about a closed hydraulic system, when the hydraulic oil flows from the consumer (3) (Fig. 2) directly
back to the pump (2).
The closed circuit consists of a high and a low pressure side, depending on the load direction (take-off moment
on the consumer).
The high pressure side is protected by pressure relief valves (4), which release oil into the low pressure side.
The medium remains in the circuit.
Only the permanent leakage on pump and motor needs to be replenished. This is accomplished by a charge
pump (1), which permanently delivers a sufficient amount of fluid (charge capacity) through a check valve (5)
into the low pressure side of the closed circuit. Any excess oil delivered by the charge pump, which works in an
open circuit, runs through a charge pressure relief valve (6) back into the tank. Charging the low pressure side
enables the pump (2) to work with higher operating data.
008 922 51 BOMAG 127

7.2 Travel pump, A10VG45 HW
Variable displacement pump, A10VG45 HW

HW, proportional control, hydraulic, path dependent

The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow.
It has been designed for mobile applications, e.g. in construction equipment.
Caution
!
The variable displacement axial piston pump must be filled with pressure fluid and purged during start-
up and operation. This must also be considered for longer periods of rest, because the system may run
empty through the hydraulic lines.
The 10VG is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed
circuits. The volumetric flow is proportional to the drive speed and the displacement. The volumetric flow can be
infinitely changed by adjusting the swash plate accordingly.
Fig. 3 A10VG
1 Drive shaft 8 Valve plate

2 Retracting plate 9 Suction port
3 Control piston 10 Low pressure side
4 Control unit 11 Cylinder
5 Pressure override valve 12 Piston
6 High pressure side 13 Slipper pad
7 Auxiliary pump (optional) 14 Swashing cradle
128 BOMAG 008 922 51

Travel pump, A10VG45 HW 7.2
Hydraulic diagram
Control unit
High pressure limitation
Charge pressure relief valve
Pressure override valve
High pressure limitation
Fig. 4 Hydraulic diagram, A4VG HW
O Work connection PS Control pressure inlet

B Work connection R Ventilation
G Pressure port for charge circuit T1 Leak oil
MA Pressure test port, pressure A T2 Leak oil
MB Pressure test port, pressure B X 1 X2 Port for control pressures, pressure in front of
nozzle
MH Port for balanced high pressure
008 922 51 BOMAG 129

Connection overview
Fig. 5
High pressure relief and charge pressure valve
HP-valve with bypass
HP-valve with bypass

Fig. 6 Valve plate
High pressure relief valves with integrated boost check valves and bypass (only travel pump / for tow-
ing)
Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safe-
guarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and re-
lieve oil into the low pressure side. The fluid quantity always remains constant in the closed hydraulic circuit.
Leakages in pump and motor are compensated by the charge pump.
HP-valves are always adjusted 10% higher than the pressure override.
The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure
side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit, in order to com-
pensate leaks and flushing quantities.
130 BOMAG 008 922 51

Bypass control
In this case the travel system is switched to free circulation. For this purpose the high pressure relief valves in-
tegrated in the variable displacement pump have a so-called bypass function. This means that by turning the
screw (1) (Fig. 7) the valve insert is relieved to such an extent, that the oil is able to circulate freely.
Fig. 7 Bypass control

l Shut down the engine.
l
Loosen the counter nuts by turning them with a hexagon spanner (SW 134) half a turn in anti-clockwise direc-
tion.
l Use an Allen key (SW 4) to turn the screws clockwise, until the screw touches the spring cup, which can be
noticed by the increasing resistance.
l Turn the screw half a turn into the spring cup.
Towing finished
After towing back the screw out again. This resets the high pressure valves to their original setting.
i Note
Tightening torque for counter nut 22 Nm.

The charge pressure valve belongs to the group of safety elements in a closed hydraulic circuit. This valve limits
the pressure in the charge circuit to the pre-adjusted value.

The pressure override limits the operating pressure. The pressure override is a kind of pressure regulation,
which, when the adjusted nominal pressure is reached, reduces the displacement of the pump to such an extent,
that the adjusted pressure is just maintained.
HW - Hydraulic control, path dependent

Depending on the actuating direction of the control lever, the control cylinder on the pump is supplied with control
pressure through the HW control unit. With this the swash plate and thus the displacement can be infinitely ad-
justed. Each actuating direction of the control lever corresponds with a flow direction.
The inclination angle of the swash plate is adjusted e.g. mechanically via a rotary journal or hydraulically via con-
trol pistons. The swash plate/swashing cradle rests light moving in friction or plain bearings and is spring centred
in neutral position. Enlarging the swashing angle increases the displacement and the torque, reducing the angle
reduces the values accordingly. If the swashing angle is 0, the pump displacement is also zero.
008 922 51 BOMAG 131

Fig. 8 Control
1 manually controlled 4/3-way valve 3 Feedback lever

2 Control piston Pilot oil portioning valve (not visible in illustra-
tion)
When actuating the travel lever the 4/3-way valve moves out of neutral position to the desired direction and
guides the pilot oil flow through the pilot oil portioning valve to the corresponding control piston side. The control
piston moves to the corresponding direction and operates the swash plate via the swashing lever accordingly.
The feedback lever, which is mounted with its ball head in the pump control shaft, follows the control piston and
interrupts the pilot oil flow when the control piston has reached a position corresponding with the displacement
of the travel lever. The pump is now able to deliver oil.
The oil from the opposite control chamber flows through the 4/3-way valve as leak oil into the pump housing.
The supply bores to both control chamber sides are fitted with nozzles (swashing time nozzles). These nozzles
restrict the pilot oil flow and enable a very sensitive control of the pump.
Fig. 9
Swashing angle  on control lever for swashing operation:
Control start at  = 3°
Control end at  = 29° (max. displacement Vg max)
Required torque on control lever max. 170 Ncm.
132 BOMAG 008 922 51

Spring zero centring
The spring centring facility automatically returns the pump to zero position (Vg = 0) when no torque is applied to
the control lever of the HW control unit (irrespective of the actuation).
! Caution
The spring reset is not a safety feature.
Internal contamination – like e.g. contaminated hydraulic fluid, abrasion or dirt residues from system
components – can cause blockagein an undefined position.
Swash plate principle, pump
Fig. 10
The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive
shaft. The pistons are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic
pumps or hydraulic motors. In pump mode the mechanical energy is converted to hydrostatic energy, when used
in motor mode the hydrostatic energy is converted to mechanical energy. When used as a pump, the flow volume
is proportional to the drive speed and the swashing angle. The available (pump) torque increases with the pres-
sure drop between high and low pressure side.
Variable displacement pumps and motors can be change their displacement, i.e. the pump delivery rate or motor
throughput, by simply changing the angle of the swash plate.
008 922 51 BOMAG 133

Description of function
Fig. 11
1 Drive shaft 8 Through drive

2 Piston 9 Valve plate
3 Piston area 10 Top dead centre TDC
4 Piston stroke 11 Bottom dead centre BTC
5 Slipping disc 12 Control slots in suction side of swash plate (for
sense of rotation shown)
6 Adjusting angle 13 Control slot on pressure side
7 Cylinder
Driven by the engine, the drive shaft rotates and drives the cylinder via a splined connection. The cylinder rotates
with the drive shaft and drives the 9 pistons. The pistons rest with their slipper pads on the sliding face of the
swashing cradle and perform an axial movement. The slipper pads are held on the sliding face and are positively
guided by a retaining device. During a complete rotation of the cylinder block each piston moves through the
bottom and top dead centre back to its initial position. From dead centre to dead centre is performs a full piston
stroke. During this process the flow volume determined by the stroke is drawn in through the control slots in the
valve plate or pumped out. During the suction stroke the hydraulic fluid is drawn into the increasing piston cham-
ber, i.e. it is actually pressed in. On the opposite side the oil is pressed out of the piston bores into the hydraulic
system during the compression stroke.
134 BOMAG 008 922 51

Drum drive motor MK05 7.3
Operating principle of radial piston motor, MK
7.3 Drum drive motor MK05
Fig. 12 Cross-sectional drawing
1 Output flange with drive shaft 6 Multi-disc brake

2 Working piston with contact roller 7 Cylinder block
3 Distributor 8 Cam race
4 Hydraulic connection on distributor 9 Taper roller bearing
5 Brake piston
008 922 51 BOMAG 135

7.3 Drum drive motor MK05
Fig. 13 Cross-sectional view of working piston positions
1 Piston position: Beginning of descending flank 6 Distributor

2 Piston position: Middle of descending flank 7 Descending flanks of cam race
3 Piston position: Top dead centre 8 Cylinder chambers
4 Piston position: Middle of ascending flank 9 Ascending flanks of cam race
5 Piston position: End of ascending flank
The high pressure hydraulic oil, which is controlled by the distributor (6) (Fig. 13) (axial bores and ring channels),
flows into the cylinder rooms (8) (radial arrangement) of the working pistons (2), which are positioned on the
descending flanks (7) of the cam race.
The working pistons "pressing against and rolling along" the cams convert the linear movement of the working
pistons into a radial movement of the drive shaft with output flange (1).
Piston position (1):

The hydraulic oil is delivered to the distributor under Pressure. The distributor guides the hydraulic oil through
ring channels and bores to the cylinders on the descending flanks of the cam race so that the oil presses against
the working pistons.
Due to the pressure on the back of the piston the roller will move along the cam, thereby causing a rotary move-
ment of the cylinder block.

At this point of the piston stroke the opening cross-sections of bores and ring channels in the distributor to the
working piston have their biggest size. As the cylinder block continues to rotate, the opening cross-sections be-
come smaller towards the valley between the cams.

At the deepest point of the cam race (dead centre) the hydraulic oil flow through the distributor to the working
piston is interrupted, the bores and ring channels block one another.
Other working pistons are driven by the hydraulic oil flowing through the distributor (see piston positions 1 to 3),
so that the working piston is moved out of this top dead centre position.

The distributor now connects the cylinder with the low pressure side. The working pistons moving along the as-
cending flank of the cam race (9) away from the bottom dead centre pump the hydraulic oil through the bores
and ring channels in the distributor back to the travel pump.
136 BOMAG 008 922 51

Drum drive motor MK05 7.3
At this point of the piston stroke the opening cross-sections of bores and ring channels in the distributor for the
hydraulic oil flow have their biggest size.

As the cylinder block continues to rotate, the opening cross-sections become smaller towards the peak of the
cam. At the highest point of the cam race (dead centre) the hydraulic oil flow through the distributor back to the
travel pump is interrupted and a new working cycle is started (see piston positions 1 to 5).
008 922 51 BOMAG 137

7.4 Wheel motor MSE02
Functional principle radial piston motors, MS/MSE

Fig. 14 Cross-sectional drawing
1 Output flange with drive shaft 6 Multi-disc brake

2 Working piston with contact roller 7 Cylinder block
3 Distributor 8 Cam race
4 Hydraulic connection on multi-disc brake 9 Bearing plate
5 Brake piston 10 Taper roller bearing
138 BOMAG 008 922 51

Wheel motor MSE02 7.4
Fig. 15 Cross-sectional view of working piston positions
1 Piston position: Beginning of descending flank 6 Distributor

2 Piston position: Middle of descending flank 7 Descending flanks of cam race
3 Piston position: Top dead centre 8 Cylinder chambers
4 Piston position: Middle of ascending flank 9 Ascending flanks of cam race
5 Piston position: End of ascending flank
The high pressure hydraulic oil, which is controlled by the distributor (6) (Fig. 13) (axial bores and ring channels),
flows into the cylinder rooms (8) (radial arrangement) of the working pistons (2), which are positioned on the
descending flanks (7) of the cam race.
The working pistons "pressing against and rolling along" the cams convert the linear movement of the working
pistons into a radial movement of the drive shaft with output flange (1).

The hydraulic oil is delivered to the distributor under Pressure. The distributor guides the hydraulic oil through
ring channels and bores to the cylinders on the descending flanks of the cam race so that the oil presses against
the working pistons.
Due to the pressure on the back of the piston the roller will move along the cam, thereby causing a rotary move-
ment of the cylinder block.

At this point of the piston stroke the opening cross-sections of bores and ring channels in the distributor to the
working piston have their biggest size. As the cylinder block continues to rotate, the opening cross-sections be-
come smaller towards the valley between the cams.

At the deepest point of the cam race (dead centre) the hydraulic oil flow through the distributor to the working
piston is interrupted, the bores and ring channels block one another.
Other working pistons are driven by the hydraulic oil flowing through the distributor (see piston positions 1 to 3),
so that the working piston is moved out of this top dead centre position.

The distributor now connects the cylinder with the low pressure side. The working pistons moving along the as-
cending flank of the cam race (9) away from the bottom dead centre pump the hydraulic oil through the bores
and ring channels in the distributor back to the travel pump.
008 922 51 BOMAG 139

At this point of the piston stroke the opening cross-sections of bores and ring channels in the distributor for the
hydraulic oil flow have their biggest size.

As the cylinder block continues to rotate, the opening cross-sections become smaller towards the peak of the
cam. At the highest point of the cam race (dead centre) the hydraulic oil flow through the distributor back to the
travel pump is interrupted and a new working cycle is started (see piston positions 1 to 5).
140 BOMAG 008 922 51

External gear motors 7.5
Outer gear motors non-reversible
7.5 External gear motors
Fig. 16 Gear motor

In their design gear motors are quite similar to gear pumps. The only difference is the slightly different axial pres-
sure field. The pressure fluid flowing into the gear motor works on the gears. It generates a torque, which is then
transferred by the output shaft.
External gear motors for one sense of rotation are of asymmetrical design, i.e. high and low pressure sides are
predetermined. Reversing operation is not possible. The arising leak oil is internally fed to the outlet. The pres-
sure load in the outlet is limited because of the radial seal.
008 922 51 BOMAG 141

7.6 External gear pumps
External gear pumps

7.6 External gear pumps
External gear pumps mainly consist of the friction bearing mounted gear pair and the housing with front and rear
covers. The drive shaft, which is sealed with a radial seal, protrudes from the front cover. The bearing forces are
absorbed by friction bearings. These have been designed for high pressures and have excellent antifriction prop-
erties - particularly at low speeds. The gears have 12 teeth each. This keeps flow pulses and noise emissions
at a low level.
Axial seal Outer pressure field Inner pressure field Radial seal
Sealing zone
Cover Flange Compensation forces
Fig. 17 Axial compensation of gear pump
Internal sealing of the pressure chambers is achieved by flow volume dependent forces. This results in an ex-
cellent rate of efficiency. On the rear side the moveable bearing bushings are pressurized and thus tightly
pressed against the gears. The pressurized pressure fields are thereby limited by special seals. Sealing around
the circumference of the gears to the housing is assured by small gaps, which appears between gears and hous-
ing in dependence on the pressure.
Function
Fig. 18
The increasing volume caused by a tooth exiting a tooth gap results in a vacuum in the suction chamber. The
pressure fluid is transported into the pressure chamber. There the meshing of teeth and tooth gaps displaces
the pressure fluid into the upper supply line.
142 BOMAG 008 922 51

External gear pumps 7.6
Fig. 19
1 Cover 6 Gear (driven)

2 Seals and gaskets 7 Shaft
3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
5 Displacement chamber 10 Bearing plate
Multiple gear pumps

Gear pumps are most suitable for multiple pump arrangements, whereby the drive shaft of the first pump is ex-
tended to a second and third pump. The shafts are connected by drivers in between. The individual pump stages
are sealed to each other, i.e. the suction ports are separated from each other.
Fig. 20
008 922 51 BOMAG 143

7.7 Pump assembly
7.7 Pump assembly
Vibration pump
Travel pump
Steering/charge pump
Fig. 1 Pump assembly

The travel pump is directly driven by the flywheel of the diesel engine via an elastic coupling, the pump speed
is therefore identical with the engine speed.
The tandem gear pump is driven by the auxiliary drive of the diesel engine.
A Working connection, forward MB Pressure test port, pressure B

B Working connection, reverse T1 Leak oil
G Pressure port for charge circuit T2 Leak oil
MA Pressure test port, pressure A
144 BOMAG 008 922 51

Pump assembly 7.7
Travel pump
Steering pressure test port
Vibration pump
Steering/charge pump
Steering pressure test port
Flushing valve
Fig. 2
008 922 51 BOMAG 145

7.8 Travel circuit
7.8 Travel circuit

The travel circuit is a closed hydraulic circuit, it consists mainly of the travel pump A10VG45HWD1 with the in-
tegrated safety elements, the flushing valve and the travel motors.
The travel pump has the function of supplying the travel circuit with hydraulic oil.
The travel circuit is additionally equipped with a flushing valve for the closed hydraulic circuit, which is flanged
to the travel pump. In travel operation a pressure difference will appear between the two sides of the closed cir-
cuit. 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. The flushing valve is fitted with a downstream 16 bar pressure relief
valve. This valve makes sure that only a certain quantity of hydraulic oil (7.5 litres/min) is flushed out of the low
pressure side. This oil flows via a cooler back to the hydraulic tank.
The travel motors are hydraulically connected in parallel mode and drive the drums or the wheel set.
The tandem gear pump driven by the auxiliary drive of the diesel engine is responsible for vibration, steering and
the charge circuit, the return flow form the steering valve passes through the charge oil filter and the charge oil
port on the travel pump.
Charge pressure is additionally used for releasing the hydraulically operated multi-disc parking brake.
The filter is equipped with a bypass valve. This valve opens at a pressure differential (pressure difference be-
tween filter inlet and filter outlet) of  p = 3.5 bar. This pressure differential depends on the filter contamination
and the viscosity of the hydraulic oil.
Fig. 1
The filter is equipped with a contamination indicator, the indicator pin of which pops out at a pressure differential
of  p = 2.5 bar.
146 BOMAG 008 922 51

Travel circuit 7.8
AD-Maschine
Steering valve
Check valve Charge oil filter

Cooler
Pressure test port
Travel pump
Tandem gear pump
Tank
Brake valve
Vibration motor Drum drive motor

Drum drive motor
Fig. 1 AD-machine
008 922 51 BOMAG 147

7.8 Travel circuit
Drum drive
Poclain travel motor, type MK05
Fig. 2 Wheel motor installation

Both drums are driven by Poclain travel motors type MK05. These are radial piston motors.
148 BOMAG 008 922 51

Travel circuit 7.8
AC-machines
Ball valve
Steering valve
Steering cylinder
Check valve
Charge oil filter
Cooler Pressure test port
Travel pump
Tandem gear pump
Tank
Wheel motors
Brake valve
Drum drive motor
Fig. 1 AC-machine
008 922 51 BOMAG 149

7.8 Travel circuit
The rubber tires of the AC-machine are driven by two radial piston motors Poclain MSE02 which are joined par-
allel to each other and also parallel to the drum drive motor.
The MSE02 is fitted with a multi-disc brake. This consists of inner and outer discs which run permanently in an
oil bath. Since the brake is normally only applied in events of emergency, it is almost wear free.
Fig. 2
1 Smooth tires 3 Wheel motors

2 Disc wheels
150 BOMAG 008 922 51

Travel circuit 7.8
Brake
Hydrostatic braking
During travel operation the machine is braked by the closed hydraulic circuit. When moving the travel lever to
neutral position the supply from the pump is interrupted, the machine is hydrostatically braked.
Parking brake or emergency brake

The hydraulic brake control is accomplished via a 3/2 way valve (Y04) which is located in the engine compart-
ment. If the solenoid valve is supplied with current while the engine is running, it will direct charge pressure to
the brake housing, the brakes will be released.
When the solenoid valve is de-energized the oil pressure in the brake housings is relieved to the tank and the
brakes are closed.
Should the charge pressure drop (caused by a hydraulic fault or by shutting down the engine), the brake close
automatically.
AC-machines
Fig. 3 mechanical brake release, ball valve

If necessary, the motors can be opened with the help of a brake releasing device, a ball valve (1) has been in-
stalled in the engine compartment for this purpose. By switching this ball valve over (position I) oil can be guided
directly to the motors (drum drive and wheel drive motors). For this purpose the steering wheel must be slowly
turned for approx. two turns in clockwise direction. In this case the steering valve works as a pump and delivers
oil to the brakes, the brakes are released.
008 922 51 BOMAG 151

7.9 Towing
7.9 Towing
! Danger
Danger of accident!
Apply appropriate measures (e.g. with metal
wheel chocks, to be provided by the operating
company) to secure the machine against rolling
away before releasing the parking brake.
Use a towing vehicle with sufficient traction and
braking power for the unbraked towed load.
Use a tow bar (to be provided by the operating
company).
Using the machine as towing vehicle is not permit-
ted.
The machine cannot be steered.
! Danger
Danger of injury!
Do not touch hot engine parts.
Fig. 4
! Caution
Tow the machine only after having released the
parking brake.
Max. towing speed 1 km/h (0.62 mph), max. towing
distance 500 m (0.3 mi).
With the precision spreader* attached the ma-
chine must not be towed backwards.
152 BOMAG 008 922 51

Towing 7.9
l Place the brake releasing device (1) across the
travel motor housing (2) and turn the screw (3) into
the tapped bore (4), until it bottoms.
l Screw the nut (5) down and tighten it approx. 1 to 2
turns.
Releasing the brakes on drum and rubber

wheels (only AC-machines)
Fig. 5
l Tow the machine by the front or rear towing eye 1
(Fig. 5).
Releasing the brakes on front and rear

drums mechanically (only AD-machines)
Fig. 8
l Unscrew the fastening screw (1) (Fig. 8).
l Switch the ball valve over.
Position "I" = Brake released
Position "II" = Brake applied
l Turn the steering wheel slowly approx. two turns in
clockwise direction.
After towing
Fig. 6
l Remove both brake releasing devices (Fig. 6). Danger
!
Danger of accident!
Apply appropriate measures (e.g. with metal
wheel chocks) to secure the machine against roll-
ing away before disconnecting the tow bar.
The machine must only be started without the me-
chanical brake releasing device being activated.
Always secure the ball valve of the brake releas-
ing feature (only AC-machines) with the locking
screw.
l
Remove the brake releasing devices and press the
plastic plugs back in (only AD machines).
l
Switch the ball valve back to position "II", turn the
Fig. 7 locking screw back in and counter it with the hexa-
gon nut (only AC-machines).
i Note
Mount the brake releasing devices to both axles.
l Remove the protection plug (6) (Fig. 7).
008 922 51 BOMAG 153

7.10 Vibration circuit

The vibration drive is an open hydraulic circuit.
AD-machine
Drum drive motor

rear
High pressure filter
Vibration valve
Vibration motor
Tank
Tandem gear pump
Front vibration motor
Fig. 9 AD-machine
154 BOMAG 008 922 51

008 922 51
Fig. 10 AC-machine
AC-machines
Vibration circuit
Tandem gear pump High pressure filter
Vibration valve
BOMAG
Tank
Vibration motor
7.10
155
Vibration drive
The vibration pump delivers the hydraulic oil from the tank through the high pressure filter to the vibration valve.
When the vibration is switched on, hydraulic oil flows to the vibration motor.
Rotation of the vibration motor causes rotation of the exciter shaft. The eccentric weight attached to the exciter
shaft generatey the vibration of the drum.
Fig. 11 Vibration drive AD drum

1 Exciter shaft
2 Rubber buffer
3 Vibration motor
4 Weight
156 BOMAG 008 922 51

Steering circuit 7.11
7.11 Steering circuit
The steering circuit is an open hydraulic circuit.
AD-machine
Steering cylinder Steering valve
Charge oil filter
Steering pump
with pressure test port
Travel pump
Tank
Brake valve
Fig. 1 AD-machine
008 922 51 BOMAG 157

7.11 Steering circuit
AC-machines
Ball valve
Steering cylinder Steering valve
Steering pump
with pressure test port
Charge oil filter
Travel pump
Tank
Brake valve
Fig. 1 AC-machine
The steering pump delivers the hydraulic oil from the tank to the steering orbitrol and to the steering cylinder. If
the steering is not operated, the complete oil flow will flow through the charge oil filter to the charge ports on
travel pump and to the brake. When turning the steering wheel the distributor valve guides the oil flow to the
piston or piston rod side of the steering cylinder.
158 BOMAG 008 922 51

Checking the hydraulic oil level 7.12
A metering pump inside the steering unit measures 7.12 Checking the hydraulic oil lev-
the exact oil quantity required for the steering wheel
rotation and feeds it to the steering cylinder. The el
steering cylinder extends or retracts and articulates
the machine. The steering unit is fitted with an inte- ! Caution
grated pressure relief valve. This valve limits the
steering pressure to 140 bar. If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped, check
Should the oil flow from the steering pump fail, the all lines, hoses and components for leaks.
steering unit will automatically act as a hand pump,
i.e. manual steerability of the vehicle is still ensured. For systems filled with Panolin HLP Synth. 46 use
However, this manual steering is not intended for per- only the same oil for topping up. With other ester
manent use. based oils consult the lubrication oil service of the
respective oil manufacturer.
Steering pressure against block: See technical da-
For quality of oil refer to the "table of fuels and lu-
ta.
bricants".
650100
Fig. 2
l
Check the oil level on the dipstick. The oil level must
be between the "MIN" and "MAX" marks (Fig. 2).
l
If the oil level is too low top up hydraulic oil immedi-
ately.
008 922 51 BOMAG 159

7.13 Change hydraulic oil and breather filter
7.13 Change hydraulic oil and

breather filter
i Note
See also the notes on the hydraulic system in the
chapter "General notes on maintenance".
Danger
!
Danger of scalding!
When draining off hot hydraulic oil! 650109
Fig. 3
!Caution l
Remove the cap from the hydraulic oil tank (Fig. 3).
The hydraulic oil must also be changed after ma-
jor repairs in the hydraulic system.
Perform the oil change when the hydraulic oil is
warm.
Replace the hydraulic oil filter elements with every
hydraulic oil change.
Change the filter only after the hydraulic oil
change and after the test run.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hydraulic
oil. 650104
Do not use any detergents to clean the system. Fig. 4
For quality and quantity of oil refer to the "table of l Fold the front cover (Fig. 4) up and take out the
fuels and lubricants". hose.
When changing from mineral oil based hydraulic l
Unscrew the drain plug from the hydraulic oil tank,
oil to an ester based biologically degradable oil, drain off and collect all hydraulic oil.
you should consult the lubrication oil service of l
Tighten the drain plug again, fasten the hose.
the oil manufacturer for details.
Environment
Catch running out oil and dispose of environmen-
tally.
l Drive the machine, until the hydraulic oil has
reached operating temperature.
l
Shut down the engine.
650105
Fig. 5
l Loosen the strap (Fig. 5) on the hydraulic oil tank
and take it off with the cover.
l Wipe the inside of the hydraulic tank clean with the
lint-free cloth.
160 BOMAG 008 922 51

Checking the hydraulic oil filter element 7.14
!Caution 7.14 Checking the hydraulic oil fil-
Do not use any detergents. This will contaminate ter element
the hydraulic oil!
l Attach the cover and tighten the strap. ! Caution
If the hydraulic oil is very cold the pin may pop up,
i Note you should therefore only check the filter and
We recommend to use our filling and filtering unit with press the pin in at operating temperature.
fine filter to fill the system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the hydrau-
lic oil filter and protects the hydraulic system.
Fig. 7
l
Check the contamination indicator (Fig. 7) at oper-
650100
ating temperature and with the engine running at
Fig. 6
maximum speed.
l
Fill in new hydraulic oil (Fig. 6). l
If necessary press the pin in.
l
Check the oil level on the dipstick. The oil level must
Pin remains pressed
be between the "MIN" and "MAX" marks (Fig. 6).
in = Hydraulic oil filter element o.k.
l Close the tank with a new cover. Pin pops out = Replacing the hydraulic oil filter el-
l
Perform a test run and check the system for leaks. ement
i Note
The breather filter for the hydraulic oil tank is integrat-
ed in the filler cap, you must therefore replace the
complete filler cap.
008 922 51 BOMAG 161

7.15 Changing the hydraulic oil filter
7.15 Changing the hydraulic oil fil- Changing the high pressure filter
ter
Danger
!
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter.
! Caution
If the filter has to be changed together with the hy-
draulic oil, the filter must only be changed after
the oil change and after the test run. 650123
Do not use the oil in the filter bowl again. Fig. 9
Visible dirt may be an early sign for the failure of l Clean the area around the high pressure filter (Fig.
system components and indicate the possible fail- 9).
ure of components. In this case determine the l Disconnect the high pressure oil lines from the high
cause and replace or repair the defective compo- pressure filter.
nents, if necessary. Negligence may cause de-
struction to the entire hydraulic system.
l Remove the high pressure filter and assemble the
new high pressure filter, pay attention to the flow di-
Do not clean or reuse the filter element.
rection (arrow).
Apart from the normal oil change intervals, the fil- l Connect and tighten the hydraulic lines.
ter element must also be changed after major re-
pairs in the hydraulic system. l After a short test run check hydraulic oil filter and
high pressure filter leaks.
Environment
Catch running out oil, dispose of oil and filter ele-
ment environmentally.
Fig. 8
l Clean the area around the hydraulic oil filter.
l Remove filter bowl (4) (Fig. 8) with filter element (3).
l Examine the surface of the filter element thoroughly
for any visible dirt.
l
Take out the old filter element and clean filter bowl
and thread.
l Reassemble the filter bowl with a new filter element
and new loop rings (1) and (2).
162 BOMAG 008 922 51

8 Tests and adjustments
008 922 51 BOMAG 163

8.1 Special tools, tests and adjustments
i Note
The following list informs about special tools for
testing and adjustment work. You should choose
the corresponding tool for the work to be carried
out.
41. Vibration reed frequency meter
1000 - 4.000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80
Fig. 1
42. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
Fig. 2
43. 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. Plastic, temper-
ature range: down to -40 °C
Fig. 3
164 BOMAG 008 922 51

Special tools, tests and adjustments 8.1
44. Digital rpm-meter for petrol engines
Fig. 4
45. Digital rpm-meter for petrol engines
Fig. 5
46. Digital rpm-meter, optical/mechanical, universal
use
Fig. 6
47. Infrared hand-held thermometer, -18 to 275°C
Fig. 7
008 922 51 BOMAG 165

48. Hydraulic test case, large
i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 8
49. Hydraulic test case, small
i Note
2X 60 bar pressure gauges
2X 600 bar pressure gauges
4 pressure test hoses
Fig. 9
50. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03
Fig. 10
51. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04
Fig. 11
166 BOMAG 008 922 51

Special tools, tests and adjustments 8.1
52. Adapter for pressure test hose
Fig. 12
53. Gear pump testing device
Fig. 13
54. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 14
008 922 51 BOMAG 167

8.2 Checking the rotation speeds
8.2 Checking the rotation speeds

Special tools:
Vibration reed frequency meter
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (approx. 40 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Apply the brake.
3. Start the diesel engine and shift the throttle lever
to max. speed position.
Fig. 1
Check the engine speed

1. Measure the rotation speeds.
Nominal value high idle speed:

See technical data.
2. Switch the vibration on .
Nominal value nominal speed:

See technical data.
Evaluation of test:
If the nominal value is not reached, perform trou-
ble shooting for the engine.
Fig. 2
168 BOMAG 008 922 51

Checking the rotation speeds 8.2
Checking the vibrator shaft speed
1. Switch on vibration and check the exciter shaft
speed with the throttle lever (Fig. 3) in position
"MAX".
MIN
MAX I
MAX II
462132
Fig. 3
Nominal value:
See technical data.
Evaluation of test:
If the nominal value is not reached, perform trou-
ble shooting on the engine or in the vibration sys-
tem.
Fig. 4
008 922 51 BOMAG 169

8.3 Pressure tests in the travel circuit
8.3 Pressure tests in the travel circuit

Special tools:
Hydraulic test case
! Caution
1. Block the drums with suitable chocks (Fig. 1).
i Note
On AC-machines block drum and rubber wheels.
Fig. 1
2. Pull the plug off the brake solenoid valve (Y04) to
close the brake (Fig. 2).
Y04
880203
Fig. 2
3. Connect a 60 bar pressure gauge to the charge
pressure test port. (Fig. 3).
Fig. 3
170 BOMAG 008 922 51

Pressure tests in the travel circuit 8.3
4. Connect 600 bar pressure gauges to high pres-
sure test ports MA and MB.
6. Read charge and high pressure gauges.
Nominal value:
Charge pressure, high idle: See technical data.
Charge pressure low idle speed: See technical
data.
High pressure gauge: Both identical pressure
(charge pressure).
Fig. 4 Travel pump
Evaluation of test:
If the nominal value is not reached, check the
steering/charge pump.
7. Move the travel lever quickly forward and back-
ward, read the pressure gauges.
Nominal value:
See technical data.
Evaluation of test:
If the charge pressure drops below the nominal
value during the high pressure test, check the in-
dividual components.
If the specified high pressure is not reached,
check the travel pump.
If the starting pressure is reached to one travel di-
rection only, check the high pressure relief
valves.
8. Push the plug back onto the brake valve (Fig. 5).
Y04
880203
Fig. 5
008 922 51 BOMAG 171

8.4 Checking / adjusting the neutral positions of the travel pump
8.4 Checking / adjusting the neutral posi-

tions of the travel pump
Special tools:
Hydraulic test case
! Caution
1. Block the drums with suitable chocks (Fig. 1).
i Note
Fig. 1
2. Pull the plug off the brake solenoid valve (Y04) to
close the brake (Fig. 2).
Y04
880203
Fig. 2
Mechanical neutral position

1. Shift the travel lever to “neutral”
i Note
The spring zero centring automatically returns the
swashing angle of the pump to 0 once there is no
control torque applied to the rotation journal.
2. Detach the travel cable from the pump and check,
whether bore in fork head (Fig. 3) is in line with
the bore in the control lever.
3. If necessary adjust the travel control cable.
Fig. 3 i Note
Check the travel cable for signs of wear.
172 BOMAG 008 922 51

Checking / adjusting the neutral positions of the travel pump 8.4
Hydraulic neutral position
1. Connect 600 bar pressure gauges to the pres-
sure test ports MA and MB (Fig. 4).
Fig. 4 Travel pump

2. Connect control chambers X1 and X2 with a hose
(Fig. 5).
i Note
Minimum diameter 6 mm
Fig. 5 Travel pump

3. Start the diesel engine, shift the throttle lever (Fig.
6) to max. speed position and read the pressure
gauges.
MIN
MAX I
MAX II
462132
Fig. 6
Nominal value:
Both pressure gauges (Fig. 7) must show identi-

cal pressure.
Fig. 7
008 922 51 BOMAG 173

8.4 Checking / adjusting the neutral positions of the travel pump
4. In case of deviations from the nominal value ad-

just the mechanical neutral position (Fig. 8), until
a pressure of less than 60 bar is reached.
5. Replace the 600 bar pressure gauges with 60 bar
pressure gauges.
6. Repeat the adjustment procedure, until both
pressure gauges show the lowest possible pres-
sure value.
7. Remove the hose line (X1 ... X2) again.
8. Reattach the travel cable to the pump.
Fig. 8
9. Push the plug (Y04) back on again (Fig. 9).
Y04
880203
Fig. 9
174 BOMAG 008 922 51

Pressure test in the vibration circuit 8.5
8.5 Pressure test in the vibration circuit
! Caution
base (rubber buffers) (Fig. 1).
2. Apply the brake.
Fig. 1
3. Connect a 600 bar pressure gauge to the pres-
sure test port on the vibration valve (Fig. 2).
Fig. 2
(Fig. 3) to max. speed position.
5. Switch the vibration on .
6. Read the pressure gauge.
MIN
Nominal value:
Start-up pressure = see technical data.
MAX I
MAX II
Operating pressure = see technical data
O=perating pressure both drums = see technical
data.
462132 Evaluation of test:

Fig. 3
i Note
If starting pressure is not reached, check the vi-
bration control valve block.
If the starting pressure is reached, but the operat-
ing pressure is too low, you should also check the
leakage quantity of the vibration motors.
If the operating pressure is too high, the bearings
for both vibrator shafts must be checked.
008 922 51 BOMAG 175

8.6 Checking the leakage rate of the vibration motor
8.6 Checking the leakage rate of the vibra-

tion motor
! Caution
base (rubber tires), apply the parking brake (trav-
el lever in neutral position) (Fig. 1).
Fig. 1
2. Disconnect the leak oil hose (Fig. 2), connect a
measuring hose and hold it into a measuring
beaker.
4. Switch the vibration on and measure the running
out leak oil during one timed minute.
! Caution
This measurement detects only the external
leak oil quantity.
Internal leaks from the high pressure side to
Fig. 2
the low pressure side are not detected.
Nominal value:
max. 0,5 l/min
Evaluation of test:
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
176 BOMAG 008 922 51

Pressure test in steering circuit 8.7
8.7 Pressure test in steering circuit
! Caution
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
Do not stand in the articulation area of the ma-
chine.
3. Turn the steering against an end stop.
Nominal value:
See technical data.
Fig. 1
Evaluation of test:
steering cylinder.
5. For this purpose disconnect the hydraulic hoses
from the ports (Fig. 2) on the steering cylinder and
close them with plugs.
6. Run the engine in idle speed.
7. Turn the steering wheel.
Nominal value:
See technical data.
Evaluation of test:
If the nominal value is reached, replace the steer-
Fig. 2 ing cylinder.
9. For this purpose reconnect the hydraulic hoses to
the steering cylinder.
10. Close the pump outlet (Fig. 3) with a 200 bar gear
pump testing device and repeat the pressure test.
11. Crank the engine with the starter
Nominal value:
approx. 200 bar
Evaluation of test:
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
Fig. 3
008 922 51 BOMAG 177

8.7 Pressure test in steering circuit
178 BOMAG 008 922 51

9 Trouble shooting
008 922 51 BOMAG 179

9.1 Perform trouble shooting
General notes on trouble shooting in hydraulic systems

9.1 Perform trouble shooting
The following tests are performed for fault diagnostics and should enable you to encircle a fault in the hydraulic
system.
At this point it is assumed that there is no fault in the electric system, i.e. trouble shooting in the electric system
has already been performed.
In some cases these tests may also be conducted to identify faults on hydraulic components of the power trans-
mission system.
On the basis of preliminary tests the individual measurements have the purpose to limit the cause of the fault
first of all to a general area and then to determine exactly which oil circuit or hydraulic component is not working
correctly.
Important points for trouble shooting and fault rectification
Danger
!
When performing trouble shooting or repair work you must strictly follow the statutory accident preven-
tion instructions and health and safety regulations as well as the "safety regulations" listed in the Serv-
ice Manual.
i Note
Please follow the "General repair instructions" in the Service Manual when performing trouble shooting and re-
pair work.
When performing the following trouble shooting procedures it is assumed that the machine is correctly equipped
and connected, that connections and hoses are leak tight and free of faults and that setscrews have not been
deadjusted without permission.
180 BOMAG 008 922 51

Engine problems 9.2
9.2 Engine problems
No or poor start- Fuel tank empty Fill fuel tank

ing of engine
Fuel filter clogged, in win- Change the fuel filter, use
ter due to paraffin separa- winter fuel
tion
Fuel lines leaking Check all line connections

for leaks and tighten the
fittings, bleed the fuel sys-
tem
Water in the fuel system Cleaning the water sepa-

rator.
Travel lever not in parking Return the travel lever to

brake position parking brake position.
Battery discharged or not Charge the battery, clean

connected, battery power the terminal clamps, tight-
too low en and cover them with
acid-free grease, have
battery tested
Emergency stop push but- Unlock the emergency

ton is locked stop switch
Especially in winter: use of Use the correct engine oil

too viscous engine oil for the ambient tempera-
tures
Engine runs ir- Fuel supply too low, fuel Change the fuel filter,
regularly with system clogged by paraf- check line connections for
poor power fin separation (winter op- leaks and tighten fittings,
eration) us winter fuel under cold
conditions.
Injection valve or injection Have examined by a spe-

pump defective cialist
Air filter dirty Clean the air filter, replace

if necessary.
Excessive play in throttle Adjust the throttle cable,

cable replace if necessary
Engine looses Engine oil level too high Drain the oil down to the
power and top dipstick mark
speed, exces-
sive exhaust Poor quality fuel Use specified fuel
smoke Air filter dirty Clean the air filter, replace
if necessary.
Injection nozzle defective Have examined by a spe-

cialist
008 922 51 BOMAG 181

9.2 Engine problems
Engine over- Radiator heavily soiled Clean the cooling fins

heating, engine
must be shut Coolant level too low Fill up coolant, check for
down immedi- leaks
ately! Injection nozzle defective Have examined by a spe-
cialist
Engine oil level too low Fill up oil down to the top
dipstick mark
V-belt loose or broken Tension or replace the V-

belt
Radiator internally corrod- Replace the radiator, flush

ed the cooling system
Thermostat defective Check the thermostat, re-

place if necessary.
182 BOMAG 008 922 51

Troubleshooting axial piston pumps 9.3
9.3 Troubleshooting axial piston pumps
The following table should be of help when performing troubleshooting This table is by no means complete.
In practice you may encounter problems that have not been listed here.
Procedure
l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and
changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.
l Get an overview over the function of the product in connection with the overall system.
l
Try to clarify whether the product was able to deliver the required function within the overall system before the
fault occurred.
l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine
driver.
Try to detect changes to the overall system, the product is installed in:
l Have conditions or area of application of the product been changed?
l Were changes (e.g. changeovers) or repairs made to the overall system (machine/plant, electrics, control) or
to the product? If yes: What kind?
l Has the product or the machine been operated as intended?
l
How does the fault occur?

Unusual noises Insufficient suction conditions, e.g.Machine or system manufacturer
air in the suction line, inadequate di-
(e.g. optimize feed conditions, use
ameter of the suction line, excessivesuitable pressure fluid).
viscosity of the pressure fluid, ex- Completely purge the axial piston
treme suction height, too low suctionunit, fill the suction line with pres-
pressure, foreign bodies in the suc- sure fluid.
tion line. Remove foreign bodies from inside
the suction line.
Inappropriate fastening of the axial Check the fastening of the axial pis-
piston unit. ton unit as specified by the machine
or plant manufacturer. Observe the
tightening torques.
Inappropriate fastening of attach- Fasten attachment parts as speci-
ment parts, e.g. coupling and hy- fied by the coupling or fittings manu-
draulic lines. facturer.
Pressure relief valves of the axial Purge the axial piston unit, check
piston unit (charge pressure, high the viscosity of the pressure fluid,
pressure, pressure override). consult the service department.
Mechanical damage to the axial pis- Replace the axial piston unit, con-
ton unit. sult the service department.
008 922 51 BOMAG 183

9.3 Troubleshooting axial piston pumps

No or insufficient volumetric flow Faulty mechanical drive (e.g. defec- Check and repair the drive.
tive coupling).
Drive speed too low. Consult the service department.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
External control and setting facilities Check the external control.
defective.
Pilot or control pressure too low. Check pilot and control pressure,
consult the service department.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial pis- Replace the axial piston unit.
ton unit.
184 BOMAG 008 922 51

Troubleshooting axial piston pumps 9.3
No or insufficient pressure Faulty mechanical drive (e.g. defec- Check and repair the drive.
tive coupling).
Poor drive power. Consult the service department.
tion line.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
External control and setting facilities Check the external control.
defective.
Pilot or control pressure too low. Check pilot and control pressure.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Mechanical damage to the axial pis- Replace the axial piston unit.
ton unit.
Drive unit defective (e.g. hydraulic Check the drive unit, replace if nec-
motor or cylinder). essary.
Fluctuations in pressure/volumetric Axial piston unit not or insufficiently Completely purge the axial piston
flow purged. unit.
tion line.
Pressure fluid too hot. Excessive input temperature on axi- Check the system, e.g. malfunction
al piston unit. of the cooler, pressure fluid level in
tank too low.
Malfunction of the pressure control Consult the service department.
valves (e.g. high pressure relief
valve, pressure override, pressure
controller).
Malfunction of the flushing valve Consult the service department.
(not for nominal size 18).
008 922 51 BOMAG 185

9.4 Fault detection via instrument cluster, A15
9.4 Fault detection via instrument 9.5 The machine does not drive
cluster, A15 If the machine does not move even though the travel
control lever has been actuated, you should first
check the pressures in the travel circuit (see corre-
sponding chapter).
The following trouble shooting should be carried out if
the pressures in the travel circuit are correct.
Trouble shooting
l Switch the ignition on.
l Release the parking brake by shifting the travel le-
ver out of neutral position

Should a defect occur on the two analog inputs (input
rotation angle sensor B39, Pin 2) or the input (interval
switch A01, Pin 3), the fault indicator lamp (red, h) will
start flashing (Fig. 1).
Fig. 2 Power board

l
The LED (Y04) (Fig. 2) on the Power board should
light.
i Note
If the LED (Y04) does not light you must check for a
fault in the switching function.
The LED lighting up indicates that the functional con-
ditions for opening the brake are fulfilled.
However, this does not mean that current is actually
flowing.
186 BOMAG 008 922 51

The machine does not drive 9.5
i Note
If the nominal value is not reached, the brake solenoid
valve will most likely be defective.
Y04 If the charge pressure is reached during this test, the
brake in one of the travel motors may most likely be
blocked.
880203
Fig. 3 Brake valve

l Check current and voltage on the solenoid valve
(Fig. 3).
i Note
The current consumption of the solenoid valve is 2.75
Amp.
If no current consumption is measured and the ap-
plied voltage is approx. 12 Volt, the magnetic coil is
defective.
However, if the current consumption is correct, you
must check the function of the solenoid valve.
Checking the function of the solenoid valve
Fig. 4
l
Connect a 60 bar pressure gauge to the brake line
for the drum drive motor (X) (Fig. 4).
l Start the engine and actuate the travel lever out of
neutral.
l Read the pressure gauge.
Nominal value:
Charge pressure, high idle: See technical data.
Charge pressure low idle: See technical data.
008 922 51 BOMAG 187

9.6 Insufficient travel power
Perform trouble shooting
Fig. 5
l Check the diesel engine speed (Fig. 5).
Nominal values:
See technical data.
i Note
If the engine speed is not correct, perform trouble
shooting on the engine.
If the engine speed is correct, check the travel control.
Checking the travel cable
Fig. 6
l
Unhook the travel control cable (Fig. 6).
l
Move the travel control lever on the pump to forward
and reverse and check whether the pump is actuat-
ed to full displacement.
l
Check the travel cable for signs of wear.
i Note
If maximum speed is not reached, adjust the end
stops for the travel lever.
188 BOMAG 008 922 51

Insufficient travel power 9.6
Adjusting the end stops on the travel lever
Fig. 7
l Adjust the front and rear stops for the travel lever
(Fig. 7).
008 922 51 BOMAG 189

190 BOMAG 008 922 51

10 Flushing and bleeding
008 922 51 BOMAG 191

10.1 Special tools for flushing

i Note
The following list informs about special tools for
flushing. You should choose the corresponding
tool for the work to be carried out.
12. Filling and filtering unit
Fig. 1
13. Flushing filter (S connection)

14. Filter element 1

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

16. Screw socket R1“ - 25S (2 pieces)
Fig. 2
17. Flushing filter (L connection)

18. Filter element

19. Flushing hose 15L (2 pieces)

20. Screw socket R3/4“ -- 15L (2 pieces)
Fig. 3
21. SAE-flange 1“ - 20S

22. O-ring
BOMAG part-no. 062 203 30
Fig. 4
192 BOMAG 008 922 51

Special tools for flushing 10.1
23. Flanged plate 1“ - 25S

24. O-ring
BOMAG part-no. 062 202 22
Fig. 5
25. Reducing fitting 18L - 15L
Fig. 6
26. Reducing fitting 25S - 20S
Fig. 7
27. Reducing fitting 20S - 16S
Fig. 8
008 922 51 BOMAG 193

28. Connecting socket 15L
Fig. 9
29. Connecting socket 18L
Fig. 10
30. Connecting socket 16S
Fig. 11
31. Connecting fitting 20S
Fig. 12
194 BOMAG 008 922 51

Special tools for flushing 10.1
32. Connecting fitting 25S
Fig. 13
33. Angular fitting 18L
Fig. 14
34. Elbow fitting 16L
Fig. 15
35. Elbow 20S
Fig. 16
008 922 51 BOMAG 195

36. Elbow 25S
Fig. 17
37. Pipe connection 16S - 16S
Fig. 18
38. Connecting hose 15L
Fig. 19
196 BOMAG 008 922 51

Flushing - general 10.2
10.2 Flushing - general Solid particles in the circuit will very quickly
cause damage to machine components.
Changing a component
! Caution
Always flush the complete oil circuit after
you have replaced a component.
Fig. 1 Chips (abrasion) in the oil

Effect of contamination l Open and clean all components in the oil
circuit, replace if necessary.
Coarse particles (> 15 µm)
Sudden failure of components. l Clean all high pressure hoses in the oil cir-
cuit, replace if necessary.
Fine particle contamination (5 – 15 µm)
l If abrasion is found in the travel circuit you
Wear of components, internal leaks, inaccurate
should also flush the vibration circuit.
controlling behaviour, blockage of valves.
l If abrasion is found in the vibration circuit
Extra fine particle contamination (< 2 – 5 you should also flush the travel circuit.
µm)
Silting of oil, accelerated aging of oil, corrosion.
Water in oil
Increased wear, accelerated aging of oil.
008 922 51 BOMAG 197

10.2 Flushing - general
Before flushing Bleeding

Change the filter element
Fig. 3
Fig. 1
l Always bleed closed hydraulic circuits if
lines had been removed or connected.
Clean the hydraulic tank
Servicing the flushing filter kit
Fig. 4
Fig. 2
l Replace the filter element of the flushing fil-
ter when the red control pin of the contami-
!Caution nation indicator is pressed out during the
Change the oil in case of excessive contam- filtering process.
ination, oil discoloration or if the oil change l Clean hoses and connections and store the
interval is almost due. flushing kit in a clean and protected envi-
l Filter the tank content with the filling and fil- ronment.
tering unit and pump it into an oil container.
l Mark all hoses and disconnect them from
the hydraulic oil tank.
l Clean the oil tank thoroughly from inside, if
necessary remove the tank cover.
l Reconnect all hoses.
l Fill the hydraulic oil tank again with the fill-
ing and filtering unit.
198 BOMAG 008 922 51

Flushing schematic for front drum drive 10.3
1 Travel pump 6 Flushing hose 25S - 20S (tool)

2 Bulkhead fitting (tool) 7 Flushing filter with filter element 1 (tool)
3 Elbow union (tool) 8 Hose connection, travel pump B/DS - front drum
drive motor
4 Screw socket 1" - 25S (tool)
9 Front drum drive motor
5 Flushing hose 25S - 20S (tool)
i Note
Do not disconnect the rear travel circuit from
the hydraulic circuit.
008 922 51 BOMAG 199

10.4 Flushing the front drum drive
Environment
Environmental damage
Any hydraulic oil must be caught and dis-
posed of in an environmentally friendly man-
ner.
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.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
1. Disconnect the high pressure hose (8) from the
travel pump (port B/DS) and connect it with the
flushing hose (6) flushing filter inlet "IN" (see
chapter "Flushing schematic for front drum
drive").
2. Connect the flushing hose (5) flushing filter outlet
"OUT" with the high pressure port (B/DS) on the
travel pump.
Disconnecting the front drum drive motor
3. Take the drum drive motor (9) out of the hydraulic
circuit by joining the hoses together.
Fig. 1
200 BOMAG 008 922 51

Flushing the front drum drive 10.4
Bleeding the travel circuit
i Note
Bleed the travel circuit, see chapter "Bleeding the
travel circuit" .
Fig. 2
Flushing the front hoses
4. Block the drums with suitable chocks.
i Note
Fig. 3
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 4
! Caution
2 Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
1 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.
1 7. Shut down the engine.
8. Reconnect the high pressure hoses to the drum
2 462096 drive motor.
Fig. 5
008 922 51 BOMAG 201

Flushing the front 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 drum with chocks .
i Note
On AC machines block the rubber wheels.
Fig. 6
i Note
flushing process.
Fig. 7
! Caution
11. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
12. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
1 pump flow by shifting the travel lever several
times between full and halve reverse travel.
2 462096
13. Shut down the engine.
Fig. 8 14. Disconnect the flushing filter and reconnect the

high pressure hose to the travel pump.
i Note
travel circuit" .
Keep circulating the tank content.

15. After completing the bleeding process circulate
the tank content with the filling and filtering unit for
another 15 minutes.
202 BOMAG 008 922 51

Flushing the front drum drive 10.4
Function test
16. Check the hydraulic oil level in the tank, fill up if
necessary.
17. Check all connections for leaks with the engine
running (visual inspection).
18. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
19. Check all ports and connections for leak tightness
(visual inspection).
650100
Fig. 9
008 922 51 BOMAG 203

10.5 Flushing schematic for rear drum drive system

3 Elbow union (tool) 8 Hose connection, travel pump B/SV - rear drum
drive motor
9 Rear drum drive motor
i Note
Do not disconnect the front travel circuit from the
hydraulic circuit.
204 BOMAG 008 922 51

Flushing the rear drum drive 10.6
10.6 Flushing the rear drum drive
Environment
ner.
i Note
! Caution
pump.
forward direction.
travel pump (port B/SV) and connect it with the
chapter "Flushing diagram drum drive rear").
"OUT" with the high pressure port (B/SV) on the
travel pump.
Disconnecting the rear drum drive motor
3. Take the drum drive motor (9) out of the hydraulic
circuit by joining the hoses together.
Fig. 1
008 922 51 BOMAG 205

i Note
travel circuit" .
Fig. 2
Flushing the rear hoses
4. Block the drums with suitable chocks.
Fig. 3
i Note
flushing process.
Fig. 4
! Caution
direction forward.
8. Reconnect the high pressure hoses to the drum
2 462096 drive motor.
Fig. 5
206 BOMAG 008 922 51

Flushing the rear drum drive 10.6
Flushing the rear drum drive motor
!Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the rear of the machine, so that the drum
can rotate freely.
10. Secure the front drum with chocks .
Fig. 6
i Note
flushing process.
Fig. 7
! Caution
2 462096
Fig. 8 14. Disconnect the flushing filter and reconnect the

high pressure hose to the travel pump.
i Note
travel circuit" .

another 15 minutes.
008 922 51 BOMAG 207

Function test
necessary.
on a gradient.
650100
Fig. 9
208 BOMAG 008 922 51

Flushing schematic, rear wheel drive motors 10.7

3 Elbow union (tool) 8 Hose connection, travel pump B/SV - rear wheel
drive motor
9 Rear wheel drive motors
i Note
Do not disconnect the travel circuit from the hy-
draulic circuit.
008 922 51 BOMAG 209

10.8 Flushing the rear wheel drive
Environment
ner.
i Note
! Caution
pump.
forward direction.
travel pump (port B/SV) and connect it with the
chapter "Flushing diagram drum drive rear").
"OUT" with the high pressure port (B/SV) on the
travel pump.
Disconnecting the rear wheel motors
3. Take the wheel drive motors (9) out of the hydrau-
lic circuit and join the hoses together.
i Note
If necessary remove the rubber wheels.
Fig. 1
210 BOMAG 008 922 51

Flushing the rear wheel drive 10.8
i Note
travel circuit" .
Fig. 2
Flushing the rear hoses
4. Block drum and wheels with suitable chocks .
Fig. 3
i Note
flushing process.
Fig. 4
! Caution
direction forward.
8. Reconnect the high pressure hoses to the wheel
2 462096 drive motors.
Fig. 5
008 922 51 BOMAG 211

Flushing the rear wheel motors
!Danger
Danger of accident!
The rubber wheels must be able to rotate free-
ly.
9. Jack up the rear of the machine, so that the rub-
ber wheels can rotate freely.
i Note
If necessary remove the rubber wheels.
Fig. 6 10. Secure the front drum with chocks .
i Note
flushing process.
Fig. 7
! Caution
2 462096
Fig. 8 14. Remove the flushing filter and reconnect the high
pressure lines.
i Note
travel circuit" .

another 15 minutes.
212 BOMAG 008 922 51

Flushing the rear wheel drive 10.8
Function test
necessary.
on a gradient.
650100
Fig. 9
008 922 51 BOMAG 213

10.9 Flushing schematic for vibration drive on AD-machines
1 Screw fitting 3/4“ - 15L (tool) 7 Front vibration motor

2 Flushing hose (tool) 8 Connecting union (tool)
3 Vibration valve 9 Flushing filter (tool)
4 Vibration motor, rear (only AD-machine) 10 Hydraulic hose, vibration valve - tank
5 Vibration pump 11 Flushing hose (tool)
6 Hydraulic oil tank 12 High pressure filter
214 BOMAG 008 922 51

Flushing the vibration circuit 10.10
10.10Flushing the vibration circuit
Environment
ner.
Changing the hydraulic filter element
i Note
! Caution
so that only cleaned oil will enter the hydrau-
lic oil tank.
1. Disconnect the hydraulic hose (10) from the vi-
bration valve (port T) and connect it with the flush-
ing hose (2) flushing filter inlet "OUT" (see
chapter "Flushing schematic for vibration cir-
cuit").
2. Connect flushing hose (11) flushing filter inlet "IN"
with the vibration valve (port T).
Flushing the vibration motors
3. Unscrew the fastening screws for the vibration
motors and pull both motors (5 and 7) out of the
coupling.
i Note
AC-machines are fitted with a front vibration mo-
tor only.
Fig. 10
008 922 51 BOMAG 215

10.10 Flushing the vibration circuit
i Note
flushing process.
4. Start the engine and run it with maximum speed.
5. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
7. Remove the flushing filter and reinstall the vibra-
tion motors.
Fig. 11
Function test
necessary.
9. Test drive.
650100
Fig. 12
216 BOMAG 008 922 51

Bleeding the travel circuit 10.11
10.11Bleeding the travel circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Secure the drums with chocks .
i Note
Fig. 1
2. Actuate the emergency stop switch.
! Danger
The engine should not start.
Fig. 2
3. Install a pressure test hose to the charge pres-
sure test port.
4. Install a pressure test hose each to the high pres-
sure test ports.
5. Hold the open ends of the pressure test hoses
(Fig. 3) into a container.
6. 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.
7. Remove the pressure test hoses.
Fig. 3
008 922 51 BOMAG 217

10.11 Bleeding the travel circuit
8. Unlock the emergency stop switch
Fig. 4
9. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 5) and run the engine
max. 15 seconds at idle speed.
10. Pause for approx. 30 seconds and keep repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.
Fig. 5
! Caution
2 With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
1 erwise the flushing filter will be subjected to
oil flow from the wrong direction.
! Danger
Run the engine with idle speed.

1 11. Start the engine.
12. Shift the travel lever (Fig. 6) approx. 1/3 to for-
2 462096 ward direction.
Fig. 6 13. 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.
14. 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.
218 BOMAG 008 922 51

11 Drum
008 922 51 BOMAG 219

11.1 Reparaturübersicht Bandage
11.1 Reparaturübersicht Bandage
Fig. 1
1 Drum shell 4 Exciter shaft

2 Vibration motor 5 Drum drive motor
3 Rubber buffer
220 BOMAG 008 922 51

Reparaturübersicht Bandage 11.1
End float: 0.6 to 1.9 mm
Fig. 2
1 Drum shell 5 Drum drive motor

2 Vibration motor 6 Vibration bearings
3 Rubber buffer 7 Travel bearings
4 Exciter shaft 8 Clutch
008 922 51 BOMAG 221

11.2 Removing and installing the drum
Removing the drum
i Note
The procedures for the removal of front and rear
drums are identical. The following instructions de-
scribe the removal of the front drum, however, the
work steps apply also for the removal of the rear
drum.
1. Jack the the machine up (Fig. 1) and support it
safely, so that the rubber buffers on the drive disc
are unloaded.
! Danger
Danger of accident!
Block front and rear drums with wedges
against rolling!
Do not work in the articulation area of the roll-
er while the engine is running.
Fig. 1
! Caution
Do not start the engine during repair work!
2. Unscrew bracket (1).
3. Mark the hydraulic hoses and disconnect them
from the vibration motor ports.
4. Close the connections with plugs.
Fig. 2
5. Unscrew the nuts (1).
6. Unscrew the screws (2) and remove the support
(3).
Fig. 3
222 BOMAG 008 922 51

Removing and installing the drum 11.2
Releasing the mechanical brake
7. Take off the brake releasing device.
Fig. 4
8. Remove the protection plug (6).
9. Place the brake releasing device (1) across the
travel motor housing (2) and turn the screw (3)
into the tapped bore (4), until it bottoms.
10. Screw the nut (5) down and tighten it approx. 1 to
2 turns.
Fig. 5
11. Unscrew bracket (2).
! Caution
ner.
12. Mark and disassemble hydraulic hoses and
pipes.
13. Close the connections with plugs.
14. Fold the scraper (1) up.
15. Unscrew the fastening screws (3) and roll the
Fig. 6 drum with travel motor and support leg out to the
front.
i Note
If necessary raise the machine further at the front,
so that the drum can be rolled out.
008 922 51 BOMAG 223

Installing the drum

16. Examine all rubber buffers for wear, replace if
necessary.
i Note
Tighten the rubber buffers with 211 Nm.
Install the drum in reverse order, for this purpose
move the drum with attached travel motor and
support legs parallel into the frame. Fasten the
support legs under pre-load and reconnect the
hydraulic hoses.
Fig. 7
Adjusting the pre-load of the rubber buffers
! Caution
Install the support legs under pre-load.
With the gap "X" between support leg and
spacer block the rubber buffers are pre-load-
ed when tightened.
Nominal value: Distance X = 2 mm
i Note
If necessary attach compensation shims on either
Fig. 8 side.
17. Check the hydraulic oil level, top up if necessary.
! Caution
Bleed the travel circuit before starting opera-
tion.
18. Perform a test drive, check function of travel sys-
tem, vibration and water sprinkling system.
19. Check all connections and fittings for leak tight-
ness.
650100
Fig. 9
224 BOMAG 008 922 51

Dismantling the drum 11.3
11.3 Dismantling the drum
Removing the drum drive motor
! Danger
Secure the drum against rolling away!
1. Remove the brake releasing device (1).
1. Attach the lifting tackle to the support leg (2).
2. Unscrew the fastening nuts (3) and separate the
drive disc with travel motor and support leg from
the drum.
Fig. 1
3. Disassemble the support leg (1) from the drum
drive motor.
Fig. 2
4. Check all rubber buffers for wear, replace if nec-
essary.
Fig. 3
008 922 51 BOMAG 225

5. Unscrew the screws (1), lift the drive disc (2) with
intermediate ring (3) from the drum drive motor
(4).
Fig. 4
Remove the vibration motor

1. Remove the vibration motor (1).
2. Check rubber buffers (2) for wear, replace if nec-
essary.
i Note
Tighten the rubber buffers with 211 Nm.
Fig. 5
3. Remove the elastic coupling (1).
4. Unscrew nut (2) and pull the coupling hub (3) off
with a puller.
5. Remove feather key (4).
Fig. 6
6. Unscrew the two fastening screws (1) and sepa-
rate the vibration motor (2) from the flange (3).
Fig. 7
226 BOMAG 008 922 51

Remove the bearing plate
1. Unclip the circlip.
Fig. 8
2. Force the bearing plate off with forcing screws.
Fig. 9
3. Knock the grooved ball bearing (1) out of the
bearing plate (3).
4. Remove the Nilos ring (2).
Fig. 10
008 922 51 BOMAG 227

Removing the exciter shaft

1. Unscrew the fastening screws (1) from the bear-
ing housing.
2. Remove the elastic coupling, check for wear, re-
place if necessary.
Fig. 11
3. Hook the lifting device (1) to a crane and slide it
over the exciter shaft.
4. Force the bearing housing out of the drum using
forcing screws.
Fig. 12
5. Pull the exciter shaft out of the drum.
Fig. 13
228 BOMAG 008 922 51

Dismantling the exciter shaft
1. Remove the bearing housing from the exciter
shaft.
Fig. 14
2. Knock the cylinder roller bearing (1) out of the
bearing housing.
Fig. 15
3. Dismantle the coupling hub (1) from the exciter
shaft.
Fig. 16
4. Pull the inner bearing races (1) off both sides of
the exciter shaft.
i Note
If the inner bearing race sits very tight, heat the
ring up with a torch.
5. Remove seal ring (2) from both ends of the excit-
er shaft.
Fig. 17
008 922 51 BOMAG 229

Removing the bearing cover

1. Unscrew the fastening screws (1) from the drum.
2. Knock the bearing cover out of the vibration drive
side.
Fig. 18
3. Remove the locking cap.
Fig. 19
4. Knock the cylinder roller bearing out of the bear-
ing housing.
Fig. 20
230 BOMAG 008 922 51

Assembling the drum 11.4
11.4 Assembling the drum
Installing the bearing cover
1. Cool the new cylinder roller bearing down to -25
°C and press it into the bearing cover until it bot-
toms.
i Note
Fill approx. 30 gram of lithium saponified high
pressure grease in between the rollers and an-
other approx. 30 gram into the dedicated grease
chamber of the bearing cover.
Fig. 1
2. Attach the locking cap.
Fig. 2
3. Assemble the bearing cover, fasten crosswise
with screws (1) and washers.
Fig. 3
008 922 51 BOMAG 231

Assembling the exciter shaft

4. Push on the seal ring (2) on both sides of the ex-
citer shaft.
i Note
Lubricate the bearing seat areas.
! Danger
Danger of burning!
Wear protective gloves
5. Heat the inner bearing races (1) up to approx.
80 °C and slide on both ends of the exciter shaft.
Fig. 4
6. Assemble the coupling hub (1).
Fig. 5
7. Knock the new bearing (1) into the bearing hous-
ing until it bottoms.
i Note
Fill approx. 30 gram of lithium saponified high
pressure grease in between the rollers and an-
other approx. 30 gram into the dedicated grease
chamber of the bearing housing.
Fig. 6
8. Slide the bearing housing on the exciter shaft.
Fig. 7
232 BOMAG 008 922 51

Installing the exciter shaft
9. Attach tghe lifting tackle to the exciter shaft and
carefully guide the exciter shaft into the opposite
bearing.
Fig. 8
10. Fasten the bearing housing with screws 1 (Fig.
9).
11. Insert the elastic coupling into the coupling hub.
Fig. 9
Measuring the end float

12. Turn the eye bolt into the bore in the exciter shaft
to measure the axial clearance.
13. Push the exciter shaft into the bearing housing
against the end stop.
Fig. 10
008 922 51 BOMAG 233

14. Measure the distance between coupling and front

face of bearing housing.
Fig. 11
15. Pull the exciter shaft out of the bearing housing
against the end stop.
Fig. 12
16. Measure the distance between coupling and front
face of bearing housing once again.
iNote
Subtract the second measurement from the first
measurement to calculate the end float.
Nominal value:
min. 0.6 mm
max. 1.9 mm
Fig. 13
Assembling the bearing plate

17. Assemble the Nilos ring (2).
18. Press the new bearing (1) into the bearing plate
(3) until it bottoms and fill it to 2/3 with lithium sa-
ponified high pressure grease.
Fig. 14
234 BOMAG 008 922 51

19. Use a drift punch to knock the bearing plate into
the bearing housing.
Fig. 15
20. Snap the circlip into the groove of the bearing
housing
Fig. 16
Installing the vibration motor

21. Fasten the vibration motor (2) to the flange (3)
with the two fastening screws (1).
Fig. 17
22. Assemble the feather key (4).
23. Slide on coupling hub (3) and tighten nut (2) with
55 Nm.
24. Install the elastic coupling (1).
Fig. 18
008 922 51 BOMAG 235

25. Install the vibration motor (1).

26. If necessary install new rubber buffers (2).
Fig. 19
Installing the drum drive motor

27. If necessary install new rubber buffers (2).
Fig. 20
28. Use screws (1) and washers to connect the drum
drive motor (4) with the drive disc (2) and the in-
termediate ring (3).
Fig. 21
29. Assemble the support leg (1) with the drum drive
motor.
30. Attach the lifting tackle to the completely assem-
bled unit.
Fig. 22
236 BOMAG 008 922 51

31. Assemble the brake releasing device (1).
32. Install the drum drive motor with drive disc and
support leg (2) to the drum.
33. Rest the drive disc on the rubber buffers and
tighten with nuts (3) and washers.
Fig. 23
008 922 51 BOMAG 237

238 BOMAG 008 922 51

12 Oscillating articulated joint
008 922 51 BOMAG 239

12.1 Repair overview oscillating articulated joint
12.1 Repair overview oscillating articulated joint
1 Housing 4 Spherical plain bearing for steering cylinder

2 Bearing block, top 5 Bearing cover
3 Bearing block, bottom
240 BOMAG 008 922 51

Repair overview oscillating articulated joint 12.1
1 Housing 6 Hinge bearing

2 Bearing block, top 7 Taper roller bearing
3 Bearing block, bottom 8 Spring collar
4 Joint cross 9 Control measurement
5 Bearing cover 10 Taper roller bearing
i Note
Press the outer race of the taper roller bearing (7) into the bearing cover only so far, that the Belleville
spring (8) touches.
008 922 51 BOMAG 241

12.2 Repairing the oscillating articulated joint
12.2 Repairing the oscillating articulated

joint
Dismantling the oscillating articulated

joint
1. Pull bearing blocks 1 (Fig. 1) off both sides.
Fig. 1
2. Remove support discs 1 (Fig. 2) and seal rings (2)
from both sides.
Fig. 2
3. Use an appropriate puller to extract the spherical
plain bearing 1 (Fig. 3).
Fig. 3
242 BOMAG 008 922 51

Repairing the oscillating articulated joint 12.2
4. Disassemble the bearing cover 1 (Fig. 4) and
take off the loop ring (2).
Fig. 4
5. Take the joint cross 2 (Fig. 5) out of the housing
(1) and remove the loop ring (3).
Fig. 5
6. Pull the outer bearing race 1 (Fig. 6) out of the
bearing housing.
7. Remove the Belleville spring (2).
Fig. 6
8. Use an appropriate puller to extract the outer
bearing race 1 (Fig. 7) from the bearing housing.
Fig. 7
008 922 51 BOMAG 243

9. Pull the taper roller bearing 1 (Fig. 8) off the joint

cross.
Fig. 8
244 BOMAG 008 922 51

Assembling the oscillating articulated
joint
1. Press the taper roller bearing 1 (Fig. 1) onto the
joint cross (2).
Fig. 1
2. Press the outer bearing race 1 (Fig. 2) into the
bearing housing (2) and fill to 2/3 with lithium sa-
ponified high pressure grease.
Fig. 2
3. Insert Belleville springs 2 (Fig. 3) with the curva-
ture pointing towards the bearing cover (3).
i Note
Press the outer race of the taper roller bearing (1)
into the bearing cover only so far, that the Bel-
leville spring (2) touches.
4. Press the outer bearing race 1 (Fig. 3) into the
bearing housing and fill to 2/3 with lithium sapon-
ified high pressure grease.
Fig. 3
008 922 51 BOMAG 245

5. Check the control measurement (13.5 mm) (Fig.

4).
Fig. 4
6. Apply some oil to the new loop ring 3 (Fig. 4) and
insert it into the groove in the joint cross.
7. Insert the joint cross (2) into the housing (1).
Fig. 5
8. Apply some oil to the new loop ring 2 (Fig. 5) and
insert it into the groove in the joint cross.
9. Install the bearing cover (1).
i Note
When tightening the bearing cover move the joint
cross to and fro to ensure a uniform wear pattern
of the individual bearing rollers.
Fig. 6
10. Knock the new rocker bearings 1 (Fig. 7) until
they bottom.
! Caution
The assembly mandrel should only contact
the outer race of the rocker bearing, as other-
wise the bearing will be destroyed!
Fig. 7
246 BOMAG 008 922 51

11. Push new seals (2) (Fig. 8) over both bearing
journals of the joint cross.
12. Assemble supporting discs (1).
Fig. 8
13. Knock both bearing blocks 1 (Fig. 9) onto the
bearing journals.
Fig. 9
008 922 51 BOMAG 247

248 BOMAG 008 922 51

13 Suppliers documentation
008 922 51 BOMAG 249

250 BOMAG 008 922 51
13.1 Travel pump
008 922 51 BOMAG 251

13.1 Travel pump
252 BOMAG 008 922 51

Travel pump 13.1
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
RDE 92 750-01-R/03.03
Verstellpumpe A10VG 28/63 ersetzt/replaces 10.02
Variable Pump A10VG 28/63

Baureihe/Series 10
Reparaturanleitung / Repair Instructions
008 922 51 BOMAG 253

13.1 Bosch Rexroth AG | Mobile Hydraulics
2 A10VG | RDE 92Travel
750-01-R/03.03
pump
Hinweis / Inhalt
Notice / Contents
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.
INHALT CONTENTS
Seite/
Page
A10VG A10VG
Schnittbild 3-4 Sectional view

Allgemeine Reparaturhinweise 5 General repair instructions
Dichtsätze und Baugruppen 6-8 Seal kits and sub assembly groups
Triebwelle abdichten 9 Sealing of the drive shaft
Hilfspumpe abdichten 10-12 Sealing of the boost pump
Stellkolbendeckel abdichten 13 Sealing of the control piston cover
Ventile abdichten 14 Sealing of the valves
Druckabschneidung abdichten 15 Sealing of the pressure cut-off valve
Regelventil abdichten 16 Sealing of the regulator valve
Steuergerät demontieren 17 Removal of the control unit
Ansteuergeräte 18-22 Control units
Pumpe demontieren 23-25 Pump disassembly
Triebwerk ausbauen 26 Removal of the rotary group
Stellkolben demontieren 27-28 Disassembly of the positioning piston
Überprüfungshinweise 29-31 Inspection notes
Turcon-Glyd-Ring montieren 32 Turcon-Glyd-ring
Pumpe montieren 33-35 Assembly of the pump
Triebwerk einbauen 36 Installation of the rotary group
Triebwerk einbauen HW, HD, EP 37-38 Installation of the rotary group HW, HD, EP
Triebwerk einbauen DA 39 Installation of the rotary group DA
Pumpe montieren 40-41 Assembly of the pump
Montageanweisung für Anziehdrehmomente 42-45 Assembly guidelines for tightening torques
Sicherheitsbestimmungen 46-47 Safety regulations
Einstellhinweise 48-55 Adjustment instructions
254 BOMAG 008 922 51

RDE 92 750-01-R/03.03
Travel pump | A10VG Mobile Hydraulics | Bosch Rexroth AG 13.13
Schnittbild
Sectional view
mit Druckabschneidung
with pressure cut-off
HW
ohne Druckabschneidung
without pressure cut-off
HDD EPD
008 922 51 BOMAG 255

750-01-R/03.03
pump
Schnittbild
Sectional view
DA
256 BOMAG 008 922 51

RDE 92 750-01-R/03.03
Allgemeine Reparaturhinweise
General repair instructions
Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!
Alle Öffnungen der Hydraulikaggregate

verschließen.
Close all ports of the hydraulic aggregates.
Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.
Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.
Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.
Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.
Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.
Fill the hydraulic units with the operating medium

before commissioning.
008 922 51 BOMAG 257

750-01-R/03.03
pump
Dichtsätze und Baugruppen

Seal kits and sub-assemblies
Dichtsatz für Triebwelle.
Seal kit for drive shaft.
Äußerer Dichtsatz.
Peripheral seal kit.
Triebwerk komplett.
Complete rotary group.
Stellkolben
Positioning piston
2 3
1. Anschlußplatte Standard,
1
2. Anschlußplatte mit Druckabschneidung
3. Anschlußplatte DA mit Druckabschneidung
1. Standard connection plate

2. Connection plate with pressure cut-off
3. DA connection
258 BOMAG 008 922 51

RDE 92 750-01-R/03.03
Ansteuergerät HW
Control unit HW
Ansteuergerät HW mit Nullagenanzeige
Control unit HW with zero indicator
alt / old
neu / new Ansteuergerät HD
Control unit HD
alt / old
neu / new
Ansteuergerät EP
Control unit EP
alt / old
neu / new
4/3 Wegeventil DA
Control unit DA
008 922 51 BOMAG 259

750-01-R/03.03
pump

Hilfspumpe mit Verschleißplatte
Boost pump with wear plates
1
2
1. HD - Ventil
2. HD - Ventil mit Bypass
3. ND - Ventil
1. High pressure valve

2. High pressure valve with bypass function
3. Low pressure valve
Druckabschneidung
Pressure cut-off
3
2
1. DA - Regelventil, verstellbar mit Hebel

1
2. DA - Regelventil, festeingestellt
3. Zuschaltventil
1. DA control valve, adjustable via a lever

2. DA control valve, fixed
3. Switching valve
260 BOMAG 008 922 51

RDE 92 750-01-R/03.03
Triebwelle abdichten
Sealing of the drive shaft
Triebwelle abkleben.
Sicherungsring ausbauen.
Protect the drive shaft (e.g. masking tape).

Remove the retaining ring.
Blechschraube in die mit Gummi gefüllten Löcher

eindrehen.
Mit Zange WDR herausziehen.
Screw the metal screws into the holes that are

fitted with rubber.
Withdraw the shaft seal using pliers.
Wellendichtring mit Buchse auf Anschlag

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
leicht einfetten.
Press-in shaft seal with bush to stop.

Lightly grease the seal, dust lips and shaft seal ring.
008 922 51 BOMAG 261

750-01-R/03.03
pump
Hilfspumpe abdichten
Sealing of the boost pump
Achtung!
* "Angefaste Seite" zum Deckel montieren.
Note!
* Mount the "chamfered side" towards the cover.
Befestigungsschrauben ausbauen.
Remove fixing screws.
Deckel abdrücken.
Pry-off cover.
Einbaulage kennzeichnen.
Mark position.
262 BOMAG 008 922 51

RDE 92 750-01-R/03.03
11
O-Ring ausbauen.
Remove O-ring.
Hilfspumpe abdrücken.
Pry off the boost pump.
2
1. Verschleißplatte
2. Fixierstift
1. Wear plate
2. Locating pin
1
3 1. Kantsil-Ring
1
2. Entlastungsnut
2 3. Fixierstift
1. Kantsil-ring
2. Unloading channel
3. Locating pin
Verschleißplatte einsetzen.
Drehrichtung beachten!
Fit wear plate taking the direction of rotation

account.
008 922 51 BOMAG 263

750-01-R/03.03
pump
Drehrichtung "Rechts" bei Blick auf die Triebwelle.
Achtung! Fixierstift
Fit wear plate.

Direction of rotation "clockwise" looking on the drive
shaft.
* Attention! Locating pin
Saugseite - suction side
Drehrichtung "Links" bei Blick auf die Triebwelle.
Achtung! Fixierstift
Fit wear plate.

Direction of rotation "anti-clockwise" looking on the
drive shaft.
*
Attention! Locating pin
Saugseite - suction side
Linkslauf - anti-clockwise
Rechtslauf - clockwise
Hilfspumpe montieren.
Fit boost pump
O-Ring und Deckel montieren.
Fit O-ring andcover plate.
264 BOMAG 008 922 51

RDE 92 750-01-R/03.03
13
Stellkolbendeckel abdichten
Sealing of the control piston cover
Achtung!
Korrekte mechanische 0-Lageneinstellung
überprüfen!
Attention!
Check that the mechanical "0"-position is
correct!
Kontermutter ausbauen, Stellschraube gegenhalten.

Maß X
Deckel kennzeichnen. Maß festhalten, Konter-
mutter lösen.
Remove lock unit, whilst holding the adjustment

screw, mark the cover plate, ascertain the
dimension, loosen locknut.
Deckel von Stellschraube "abschrauben".
Remove the cover from the adjustment screw by

unscrewing it from the adjustment screw.
Kontrolle! O-Ring (1), Nut (2), Gehäuse und

Deckel (3).
Achtung!
Korrekte mechanische 0-Lageneinstellung muß
nach Einbau im Gerät bzw. Prüfstand erfolgen.
Check! O-ring (1), groove (2), housing with

cover (3).
Attention!
The correct mechanical "0" position has to be
adjusted after the unit has been built into the
machine or on a test rig.
008 922 51 BOMAG 265

750-01-R/03.03
pump
Ventile abdichten
Sealing of the valves
PHD -Ventil mit Bypass
PHD -valve with bypass-function
PSP-Ventil
PSP -valve
Gewinde vor Montage des neuen O-Ringes

abkleben.
(Beschädigungsschutz).
Cover threads before fitting new O-rings.

(Damage protection).
*
Ventilkegel mit Druckfeder ausbauen.
Stützring
* mit Bypassfunktion
Remove valve poppet with compression spring.

* with bypass function
*
O-Ring
O-Ring und Stützring mit Hilfswerkzeug (Hülse)

aufziehen.
Place on O-ring and back-up ring

with auxiliary tool (sleeve).
266 BOMAG 008 922 51

RDE 92 750-01-R/03.03
15
Druckabschneidung abdichten
Sealing of the pressure cut-off valve
Wechsel der Dichtmutter.

Einstellmaß festhalten (*).
*
Exchanging the sealing nut.
Ascertsion the adjustment dimension (*).
Achtung!
Nach Einbau "Ventileinstellung" überprüfen.
Attention!
After assembly check "valve setting".
008 922 51 BOMAG 267

750-01-R/03.03
pump
Regelventil abdichten
Sealing of the control valve
Regelventil ausbauen.
Remove control valve.
Blendendurchmesser nicht beschädigen.

Kontrolle:
Blendendurchmesser
Do not damage the orifice diameter.

Check: Orifice diameter.
Gewinde vor Montage des neuen O-Ringes

abkleben.
Before fitting the new O-ring cover the threads

(e.g. tape).
268 BOMAG 008 922 51

RDE 92 750-01-R/03.03
17
Steuergerät demontieren
Removing of the control unit
HW
alt / old
DA alt / old
neu / new
HD
neu / new
EP alt / old
neu / new
HW mit Nullagenschalter
HW with zero position switch
* Befestigungsschrauben demontieren.
*
* Remove fixing screws.
Ansteuergerät abdrücken.
Pry-off the control unit.
Kontrolle
Dichtfläche (1), Flachdichtung (2), O-Ringe (3).
Check
Sealing surface (1), gasket (2), O-rings (3).
008 922 51 BOMAG 269

750-01-R/03.03
pump
Ansteuergeräte
Control units
Ansteuergerät HW
NG / Size 28
HW control unit
NG / Size 45
4/3 Wegeventil DA
DA control unit
Anziehmoment 5+1 Nm
Steckschlüssel SW 26
Tightening torque 5+1 Nm
26 A/F socket spanner
Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm
270 BOMAG 008 922 51

RDE 92 750-01-R/03.03
19
Ansteuergeräte
Control units
Ansteuergerät HD - EP alt
HD - EP control unit old
HD alt / old
EP alt / old
HD alt / old
EP alt / old
Neues Ansteuergerät HD - EP
New HD - EP control unit old
202,0 mm
131,0 mm
214,4 mm
77,4 mm
008 922 51 BOMAG 271

750-01-R/03.03
pump
Ansteuergeräte
Control units
Ansteuergerät HD neu
HD - control unit new
Ansteuergerät EP neu
EP - control unit new
272 BOMAG 008 922 51

RDE 92 750-01-R/03.03
21
Ansteuergeräte
Control units
* Markierung Montageposition HD *
* Marking the assembly position HD
*
*
*
* Markierung * Assembly position marker HD

Montageposition HD
Wird von EP- auf HD-Ausführung umgebaut - Is converted from EP into the HD version -
Deckelposition beachten siehe Markierung take note of the cover position, see marker
Leckölkanal offen wird geschlossen. The open leakage port is plugged
Zugfeder tauschen! Exchange the tension spring!
008 922 51 BOMAG 273

750-01-R/03.03
pump
Ansteuergeräte
Control units
Markierung Montageposition EP Die neuen Proportionalmagnete müssen bei der Inbe-

Assembly position marker EP triebnahme entlüftet werden. Wird die Luft nicht aus
* dem Ankerraum entfernt, kann es zum Schwingen der
Hydraulische Nullage
Ansteuerung kommen.
Hydraulic zero position
Zum Entlüften ist am Ende des Magneten, im Messing-
Klemmschraube teil, ein kleiner Gewindestift M4, SW 2 vorhanden.
Clamping screw Dieser Gewindestift ist max. 2 Umdrehungen heraus-
* zudrehen und nach dem Entlüften mit 1 Nm wieder
festzuziehen.
Bei der Ausführung mit Nothand mit Federrückzug muß
zum Entlüften die Kunststoffmutter mit Gummibalg
entfernt und nach dem Entlüften mit 5+1 Nm wieder
angeschraubt werden.
Entlüftungsschraube * max. 2 Umdrehungen herausdrehen. The new proportional solenoids must be bled during
Bleed screw *. Unscrew by commissioning. If the air is not removed from the
a max. of 2 turns armature chamber oscillations at the control can occur.
* For bleeding purposes there is, on the end of the sole-
* noid, in the brass component a small set screw M4,
2A/F. This can be unscrewed by a maximum of 2 turns
and then after completion of the bleeding tightened to
a maximum of 2 Nm.
For the version with hand override and spring return
the plastic nut with rubber coating has to be removed
for bleeding. After bleeding it has to be replaced and
tightened with 5+1 Nm.
Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm
* *
Markierung
Klemmschraube 6,1 Nm Anziehmoment 5+1 Nm
Montageposition EP
Clamping screw 6,1 Nm Steckschlüssel SW 26
Assembly position
marker EP Tightening torque 5+1 Nm
26 A/F socket spanner
Hydraulische Nullage
Exzenterstift
Hydraulic
zero point
Eccentric pin
Beim Lösen der Klemmschraube
Exzenterstift - Hydraulische Nullage festhalten.
When loosening the clamping screw

Hold the eccentric pin - hydraulic zero point
274 BOMAG 008 922 51

RDE 92 750-01-R/03.03
23
Pumpe demontieren
Pump disassembly
HD alt/old
EP alt/old
HD neu/new
EP neu/new
Druckabschneidung
Pressure cut-off
DA alt/old
DA neu/new
Excenterschraube
Eccentric screw
008 922 51 BOMAG 275

750-01-R/03.03
pump
Pumpe demontieren
Pump disassembly
Lage der Hilfspumpe und Anschlußplatte

markieren.
Hilfspumpe abbauen.
Mark position of the boost pump and the port plate.

Remove the boost pump.
DA-Ausführung:
Lage der Verdrillschraube markieren (1).
Verdrillschraube auf Demontageposition stellen (2).
DA-design:
Mark the position of the eccentric screw (1).
Set the eccentric screw to disassembly position
(2).
Anschlußplattenbefestigung lösen. Anschlußplatte

abheben.
Remove connecting plate fixing screws.

Lift off the connection plate.
Steuerplatte abdrücken.
Lage notieren.
Lift off control plate.

Note position.
Kontrolle!
2 4 O-Ring mit Nut (1)
3 O-Ring mit Nut (2)
Fixierstift - Steuerplatte (3) Bei DA - kein Stift
1 T - Ablauf verschlossen (4)
Check
O-ring and groove (1)
O-Ring and groove (2)
Locating pin - control plate (3) type DA has no pin
T drain plugged (4) open for type DA
276 BOMAG 008 922 51

RDE 92 750-01-R/03.03
25
Pumpe demontieren
Pump disassembly
DA-Ausführung
Zylinder nach unten drücken (1).
Verdrillschraube herausdrehen (2).
Triebwerk ausheben (3).
DA- version
Press the cylinder downwards (1).
Remove the eccentric screw (2).
Lift out the rotary group (3).
"Ausbauen"
1. Zylinder
2. Schwenkwiege
3. Gelenkstift
"Remove"
1. Cylinder
2. Swash plate
3. Joint pin
Sicherungsring, WDR ausbauen.
Remove retaining ring, remove drive shaft seal.
008 922 51 BOMAG 277

750-01-R/03.03
pump
Triebwerk ausbauen
Removal of the rotary group
Triebwelle mit leichten Hammerschlägen austreiben.
Remove drive shaft with light hammer strokes.
Lagerschalen ausbauen.
Remove bearing shells.
Feder mit Vorrichtung vorspannen.
Pre-tension the spring using a suitable device.
Sicherungsring demontieren.
Feder und Druckstifte ausbauen.
Remove circlip.
Remove spring and pressure pins.
278 BOMAG 008 922 51

RDE 92 750-01-R/03.03
27
Stellkolben demontieren - Gehäuse mit Buchse

Disassembly of the positioning piston - housing with bush
Steuergerät abbauen.
Remove control unit.
Stellkolben (1) ziehen.
Pull out control piston (1).
Stellkolben zerlegen.
Disassemble the control piston.
008 922 51 BOMAG 279

750-01-R/03.03
pump
Stellkolben demontieren - Gehäuse mit Turcon-Glyd-Ring

Disassembly of the positioning piston - housing with Turcon-Glyd-ring
Steuergerät abbauen.
Remove control unit.
Stellkolben (1) ziehen.
Pull out control piston (1).
Stellkolben zerlegen
(Gehäuse Turcon-Glyd-Ring Abdichtung).
Disassemble the control piston

(Housing Turcon-Glyd-ring).
280 BOMAG 008 922 51

RDE 92 750-01-R/03.03
29
Überprüfungshinweise
Inspection notes
Alle Lager erneuern.
Replace all bearings.
Kontrolle!
1. Verzahnung, ausgeschlagen, Passungsrost.
2. Lauffläche.
3. Einlaufrillen vom Wellendichtring.
Check!
1. Splines, wear steps, corrosion.
2. Running surfaces.
3. Grooves made by the shaft seal.
Stellkolbenlaufbüchse (1) riefenfrei, nicht

ausgelaufen.
1
Check that the control piston guide bush (1)
1
is free of grooves and is free of wear.
Kontrolle!
Stellkolben (1) riefenfrei.
Check!
Control piston (1) is not scored.
008 922 51 BOMAG 281

750-01-R/03.03
pump
Inspection notes
Kontrolle!
Gleitfläche riefenfrei.
Check!
Sliding surface free of grooves.
Kontrolle!
Verbindung Gleitstein/Schwenkzapfen spielfrei.
Check!
That the connection of slide ring/swivel pin is free
of play.
Kontrolle!
Rückzugeinrichtung riefenfrei (1), keine Einlaufs-
puren (2)
im Gleitschuhbereich.
Check!
That the retaining plate is free of grooves (1) and
that there is no wear (2) in the slipper pad area.
Kontrolle!
Lauffläche (1) keine Kratzer, keine Metallein-
lagerungen,
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).
Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).
Check!
Cylinder bores (1), splines (2).
282 BOMAG 008 922 51

RDE 92 750-01-R/03.03
31
Inspection notes
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).
Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.
Check!
Mounting surface - control plate undamaged
Hinweis:
Bohrung bei DA-Regelung offen. (gültig nur bei
A10VG 45).
Information:
Hole for DA-control is open, without DA control valve
it is plugged.
Kontrolle!
Lagerbahnen (1)
Check!
Bearing surfaces (1)
Riefenfrei, keine Einlaufspuren
Free of grooves, no wear.
008 922 51 BOMAG 283

750-01-R/03.03
pump
Gehäuse - Turcon-Glyd-Ring montieren

Assemble housing - Turcon-Glyd-ring
Dichtring in die Montagezange einlegen.
Fit the seal ring into the assembly tool.
Dichtring mit Zangenschenkel nierenförmig

zusammendrücken. Die Verformung von Turcon-
Dichtungen ist sorgfältig vorzunehmen, damit die
Dichtkanten nicht beschädigt werden.
Press the seal ring into the kidney shape using the
assembly tool. The deformation of the Turcon seal
has to be done with care so as not to damage the
sealing edges.
O-Ring in Nut einlegen.

Dichtring ins Gehäuse einführen und in der
Aufnahmenut plazieren. Dann Spannung lösen und
Montagezange herausziehen. Lage des Dicht-
ringes prüfen - eventuell mit dem Finger
egalisieren.
Position the seal ring into the groove.

Position the seal ring into the housing and place it
into the groove. Release the tension and withdraw
the assembly tool. Check the position of the seal
ring if necessary straighten using a finger.
Kalibrieren des Dichtringes mit einem Kalibrierdorn

(Stellkolben) - mit langer Schräge 10o bis 15o.
Calibrate the seal ring using a cylindrical plug gauge

(positioning piston) at an angle of 10o to 15o.
284 BOMAG 008 922 51

RDE 92 750-01-R/03.03
33
Pumpe montieren
Assembly of the pump
Lagerschalenpaar einsetzen.
Insert bearing shells.
Stellkolben ins Gehäuse einsetzen.

Hinweis:
Stellkolben vor Einbau einölen.
Insert positioning piston into the housing.

Instruction:
Oil positioning piston before assembly.
Stellkolben mit Hebel (Id.Nr. 2774491) ausrichten.

* Führung für Gleitstein - Schwenkwiege
Position stroke piston with lever (Id.No. 2774491).

* Sliding stone guidance in the piston.
Lager, Draht, Gleitstein und Gelenkstift montieren.

Montagehilfe: z.B. - Klammer / Gummiringe / Fett
Assemble the bearing, wire, slide ring and joint pin

Assemble aids:
e.g. - clips / rubber rings / grease
Schwenkwiege komplett ins Gehäuse einsetzen.

Auf korrekten Sitz der Schwenklager im Gehäuse
"achten".
Montagehilfe ausbauen.
Insert the swash plate into the housing.

Ensure that the swivel-bearing is correctly located
in the housing.
Remove assembly aid.
008 922 51 BOMAG 285

750-01-R/03.03
pump
Pumpe montieren
Kontrolle: Sitz der Schwenklager in der

Lagerbahn.
Mittig stellen mit Meßvorrichtung (Uhr oder
Tiefenmaß)
Punkt 1 und 2 kontrollieren - gleiches Maß.
Check: Location of the swivel-bearing

in the bearing.
Centralise by using a measuring device (dial gauge
or depth measurement).
Check points 1 and 2 - they should have the same
dimension.
Gelenkstift montieren.
Fit joint pin.
286 BOMAG 008 922 51

RDE 92 750-01-R/03.03
35
Pumpe montieren
Haltevorrichtung montieren.
Mit Gewindestift Schwenkwiege festhalten.
Keine Gewaltanwendung.
Fit holding device.

Hold swash plate in position utilising the set screw.
Do not use force.
Haltevorrichtung "Schwenkwiege" A4V

Holding device "swivel cradle" A4V
Teil/Part 3 Teil/Part 4
∅ ∅
6, 7, 8, 9
∅ ∅
3, 4, 5
∅ ∅
Teil/Part 5
∅
2
∅
1
Pos./Item Benennung/Designation Stck./Qty.

1 Winkel/Angle 2
2 Gewindestift/Threaded pin 2
3 Scheibe/Shim 2
4 Scheibe/Shim 2
5 Scheibe/Shim 2
6 Zyl. Schraube/Cyl. screw M12 x 25 DIN 912 2
008 922 51 BOMAG 287

750-01-R/03.03
pump
Triebwerk einbauen
Installation of the rotary group
Neue Montageposition!
Triebwelle mit Lager und Wellendichtring einbau-
en.
Assemble drive shaft with bearings and radial seal

rings.
Mit Vorrichtung Druckstifte montieren.
Fit pressure pins using an assembly aid.
Feder mit Vorrichtung vorspannen.
Pre-tension the spring using a suitable device.
Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.
Assemble piston with retaining plate.

Note:
Oil piston and piston pad.
288 BOMAG 008 922 51

RDE 92 750-01-R/03.03
37
Triebwerk einbauen HW / HD / EP
Installation of the rotary group HW / HD / EP
Vorrichtung ausbauen.
Zylinder mit Kolben und Rückzugeinrichtung
einbauen.
Remove holding device.

Fit cylinder complete with pistons and
retaining device.
Montagehilfe:
Mit O-Ring Kolben festhalten.
Assembly aid:
Hold the pistons by using an O-ring.
Bei Ausführung mit Verdrillschraube:

Zylinder nach unten drücken - Verdrillschraube
auf Maß x einschrauben.
* Kerbe in Montageposition.
For the version with eccentric screw:

Push the cylinder down - screw in the eccentric
screw in the eccentric screw until dimension x is
reached.
* groove in assembled position.
Fixierstift für Steuerplatte einsetzen.

Bei DA - Ausführung mit Verdrillschraube
ohne Fixierstift.
Fit locating pin for control plate.

For the DA version with eccentric screw without
locating pin.
008 922 51 BOMAG 289

750-01-R/03.03
pump
Triebwerk einbauen HW / HD / EP
Installation of the rotary group HW / HD / EP
Steuerplatte Rechtslauf
* Fixierstift
* Control plate, clockwise rotation
* Locating pin
Steuerplatte Linkslauf
* * Fixierstift
Control plate, anti-clockwise rotation

* Locating pin
Zylinderflächen einölen, neue O-Ringe mit Fett

einreiben und einsetzen.
Oil the cylinder surfaces, grease the new O-rings

and fit into place.
Lagerichtig aufsetzen.
Hinweis:
HW, HD, EP Steuerplatte mit Fett auf
Anschlußplatte.
Place in correct position.

Note:
HW, HD, EP - Locate the control plate on the
connection plate using grease.
290 BOMAG 008 922 51

RDE 92 750-01-R/03.03
39
Triebwerk einbauen DA
Installation of the rotary group DA
Bei Ausführung mit Verdrillschraube:

Zylinder nach unten drücken - Verdrillschraube
auf Maß x einschrauben.
* Kerbe in Montageposition.
For the version with eccentric screw:

Push the cylinder down - screw in the eccentric
screw in the eccentric screw until dimension x is
reached.
* groove in assembled position.
Maß X mit Vorrichtung neu ermitteln.

Zylinder mit Vorrichtung nach unten drücken.
Verdrillschraube bis Anschlag einschrauben -
Maß X - Kerbe in Montageposition drehen.
Re-identify dimension X with device.

Push cylinder down with device.
Screw in eccentric screw till stop - Dimension X -
Turn groove in assembly position.
Ident. Nummer Hilfsvorrichtung/

Ident- No. Auxiliary device
NG / Size 28 = Ι 2 775 075
NG / Size 45 = Ι 2 774 882
NG / Size 63 = Ι 2 775 076
Steuerplatte Rechtslauf mit Verdrillschraube
Control plate, clockwise rotation with eccentric

screw
Max. Einschraubtiefe beachten.

Einstellhinweis beachten
Max. depth - take into account!
Lagerichtig aufsetzen.
Bei DA Steuerplatte auf Zylinderfläche legen.
Place in correct position.

For the DA version, place control plate on the
cylinder surface.
008 922 51 BOMAG 291

750-01-R/03.03
pump
Pumpe montieren
Schrauben über Kreuz anziehen.

Verdrillschraube auf Markierung drehen.
Tighten the screws aross corners.

Turn the eccentric screw until the marker is reached.
Hilfspumpe montieren.
Fit boost pump.
Ansteuergerät mit Dichtung montieren.
Fit control device with seal.
292 BOMAG 008 922 51

RDE 92 750-01-R/03.03
41
Pumpe montieren
Ansteuergerät mit Dichtung montieren.
Fit control device with seal.
Dichtung mit zwei Befestigungschrauben

zentrieren und Ansteuergerät einbauen.
Alle vier Schrauben mit halbem Drehmoment an-
ziehen.
Centre the seal using two fixing screws and fit

the control unit.
Tighten all four screws to half of specified torque.
Fünfte Schraube einsetzen und mit

Drehmoment = 10,4 Nm festziehen.
Restliche vier Schrauben nach Drehmoment
festziehen.
Fit the fifth screw and tighten to a torque

of 10,4 Nm.
Then tighten the other four screws to there
correct torque.
008 922 51 BOMAG 293

750-01-R/03.03
pump
Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques
1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)
Die Werte gelten für Schaftschrauben mit metri- The values stated are valid for bolts with metric
schem ISO-Gewinde nach DIN 13 Teil 13, sowie ISO threads to DIN 13 part 13, as well as head
Kopfauflagemaßen nach DIN 912 Zylinder- areas to DIN 912 socked head cap screws, DIN
schrauben, DIN 931 Sechskantschrauben mit 931 hexagon bolt or DIN 933 hexagon bolts with
Schaft bzw. DIN 933 Sechskantschrauben mit threads up to the head.
Gewinde bis Kopf.
Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240
294 BOMAG 008 922 51

RDE 92 750-01-R/03.03
43

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).
G
EOLASTIC-
Dichtung / Seal
Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300
008 922 51 BOMAG 295

750-01-R/03.03
pump

5. Verschlußschrauben mit Innensechskant, 5. Plugs with internal hexagon, O-ring and UNF-,
O-Ring und UNF-, UN-Gewinde nach SAE J 514 UN- threads to SAE J 514 (nach N 02.106)
(nach N 02.106)
G
O-Ring / O-ring seal
Dichtung / Thread
Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 10
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 35
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390
6. SEAL-LOCK-Dichtmuttern (nach N 02.100) 6. SEAL-LOCK - sealing nuts (to N 02.100)
Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm
M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180
296 BOMAG 008 922 51

RDE 92 750-01-R/03.03
45

A10V - Düsen / orifices
Gewinde / Anziehdremomente Nm /
Thread Tightening torques Nm
bisher / up to neu / new
M6 6,5 3
M10 28 12
008 922 51 BOMAG 297

750-01-R/03.03
pump
Sicherheitsbestimmungen
Safety regulations
Allgemein General advice
● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.
Vor dem Start Before starting
● Beachten Sie die Bedienungshinweise vor dem Starten. ● Observe the operating instructions before starting.
● Prüfen Sie die Maschine auf auffällige Fehler. ● Check the machine for remarkable faults.
● Fahren Sie die Maschine nicht mit defekten Instrumenten, ● Do not operate the machine with defective instruments,
Kontrolleuchten oder Steuerorganen. warning lights or control elements.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. ● All safety devices must be in a secure position.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen ● Do not carry with you movable objects or secure them to the
Sie diese an der Maschine. machine.
● Halten Sie die Maschine von öligem und zündfähigem ● Keep oily and inflammable material away from the machine.
Material frei. ● Before entering thc driver’s cabin, check if personsor
● Prüfen Sie vor dem Besteigen der Maschine, ob sich obstacles are beside or beneath the machine.
Personen oder Hindernisse neben oder unter der Maschine ● Be careful when entering the driver’s cabin, use stairs and
befinden. handles.
● Vorsicht beim Besteigen der Maschine, benützen Sie ● Adjust your seat before starting.
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.
298 BOMAG 008 922 51

RDE 92 750-01-R/03.03
47
Safety regulations
Starten Start
● Beim Starten müssen alle Bedienhebel in “Neutralstellung” ● When starting all operating levers must be in “neutral position”.
stehen. ● Only start the machine from the driver’s seat.
● Die Maschine nur vom Fahrersitz aus Starten. ● Check the indicating instruments after start to assure that all
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um functions are in order.
sicher zu gehen, daß alles ordnungsgemäß funktioniert. ● Do not leave the machine unobserved when the motor is
● Lassen Sie die Maschine nicht unbewacht, während running.
der Motor läuft. ● When starting with battery connection cables connect plus
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus with plus and minus with minus. Always connect mass cable
mit Plus und Minus mit Minus. Massekabel (Minus) immer (minus) at last and cut off at first.
zuletzt anschliesen und zuerst abtrennen.
Vorsicht Attention
● Auspuffgase sind lebensgefährlich. Bei Start in ● Exhaust gas is dangerous. Assure sufficient fresh air when
geschlossenen Räumen für ausreichende Luftzufuhr starting in closed rooms!
sorgen!
Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck- Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. Daher heavy injuries. Therefore immediately consult a doctor as
sofort einen Arzt aufsuchen, da anderenfalls schwere otherwise heavy infections can be caused.
Infektionen entstehen können! 2. When searching leakages use appropriate auxiliary devices
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr because of the danger of accidents.
geeignete Hilfsmittel verwenden! 3. Before working at the hydraulic equipment, lower pressure
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt to zero and lower working arms of the rnachine.
drucklos machen und angebaute Geräte absenken! 4. When working at the hydraulic equipment, absolutely stop
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor motor and secure tractor against rolling away (parking brake,
abstellen und Traktor gegen Wegrollen sichern shim)!
(Feststellbremse, Unterlegkeil)! 5. When connecting hydraulic cylinders and motor pay attention
5. Beim Anschließen von Hydraulikzylindern und -motoren ist to correct connection of hydraulic flexible hoses.
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu 6. In case of exchanging the ports, the tunctions are vice versa
achten! (f. ex. lift-up/lower) - danger of accidents!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen 7. Check hydraulic flexible hoses regularly and replace them in
(z.B. Heben/Senken) - Unfallgefahr! case of dammage or wear! The new hose pipes must comply
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei with the technical requirements of the machine manufacturer!
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen Orderly disposal or recycling of oil, fuel and
des Geräteherstellers entsprechen! filters!
Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!
008 922 51 BOMAG 299

750-01-R/03.03
pump
Einstellhinweise - ND-Ventil (Speisedruck)

Adjustment instructions - Low pressure valve (Boost pressure)
Achtung! Attention!
Sicherheitsbestimmungen beachten! Observe safety regulations!
Hinweis: Note:
Nachjustierung nur bei Betriebstemperatur. Readjusting only at operating temperature.
Manometer an "G" anschließen. Connect pressure gauge to "G".
Achtung! Attention!
* Speisedruckeinstellung! * Boost pressure setting!
Nenndruck pH - 20 bar Nominal pressure pH - 20 bar
Höchstdruck pH - 40 bar Peak pressure pH - 40 bar
Bei Max.-Drehzahl. at max. speed.
Hinweis: Note:
Einstelldaten nach Werksauftrag. Setting data is in accordance to the works order.
* bei DA-Ausführung * with the DA version
60 bar
"G"
*
300 BOMAG 008 922 51

RDE 92 750-01-R/03.03
49
Einstellhinweise - Mechanische "Nullage"

Adjustment instructions - Mechanical "zero position"
HW
alt / old
alt / old
DA
neu / new
HD
neu / new
EP alt / old
neu / new
HW with zero position switch
Achtung!
Sicherheitsbestimmungen beachten!
Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignal
aus hydraulischer Nullage.
Manometer an MA und MB anschließen.
Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Totband der Nullage - vermitteln.
600 bar
Attention!
Observe safety regulations!
Connect both control chambers with a nominal size
600 bar
6 hose. Avoidance of residual signals from hydraulic
zero position.
Connect pressure gauges to MA and MB. Adjust
the zero position so that with at blocked drive both
pressure gauges indicate the same pressure valve.
Note:
Ascertain the zero position dead band.
008 922 51 BOMAG 301

750-01-R/03.03
pump
Einstellhinweise - Hydraulische "Nullage"

Adjustment instructions - Hydraulic "zero position"
HD neu/new Achtung!
HW beachten!
*
* HD alt/old Attention!
*
*
*
HW with zero position switch EP alt/old
EP neu/new
60 bar
60 bar
Manometer (60 bar) an X1 und X2 anschließen.

* Nullage so einstellen, daß bei blockiertem
Antrieb beide Manometer auf gleichem Druck-
wert stehen.
Hinweis:
Excenterjustierung - nicht über ± 90° verdrehen.
Connect pressure gauges(60 bar) to X1 and X2.

* Adjust the zero position so that with a block
drive both pressure gauges indicate the same
pressure value.
Note:
Eccentric adjusting - Do not turn more than ± 90°.
302 BOMAG 008 922 51

RDE 92 750-01-R/03.03
51
Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung

Adjustment instructions - HP- valves (High pressure) and pressure cut-off
Achtung!
HD-Ventil ohne Bypass
Druckabschneidung 1. HD-Ventile sind immer 10% höher eingestellt als die

Pressure cut-off 2 Druckabschneidung.
1 2. Nachjustierung nur bei Betriebstemperatur
Manometer (600 bar) an MA und MB anschließen.
Druckabschneidung:
Zum Blockieren der Druckabschneidung beim Überprüfen
der Hochdruckventile die Einstellschraube Pos. 1 mit
gelöster Kontermutter Pos. 2 bis zum Anschlag mit
max. 2 Nm im drucklosen Zustand eindrehen!
HD-Ventile: Mit geringer Pumpenmenge über Ventile fahren.

Einstellwert kontrollieren.
(Nur kurzzeitig "Temperatur“.)
Einstellwert verändern - siehe Serviceinfo
Druckabschneidung:
Einstellschraube auf Maß (*) zurückdrehen.
Druckwert kontrollieren bzw. nachjustieren.
Achtung! Differenz von 10% HD-Ventile und
Druckabschneidung beachten!
Hinweis: Einstelldaten nach Werksauftrag.
Attention!
Observe safety regulations.
HD- Ventile
HP- valves
HP valve without bypass-function
1. HP valves are always adjusted 10% higher than the
pressure cut-off.
2. Readjusting only at operating temperature.
Connect pressure gauge (600 bar) to MA and MB.
Pressure cut-off:
To block the pressure cut-off when testing the high
pressure valves, the adjustment screw (item 1), with the
lock-nut (item 2) loosened, has to be screwed in
with a max. torque of 2 Nm in the depressurised condition
until the end stop is reached.
HP valves: Operate the valves with small pump flow over the
valves.
Check setting value. (only for a short time "temperature“).
Change setting value - see service information.
Pressure cut-off:
Turn back setting screw to measurement (*).
Check pressure value and readjust if necessary.
Attention! Observe the 10% pressure difference
between the HP valves and the pressure cut-off!
Note: Setting data is in accordance with the works order.
008 922 51 BOMAG 303

750-01-R/03.03
pump
Einstellhinweise - Bypassventil HW, HD, EP

Adjustment instructions - Bypass valve HW, HD, EP
1
1
Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit hydro- Vehicle with a pure hydrostatic transmission or with a hydrostatic
statischem Fahrantrieb und Schaltgetriebe ohne Leerlaufstellung drive with gear box without free wheel position.
(Freilauf).
Hydrostatic transmission / Bypass condition
Hydrostatischer Antrieb / Bypaß-Schaltung
In this case the travel drive is switched on to the free wheel
In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. position. For this purpose the high pressure valves of the variable
Zu diesem Zweck haben die in der Verstellpumpe integrierten displacement pump have a so-called bypass function.
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion. By turning the relevant screw (item 1) the valve is so released
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird that free oil circulation is made possible.
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich Bypass: Screw in item1 until it is level with the nut.
ist.
Bypass: Pos.1 einschrauben bis eben mit Mutter. Towing speed
Mutter wieder anziehen. The max. towing speed of 2 km/h should not be exceeded.
● Higher permissible speeds are depended on the hydraulic
Schleppgeschwindigkeit motor speed or the selected gear.
Die maximale Schleppgeschwindigkeit sollte 2 km/h nicht
überschreiten. Towing distance
● Höhere zulässige Schleppgeschwindigkeiten The towing distance should not exceed 1 km.
sind abhängig von der Hydromotordrehzahl
bzw. dem eingelegten Gang. ● With no boost avaiable the hydraulic circuit drains.
The heat generation in the hydraulic motor rotary group
Abschleppdistanz has to be taken into account.
Die Schleppentfernung sollte 1 km nicht überschreiten.
● Bei fehlender Einspeisung entleert sich der Termination of the towing operation
Hydraulik-Kreislauf. After termination of the towing operation turn back item 1.
Zu beachten ist die Wärmeentwicklung im The original set pressure value is thereby avaiable.
Hydromotor-Triebwerk. Valve function: Screw back item 1 up to stop.
Screw up the nut.
Abschleppvorgang beendet
Nach beendetem Abschleppvorgang Pos.1 zurückdrehen.
Der ursprüngliche Einstellwert der Hochdruckventile liegt somit
wieder vor.
Ventilfunktion: Pos.1 zurückschrauben bis
Anschlag. Mutter anziehen.
304 BOMAG 008 922 51

RDE 92 750-01-R/03.03
53
Einstellhinweise - Bypassventil DA
Adjustment instructions - Bypass valve DA
A10VG 28-45 Bypass: Pos.1 einschrauben bis Schraube am Federteller

DA-Control anliegt.Schraube maximal 1/2 Umdr. weiterdrehen!
Bypass: Screw in item 1 until contact, max 1/2 turn more.
Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit hydro-

statischem Fahrantrieb und Schaltgetriebe ohne Leerlaufstellung
(Freilauf).
Hydrostatischer Antrieb / Bypaß-Schaltung Vehicle with hydrostatic transmission and gear shift without idling
In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. setting position (free wheeling).
Zu diesem Zweck haben die in der Verstellpumpe integrierten Hydrostatic transmission / Bypass-switching
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion. In this case the travel transmission is switched on to free
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird wheeling.For this purpose the variable displacement pump has
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich incorporated high pressure relief valves with bypass function.
ist. The screw (item 1) is unscrewed to such an extent, that the valve
Bypass: Pos.1 einschrauben bis Schraube am cartridge is released and free oil circulation is possible.
Federteller anliegt.
Maximal 1/2 Umdrehung weiter drehen. Bypass: Screw in item1 until contact,
Max. 1/2 turn more.
Schleppgeschwindigkeit
Die maximale Schleppgeschwindigkeit sollte 2 km/h nicht
überschreiten. Towing speed
● Höhere zulässige Schleppgeschwindigkeiten sind The max. towing speed of 2 km/h should not be exceeded.
abhängig von der Hydromotordrehzahl bzw. dem ● Higher admissible towing speeds depend on the avaiable
eingelegten Gang. hydr. motor speed and engaged gear shift.
Abschleppdistanz Towing distance

Die Schleppentfernung sollte 1 km nicht überschreiten. The towing distance should not exceed 1 km.
● Bei fehlender Einspeisung entleert sich der Hydraulik- ● If there is a lack of oil boosting, the hydraulic circuit will get
Kreislauf. empty.
Zu beachten ist die Wärmeentwicklung im Hydromotor- Take care of the heat development in the hydr. motor-rotary
Triebwerk. group.
Abschleppvorgang beendet Towing operation terminated

Nach beendetem Abschleppvorgang Pos.1 zurückdrehen. Der After termination of the towing operation turn item 1 back. The
ursprüngliche Einstellwert der Hochdruckventile liegt somit original pressure value setting of the high pressure relief valves
wieder vor. will be avaiable again.
Ventilfunktion: Pos.1 zurückschrauben bis Anschlag. Valve function: Screw back item 1 up to stop.
Mutter anziehen. Screw up the nut.
008 922 51 BOMAG 305

750-01-R/03.03
pump
Einstellhinweise - DA- Regelung

Adjustment instructions - DA control
Achtung!
Überprüfung der Einstelldaten

Betriebstemperatur soll während des Über-
prüfungsvorgangs weitgehend konstant gehalten
werden.
Antriebsmotor starten, Leerlaufdrehzahl
Blockzustand
Fahrtrichtungsschalter "0“
Motordrehzahl langsam steigern bis zur max.
Motordrehzahl, dabei Meßgeräte beobachten.
Speisedruck:
Leerlaufdrehzahl
Psp = ca. 15-20 bar
max. Motordrehzahl
Psp = . . . . . . . . bar*
Blockzustand
Fahrtrichtungsschalter - vorwärts
(Straßengang und Festgebremst)
*
Einstelldaten Pumpe A10V/DA überprüfen
* Regelbeginn
HD 40 - 50 bar
Motordrehzahl . min.1 * Psp . . . . . bar*
HD . . . . . . bar
Nachjustierung - Regelbeginnschraube
Regelende
Verdrillung Regelbeginn
HD . . . . . bar*
Motordrehzahl . . . . . min.1 * Psp . . . . . bar*
Nachjustierung - Verdrillschraube
Hinweis:
Excenterjustierung - Drehrichtung beachten
Hinweis: * Einstelldaten nach Werksauftrag!
306 BOMAG 008 922 51

RDE 92 750-01-R/03.03
55
Einstellhinweise - DA- Regelung

Adjustment instructions - DA control
Attention!
Check setting data.

Operating temperature should be generally kept
constant during the checking procedure.
Start prime mover, idle speed.
Block position
Drive direction switch - "0“.
Slowly increase motor speed up to the max. motor
speed and observe measuring instruments.
Boost pressure:
Idle speed of prime mover
Psp = approx. 15 - 20 bar
max. motor speed
Psp = . . . . . . . . . bar*
Block position
* Drive direction switch - forwards
(Road gear and fully applied brake)
Check setting data pump A4VIDA

* Start of control:
HD 40 - 50 bar
Motor speed . . . . . rpm* Psp . . . . . . . bar*
HD . . . . . . . bar*
Readjustment of start of control screw
Begin of control
End of control
Timing HD . . . . . . . . bar
adjustment screw Motor speed . . . . . . rpm* Psp . . . . . . . bar*
Readjustment of the indexing screw
Note:
Eccentric adjusting - observe direction of
rotation.
Note: * Setting data is in accordance to the

order work!
008 922 51 BOMAG 307

13.1 Travel pump
Brueninghaus Hydromatik GmbH

Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm@boschrexroth.de
www.boschrexroth.com/brm
© 2003 by Brueninghaus Hydromatik © 2003 by Brueninghaus Hydromatik

GmbH, 89275 Elchingen GmbH, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Brueninghaus Hydromatik GmbH
any form or by any means, without the reproduziert oder unter Verwendung
prior written authorization of Bosch elektronischer Systeme gespeichert,
Rexroth AG. In the event of verarbeitet, vervielfältigt oder verbreitet
contravention of the above provisions, werden. Zuwiderhandlungen
the contravening party is obliged to verpflichten zu Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist zu
remembered that our products are beachten, dass unsere Produkte einem
subject to a natural process of wear natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.
Printed in Germany
RDE 92 750-01-R/02.03
308 BOMAG 008 922 51

13.2 Travel motor
008 922 51 BOMAG 309

13.2 Travel motor
310 BOMAG 008 922 51

Travel motor 13.2
Moteurs hydrauliques
MK
Hydraulic motors
Réparations
Repairs
05 08 09 11 18
MK
(MC05) (MC08) (MC11) (MC18)
MKE
(MC23)
Dépannage
Trouble shooting
Interventions
Maintenance
Réparations
Repairs
Pièces de rechange
Spare parts
POCLAIN HYDRAULICS Industrie

Ref : 800078181E B.P. 106
60411 Verberie Cedex – France
DOC-REPAIR-MK05-MKE18-FR-EN
Tel. : 33 3 44 40 77 77
Rev : 15/09/2006 Fax : 33 3 44 44 77 99
www.poclain-hydraulics.com
008 922 51 BOMAG 311

13.2 Travel motor
POCLAIN HYDRAULICS
Ce document s'adresse aux constructeurs des machines qui intègrent This document is provided to machine manufacturers integrating
les produits POCLAIN-HYDRAULICS. II préconise les processus POCLAIN-HYDRAULICS products.. It suggests processes that
que les constructeurs peuvent mettre en œuvre pour réparer ces manufacturers may utilize to repair products after the warranty period.
produits à l'issue de la période de garantie.
Il est recommandé que toutes les opérations soient effectuées par

des techniciens ayant bénéficié de la formation adéquate. Les It is recommended that all operations be performed by technicians
techniciens doivent avoir lu et compris les informations figurant dans trained accordingly. The technicians should read and understand the
ce document et avoir été habilités par le constructeur de la machine. information given in this document and be authorised by the machine
Ces techniciens devront impérativement observer les directives de manufacturer.
sécurité et de protection contre les accidents. It is essential that the technicians comply with safety instructions to
prevent injury.
Ce document inclut des remarques importantes concernant la
sécurité. Elles sont mentionnées de la manière suivante: This document includes major safety warnings announced in this way:
! Remarque de sécurité.
! Safety warning.
Ce document inclut également des instructions essentielles au Additionally, this document includes instructions essential to product
fonctionnement du produit ainsi que des informations générales. Elles function as well as those providing general information. Both are
sont mentionnées de la manière suivante: announced similar to the following examples:
Instruction essentielle. Essential instruction.
Information générale. General information.
POCLAIN HYDRAULICS est concepteur de produits que ses clients POCLAIN HYDRAULICS designs products that are integrated by its
intègrent aux machines qu'ils conçoivent. De ce fait, POCLAIN customers in the machines they design. Subsequently POCLAIN
HYDRAULICS ne peut être tenu pour responsable des HYDRAULICS disclaims liability for consequences of improper
conséquences liées à la mauvaise intégration de ses produits, ni des integration of its products and of improper set-up of adjustable
conséquences pouvant résulter du mauvais paramétrage de leurs devices. In the same way, POCLAIN HYDRAULICS may not be liable
dispositifs réglables. De la même manière, POCLAIN HYDRAULICS for incomplete or improper operating and maintenance instructions
ne peut être tenu pour responsable d'instructions d'utilisation et de provided to the end user by the machine manufacturer nor for failures
maintenance erronées ou incomplètes qui auraient été resulting from operations performed by any person using these
communiquées par les constructeurs de machines aux utilisateurs suggested procedures.
finaux ni d'incidents qu'aurait engendrés quiconque ayant appliqué
les processus préconisés dans ce document. A re-certification of the machine may be required for every change in
Toute modification de paramétrage des dispositifs réglables peut set-up of adjustable devices.
nécessiter une nouvelle homologation des machines.
In order to offer the best quality service, POCLAIN HYDRAULICS
Dans le but d’offrir le meilleur service, POCLAIN HYDRAULICS recommends to its customers to have applications approved by
recommande à ses clients de lui faire approuver chaque application. POCLAIN HYDRAULICS.
Opening of products voids the warranty contract.
L'ouverture des produits conduit à la perte de la garantie. N'utilisez Use only POCLAIN HYDRAULICS genuine spare parts. Using parts
que des pièces de rechange d'origine POCLAIN HYDRAULICS. Le from different sources could reduce the performance of the product
montage de pièces d'origine différente pourrait nuire au and pose a safety hazard..
fonctionnement du composant et du système et à la sécurité.
In accordance with its policy of continuous improvement, POCLAIN
Soucieux d’améliorer ses fabrications, POCLAIN HYDRAULICS se HYDRAULICS reserves the right to modify the specifications of all
réserve le droit d’apporter sans préavis, toutes les modifications qu’il products described herein without prior notice.
jugerait utile aux produits décrits dans ce document.
This document contains sections written in French and sections
Ce document contient des sections en langue Française et des printed in italics composing the English translation of the French
sections imprimées en italique constituant leur traduction en langue sections.
Anglaise. En cas de contestation, les sections en langue Française The French sections will be the reference in case of dispute.
feront foi. Les mesures sont exprimées en unités métriques. Les All measures are expressed in metric units. Converted values to other
correspondances à d’autres systèmes de mesure (notamment anglo- systems (notably US and UK) are given for reference only.
saxons) sont données à titre indicatif.
¤ POCLAIN HYDRAULICS Industrie 1998.
¤ POCLAIN HYDRAULICS Industrie 1998. The trademark POCLAIN HYDRAULICS is the property of POCLAIN
La marque POCLAIN HYDRAULICS est la propriété de POCLAIN HYDRAULICS S.A.
HYDRAULICS S.A. This document is the property of POCLAIN HYDRAULICS Industrie.
Ce document est la propriété de POCLAIN HYDRAULICS Industrie. It is strictly confidential. It must not be used, duplicated, copied or
Il est strictement confidentiel. Il ne doit pas être utilisé, reproduit, disclosed to a third party in full or in part without our prior written
copié ou divulgué à un tiers en totalité ou en partie sans notre accord consent.
écrit préalable.
FACOM is FACOM SA. registered trademark
FACOM est une marque déposée de FACOM SA LOCTITE is LOCTITE SA. registered trademark
LOCTITE est une marque déposée de LOCTITE SA. AUTO-TOP is AGIP SPA. registered trademark
AUTO-TOP est une marque déposée de AGIP SPA.
2 DOC-REPAIR-MK05-MKE18-FR-EN 800078181E
312 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Sommaire Contents
SÉCURITÉ ET QUALITÉ......................................................................................4 SAFETY AND QUALITY.......................................................................................4
AVANTTOUTEINTERVENTION......................................................................................4 BEFORESERVICING .......................................................................................................4
DURANTL'INTERVENTION.............................................................................................4 DURINGSERVICING........................................................................................................4
APRÈSINTERVENTION...................................................................................................4 AFTERSERVICING...........................................................................................................4
IDENTIFICATIONDESCOMPOSANTS ...........................................................................5 IDENTIFICATIONOFTHECOMPONENTS......................................................................5
EVOLUTION DES DÉSIGNATIONS DES MOTEURS MC...5 DESCRIPTION CHANGE OF THE MC MOTORS...................................5
CONTRÔLEDEL’EFFICACITÉDUFREINDEPARKING...............................................6 CHECKINGTHEPARKINGBRAKEEFFICIENCY...........................................................6
INTERVENTION........................................................................................................7 MAINTENANCE........................................................................................................7
REMPLACEMENT DUMOTEUR.....................................................................................7 REPLACINGOFTHEMOTOR.........................................................................................7
Dépose ........................................................................7 Removal ...................................................................... 7
Repose ........................................................................7 Reinstallation............................................................... 7
DÉPANNAGE.............................................................................................................8 TROUBLE SHOOTING..........................................................................................9
DÉFREINAGEMÉCANIQUE..........................................................................................16 MECHANICALBRAKERELEASE..................................................................................16
DÉFREINAGEÀLAGRAISSE........................................................................................17 BRAKERELEASEUSINGGREASE ..............................................................................17
REPARATIONS.......................................................................................................18 REPAIRS.....................................................................................................................18
REMPLACEMENT DUJOINTDEPISTONDEFREIN...................................................18 REPLACINGOFTHEBRAKEPISTONO-RING...........................................................18
Démontage................................................................18 Disassembly..............................................................18
Remontage................................................................20 Reassembly ..............................................................20
Frein MK09................................................................23 Brake MK09 ..............................................................23
MOTEUR MK08 REMPLACEMENT DE LA BAGUE D’ÉTANCHÉITÉ (118)..40 MK08 MOTORREPLACINGOFTHESEALINGRING(118)....................................40
REMPLACEMENT DEL'ÉTANCHÉITÉRENFORCÉE.................................................42 REPLACINGOFTHEREINFORCEDSEAL..................................................................42
MOTEURS MK05 MK08 ...........................................42 MK05 MK08 motors ..................................................42
MOTEUR MK09 ........................................................44 MK09 MOTOR ..........................................................44
MOTEURS MK11 MK18 MKE18 ..............................49 MK11 MK18 MKE18 motors .....................................49
MK05 MK11 REMPLACEMENTDEL’ENSEMBLEBLOC-CYLINDRES- CAME.54 MK05 MK11 REPLACEMENTOFTHECYLINDER-BLOCK- CAMASSEMBLY..54
MK09 REMPLACEMENTDEL’ENSEMBLEBLOC-CYLINDRES- CAME...............64 MK09 REPLACEMENT OF THE CYLINDER-BLOCK - CAM ASSEMBLY 64
MK18, MKE18 : REMPLACEMENT DU BLOC-CYLINDRES OU DE LA CAME 66 MK18, MKE18: REPLACE-MENTOFCYLINDER-BLOCKORCAM ....................66
REMPLACEMENT DELAGLACE(047) MK05 - MK08 - MK09........................69 REPLACEMENTOFTHEVALVING(047) MK05 – MK08 – MK09...................69
REMPLACEMENT DELAGLACE(047) MK11-MK18..........................................74 REPLACEMENTOFTHEVALVING(047) MK11-MK18........................................74
REMPLACEMENT DUCAPTEUR(OPTION)................................................................77 REPLACINGOFTHESENSOR(OPTIONAL)...............................................................77
REMPLACEMENT DUNOUVEAUCAPTEUR..............................................................78 REPLACINGOFTHENEWSENSOR............................................................................78
RÉCAPITULATIF OUTILLAGE.......................................................................79 TOOLING INVENTORY.......................................................................................79
Outillage standard .....................................................79 Standard tools ...........................................................79
Outillage à réaliser ....................................................80 Special tools..............................................................80
COUPLES DE SERRAGE STANDARDS EN N.M ± 10%84 STANDARD TIGHTENING TORQUES IN [LBF.FT] ± 10%..............84
RÉSUMÉ DES COUPLES DE SERRAGE................................................85 TIGHTENING TORQUE SUMMARY............................................................85
PIÈCES DE RECHANGE...................................................................................87 SPARE PARTS........................................................................................................87
PLANCHE PIÈCES DE RECHANGE...........................................................90 EXPLODED VIEW..................................................................................................90
800078181E DOC-REPAIR-MK05-MKE18-FR-EN 3
008 922 51 BOMAG 313

13.2 Travel motor
POCLAIN HYDRAULICS
Sécurité et Qualité Safety and Quality

Avant toute intervention Before servicing
x Prendre toutes les dispositions de sécurité x Be extremely careful to prevent personal injury and
nécessaires (hommes et matériel) en se conformer to avoid damage to material. Comply with all safety
aux réglementations de sécurité en vigueur. regulations.
x Engager le frein de parking et immobiliser la x Apply the parking brake and prevent the machine
machine avec des cales. from rolling with tire blocks.
x Stopper le générateur d'énergie (moteur) du système x Stop the hydraulic system power source (engine)
hydraulique et déconnecter l'alimentation électrique. and disconnect the battery.
x Le cas échéant, délimiter le périmètre de sécurité. x If necessary, block off the safety area.
x Nettoyer l'extérieur des composants pour en retirer x Wash dirt and grease from exterior of the
toute trace de boue et de graisse. components.
x Attendre le refroidissement et la dépressurisation x Await the complete cooling down and
complète du système hydraulique (décharger les depressurization of the hydraulic system
accumulateurs). (accumulators must be purged).
L'huile chaude ou sous pression peut Hot or pressurized hydraulic fluid may cause
! provoquer des brûlures graves avec infection.
Consulter un médecin en cas d'accident.
! serious burns & infections to the human body.
Consult a physician in case of accident.
Durant l'intervention During servicing

x Certains composants sont très lourds. Les soutenir x Some hydraulic components are very heavy. Secure
au moyen d'un dispositif de levage de capacité them with a lifting device of adequate capacity when
adéquate pour les déposer du châssis. removing from the machine frame.
x La propreté est essentielle au fonctionnement des x Cleanliness is essential to functioning of the
composants hydrauliques. La plupart des pièces hydraulic components. Most of the parts may be
peuvent être nettoyées au moyen d'un solvant propre. cleaned with a clean solvent.
x Durant les manutentions, protéger toutes les surfaces x During handling, protect all sensitive surfaces from
sensibles contre les chocs (centrages, parties frottantes, shocks (piloting and interface surfaces, thrust &
appuis, portées des joints et des roulements, etc...). bearings surfaces, seal races, etc...)
x Nettoyer ces surfaces avant remontage. x Clean up these surfaces before reassembling.
x Toujours remonter des joints neufs en éliminant x Always install new O-rings, seals & gaskets
systématiquement les joints démontés. Nous discarding the old ones. We recommend to lubricate
recommandons de graisser tous les joints avant all seals before assembling.
montage.
x Huiler toutes les surfaces frottantes en y déposant un film x Lubricate all surfaces which have relative motion
de fluide hydraulique propre qui assurera une lubrification between parts by coating them with a film of clean
correcte lors du premier (re)démarrage. hydraulic fluid to assure lubrication at first start.
x Ne jamais chauffer le fluide hydraulique qui peut x Never heat hydraulic fluid, as it may flame at high
s'enflammer à haute température. Certains solvants temperature. Some solvents are also flammable.
sont également inflammables. Ne pas fumer durant Do not smoke during servicing.
l'intervention.
Après intervention After servicing
Réinstaller les composants et remettre le système Reinstall the components and restart the hydraulic
hydraulique en service selon les instructions figurant system according to instructions defined in the following
dans les documents suivants: documents:
x INSTALLATION MK F/GB (ref.677777846M) x INSTALLATION MK F/GB (ref. 677777846M)
x INSTALLATION CIRCUITS F/GB (ref. 677777831V) x INSTALLATION CIRCUITS F/GB (ref. 677777831V)
! Ne pas surtarer les soupapes de sécurité. ! Do not overset relief valves
314 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Identification des composants Identification of the components
B
A
MK05-5-12E-K05-1340-A000
006743787D
141 7572
C D
A : Désignation commerciale A: Commercial description:
Ex : MK05-5-12E-K05-1340-A000 E.g : MK05-5-12E-K05-1340-A000
B : Code : Code Article B: Code: Part number.

E.g : 006743787D
Ex : 006743787D
C: Series: Manufacturing batch number.
C : Série : Numéro de fabrication
E.g : 141
Ex : 141
D: Num.: Chronological serial number.
D : Num. : Numéro d’ordre chronologique
E.g : 7572
Ex : 7572
The part number and the chronological

Le Code article et le numéro dordre
serial number must be specified to order
doivent être indiqués pour toute
spare parts.
commande de pièces de rechange.
Evolution des désignations des Description change of the MC

moteurs MC. motors.
ÉTAIT WAS DEVIENT BECOME

MC05 MK05
MC08 MK08
MC11 MK11
MC18 MK18
MC23 MKE18
008 922 51 BOMAG 315

13.2 Travel motor
POCLAIN HYDRAULICS
Contrôle de lefficacité du frein de parking Checking the parking brake efficiency

Les opérations de contrôle doivent être effectuées The verifications should be accomplished with the
moteur monté sur l'engin. motor mounted on the machine.
Pression d'alimentation du frein Brake supply pressure
Moteurs Frein Pression (bar) Pressure [PSI]

Motors Brake Mini Maxi
MK05 F04 12 [174] 30 [435]
MK05 K05 12 [174] 30 [435]
MK05 F07 18 [261] 30 [435]
MK08 F08 14 [203] 30 [435]
MK09 F08 14 [203] 30 [435]
MK11 F11 12 [174] 30 [435]
MK18 F12 F19 12 [174] 30 [435]

MKE18
x Brancher les manomètres : x Connect pressure gauges :
x 0 - 400 bar : sur chaque tuyauterie x 0 - 400 bar [0 - 5801 PSI] : on each motor
d'alimentation du moteur. supply line.
x 0 - 100 bar : sur la tuyauterie de pilotage du x 0 - 100 bar [0 - 1450 PSI] : on the brake release
défreinage. pilot line.
x (Moteurs MK18 MKE18) effectuer la purge du x (MK18 MKE18 Motors) purge the brake using
frein par la vis (112) située au niveau le plus haut, the screw (112) located at the highest level
x S'assurer que la pression d'alimentation du frein est x Make sure that the brake supply pressure is
nulle. zero.
x Alimenter le moteur et lire la pression à laquelle x Feed the motor with fluid and read the pressure
le moteur commence à tourner en faisant varier la at which the motor starts turning, make vary the
pression par la soupape de sécurité du circuit ou pressure by means of the circuit safety valve or
régulateur. regulator valve.
La différence de pression entre les deux branches The difference in pressure between the two supply lines
d'alimentation du moteur doit être au minimum égale à of the motor must be at least equal to 350 bar
350 bar (cylindrée 447 cm3). Si cette valeur n'est pas [5076 PSI] (447 cm3 [27.27 cu.in] displacement). If this
atteinte, il est nécessaire de consulter un centre value is not reached it is necessary to consult a repair
technique de rénovation pour remplacer le frein. center to change the brake.
!
Les freins multidisques ne doivent pas
être rodés ! Do not run in multidisc brakes
Lorsque le frein a été utilisé en frein de sécurité, When the brake has been used as a security brake, (to
(immobilisation de l'engin en cas de rupture de immobilize the machine in case of leaks on high
tuyauterie haute pression) il est impératif de procéder à pressure piping) it is essential to overhaul the brake.
la révision du frein. (frein à disques ou crabots) (Disc or clutch brake)
316 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
INTERVENTION MAINTENANCE
Remplacement du moteur Replacing of the motor
Dépose Removal
x Éliminer la pression dans le circuit d'alimentation. x Release the pressure in the supply lines.
x Débrancher la tuyauterie de drainage au niveau x Disconnect the drain lines at the tank level to
du réservoir afin d'éviter le siphonnage de celui-ci. avoid its siphoning.
x Débrancher et boucher les tuyauteries ou x Disconnect and plug the pipes or hoses which
flexibles raccordés sur le moteur. are connected to the motor.
x Débrancher le connecteur du capteur tachy x Disconnect the speed sensor
x Démonter les vis de fixation, puis déposer le x Disconnect the mounting screws, and remove
moteur. the motor.
x Vidanger le carter. x Drain the casing.
Repose Reinstallation
x Contrôler l'état du plan de fixation. x Check the condition of the motor’s mounting
surface.
x Mettre en place le moteur x Position the motor.
x Monter et serrer les vis de fixation. (voir tableau) x Install and tighten the mounting screws.(see table)
x Rebrancher le connecteur du capteur tachy (option) x Reconnect the speed sensor (optional).
x Déboucher et rebrancher les tuyauteries ou x Remove the plugs and reconnect the pipes or
flexibles sur le moteur. hoses to the motor.
x Rebrancher la tuyauterie de drainage au niveau du x Reconnect the drain line at the tank level.
réservoir.
x Procéder au remplissage du carter. x Fill the casing.
Veuillez vous reporter aux documentations suivantes : Please refer to the following documentation brochures :
x INSTALLATION MK F/GB (ref. 677777846M) x INSTALLATION MK F/GB (ref. 677777846M)
x INSTALL GENERIQUE F (ref. 801478127K) x INSTALL GENERIQUE GB (ref. 801478197L)
Couple de serrage (1) Tightening torque (2) ± 10%

Moteurs Motors cl 10.9 cl 12.9
N.m lbf.ft N.m lbf.ft
MK05 (7 x M16) 300 222 350 260
MK08 (9 x M16) 300 222 350 260
Le nombre et la taille des vis
MK09 (M12) dépendent de la plaque client 120 88.5 230 170
(M12 ou M16)
The number and the size of the
MK09 (M16) screws depend on the plate 300 222 350 260
customer (M12 or M16)
MK11 (8 xM16) 300 222 350 260
MK18 MKE18 (8 xM20) 580 428 690 509
(1) (2)
Les couples de serrage sont donnés à titre indicatif Tightening torques are given for information only.
008 922 51 BOMAG 317

13.2 Travel motor
POCLAIN HYDRAULICS
DÉPANNAGE
Le moteur est bruyant
Moteur bruyant
OUI OUI
Moteur bruyant Ronronnement régulier : Remplacer
à vide palier usagé le palier
NON
Vibrations : OUI
Resserrer
NON desserrage des fixations
au couple
et/ou des tuyauteries
OUI OUI
Moteur bruyant Claquements : pression Tarer la soupape
en charge de gavage faible de contre-pression
NON
OUI Remplacer le
Cavitation : fuites internes
trop importantes bloc-cylindres et
la distribution
318 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
TROUBLE SHOOTING
The motor is noisy
Noisy motor
YES YES
Motor is noisy Regular rumbling : Replace the
without load worn bearing support bearing support
NO
Vibrations : mountings YES

NO and/or hydraulic piping Tighten to
become loose torque
YES YES
Motor is noisy Clattering : boost Set the counter-
under load pressure too low pressure valve
NO
YES Replace the

Cavitation: excessive
cylinder-block and
internal leaks
valving assembly
008 922 51 BOMAG 319

13.2 Travel motor
POCLAIN HYDRAULICS
Le moteur ne tourne pas
Le moteur ne
tourne pas
OUI
Le moteur n’est Contrôler l’entraînement de
pas alimenté la pompe et son alimentation
NON
OUI
Le circuit ne monte Contrôler l’état de la soupape
pas en pression de sécurité (régulateur)
NON
OUI
Fuites internes Remplacer le bloc-cylindres
trop importantes et la distribution
NON
OUI
Le frein reste Contrôler le circuit de
serré pilotage du frein
320 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
The motor does not revolve
The motor does

not revolve
YES
No flow to Check the pump drive
the motor and pump inlet
NO
The circuit does YES

Check the safety valve
not reach working
condition (regulator)
pressure
NO
YES
Excessive internals Replace the cylinder-block
leaks and valving assembly
NO
YES
The brake reminds Check the brake pilot circuit
engaged
008 922 51 BOMAG 321

13.2 Travel motor
POCLAIN HYDRAULICS
Le moteur ne tourne pas à sa vitesse normale en charge
Le moteur ne tourne
pas à sa vitesse
normale en charge
OUI
Le débit de la pompe Contrôler la vitesse
est insuffisant d’entraînement de la pompe
NON
La pression de OUI Contrôler le tarage de

fonctionnement est la soupape de sécurité
trop faible (régulateur)
NON
Mauvais OUI
fonctionnement du Contrôler le circuit d’échange
circuit d’échange
NON
OUI
322 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
The motor does not revolve at its normal speed under load
The motor does not

revolve at its normal
speed under load
YES
Pump flow is Check the pump drive speed
too low
NO
YES
Working pressure Check the safety valve
is too low setting pressure (regulator)
NO
YES
Bad working of the Check the replenishing circuit
replenishing circuit
NO
YES
008 922 51 BOMAG 323

13.2 Travel motor
POCLAIN HYDRAULICS
Le moteur tourne irrégulièrement
Le moteur tourne
irrégulièrement
OUI
Le débit de la pompe Contrôler le débit
est irrégulier de la pompe
NON
OUI
Le moteur fuit
Le moteur fuit
OUI
La pression du carter Contrôler le circuit de
est trop élevée drainage et l’état du filtre
NON
OUI
Les joints sont Remplacer les joints
détériorés
NON
OUI Contrôler le serrage des vis

Le montage
est défectueux d’assemblage, des vis de
purges et des raccordements
324 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
The motor revolves irregularly
The motor revolves

irregularly
YES
Pump flow is Check the pump flow
irregular
NO
YES
The motor leaks
The motor leaks
The housing YES

Check the drain circuit
pressure is
and filter condition
too high
NO
YES
The seals are Replace the seals
deteriorated
NO
YES Check tightening of mounting

The assembly
screws, bleed screws
is incorrect
and hydraulic fittings
008 922 51 BOMAG 325

13.2 Travel motor
POCLAIN HYDRAULICS
Défreinage mécanique Mechanical brake release

(pour le moteur MK08, MK09 et (For the MK08, MK09 and MK05
MK05 Axial, et MK11 passage Axial, and MK11 hollow shaft
central voir le défreinage à la motors see the brake release
graisse). using grease).
Dans certain cas de dépannage, il Under certain service situations, it

peut être nécessaire que le moteur may be necessary to release the
soit défreiné, pour cela effectuer les motor brake. To achieve this,
opérations suivantes : perform the following operations:
Freins standards (F04 F07 - F11 Standard brakes (F04 - F07 - F11 -
- F12 F19) F12 – F19).
x Extraire le bouchon (142) de la x Remove the plug (142) from the
coiffe (141). cover (141).
x Serrer la vis dans le piston. x Tighten the screw in the piston.
x Serrer l'écrou jusqu'à ce que x Tighten the nut until the shaft
l'arbre tourne librement. turns freely
Après défreinage, monter un After brake release, install a new

bouchon (142) neuf. plug (142).
326 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Défreinage à la graisse Brake release using grease

C
Lorsque l'accessibilité du frein ne When lack of access prevents
permet pas le défreinage mécanique, mechanical brake release, it is D
il est possible d'utiliser une pompe à possible to use a normal grease
graisse d'usage courant en pump (grease gun), while taking the B
respectant les précautions suivantes : following precautions.
La pression maximum It must be possible to check the A
d'alimentation du frein doit pouvoir maximum supply pressure to the
être contrôlée pendant l'opération, brake during the operation. Install a
prévoir un manomètre 0 - 40 bar. 0 - 40 bar [0 - 580 PSI] pressure Moteurs MK05 MK08
gauge . MK05 MK08 motors
Après avoir débranché After disconnecting the brake C
l'alimentation du frein, s'assurer qu'il supply line, make sure that it is full A
est rempli d'huile afin de limiter la of oil to limit the amount of grease
quantité de graisse introduite dans introduced into the oil. D
l'huile.
B
Moteurs MK11 MK18 MKE18

MK11 MK18 MKE18 motors.
x Effectuer le branchement de x Connect the grease pump A) : Graisseur Greaser

la pompe à graisse. (grease gun).
x Actionner la pompe jusqu'à x Operate the pump until 30 B) : Manomètre 0 - 40 bar
lire 30 bar puis effectuer la bar [435 PSI] is shown on the 0 - 40 bar [580 PSI] pressure gauge
manœuvre de remorquage de gauge. Then the machine can be
l’engin. taken in tow. C) Bloc raccord Connector block
x Faire chuter la pression par x Reduce the pressure using
le graisseur puis débrancher le bloc the greaser and disconnect the D)Pompe à graisse Grease pump
raccord ( C) connector block (C). (grease gun)
x Rebrancher l’alimentation du x Reconnect the brake supply.
frein.
008 922 51 BOMAG 327

13.2 Travel motor
POCLAIN HYDRAULICS
REPARATIONS REPAIRS
Remplacement du joint de Replacing of the brake
piston de frein piston O-ring.
Freins standards (F04 F07 - F11 Standard brakes (F04 – F07 - F11
- F12 F19) - F12 – F19)
Prévoir la fourniture de la Plan the supply of the

coiffe équipée (141) car cover assembly (141) as it
elle sera détruite au will be destroyed while
démontage. disassembling.
Démontage Disassembly
x Déposer le moteur. x Remove the motor.
x Démonter et éliminer la xRemove and discard the cover

coiffe (141). (Uniquement sur les (141). (Only on motors without
moteurs sans passage central) hollow shaft)
x Éliminer le joint torique x Discard the O-ring (143) (motor

143
(143). (Moteur sans passage without hollow shaft).
central)
x Comprimer la rondelle x Compress the spring washer

élastique (108) à l’aide du mandrin (108) using the mandrel (see tools
(voir outillage 80). 80).
x Soit manuellement en x Or manually, using the mandrel

utilisant avec le mandrin, un and an extractor. (see tools page
extracteur (voir outillage page 79) 79).
328 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Soit en plaçant l’ensemble x This is done either by placing
sous une presse. the assembly under a press.
x Soit manuellement, en x Or manually using the

utilisant avec le mandrin, une tige mandrel, a threaded rod and a
filetée et une rondelle en bout washer at the shaft end (see tools
d’arbre (voir outillage page page 80). (Motor with hollow shaft)
80)(Moteur avec passage central)
x Démonter l’anneau d’arrêt (109) x Remove the snap ring (109), 109
à l’aide d’une pince à anneau using internal snap ring pliers (see
d’arrêt intérieur (voir outillage page tools page 79).
79).
x Extraire la rondelle élastique x Extract the spring washer (108).

(108).
108
x Extraire le piston de frein (107). x Extract the brake piston (107). 107
008 922 51 BOMAG 329

13.2 Travel motor
POCLAIN HYDRAULICS
x Éliminer le joint torique (106). x Discard the O-ring (106). 106
Remontage Reassembly
Toute trace de rouille, All traces of rust, mud
! boue, eau doit être
supprimée. ! or water must be
removed.
x Enduire de graisse antioxydante : x Coat with anti-oxidizing grease: 3

1. les gorges de l’anneau d’arrêt 1. the grooves of the snap ring
et de la coiffe (141), and the cover (141), 5
1
2. la portée du joint de piston dans 2. the piston sealing surface in the
le corps de frein, brake body, 4
2
3. le dessus du piston de frein, 3. the top of the brake piston,
4. la rondelle élastique, 4. the spring washer,
5. l’anneau d’arrêt. 5. the snap ring.
x Graisser, puis monter un joint x Grease and install an O-ring

107
torique (106) sur le piston (107). (106) on the piston (107).
Le joint doit être serré The ring should be tight

sur le piston. against the piston.
106
x Monter le piston (107) dans le x Install the piston (107) in the

corps de frein (101). brake body (101) 107
Attention au passage du Take care when passing

joint sur la gorge de the seal over the snap
lanneau darrêt. ring groove.
330 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Monter la rondelle élastique (108) x Install the spring washer (108)
108
x Comprimer la rondelle x Compress the spring washer

élastique (108) à l’aide du mandrin (108) using the mandrel (see tools
(voir outillage page 80) page 80)
x Soit manuellement en x or manually, using the mandrel
utilisant avec le mandrin, un and an extractor. (see tools page
extracteur (voir outillage page 79). 79).
x Soit en plaçant l’ensemble x This is done either by placing

sous une presse. the assembly under a press.
x Soit manuellement, en x Or manually using the

utilisant avec le mandrin, une tige mandrel, a threaded rod and a
filetée et une rondelle en bout washer at the shaft end (see tools
d’arbre (voir outillage page 80). page 80). (Motor with hollow shaft)
(Moteur avec passage central)
x Monter l’anneau d’arrêt (109) à x Install the snap ring (109), using
l’aide d’une pince à anneau d’arrêt internal snap ring pliers (see tools
intérieur (voir outillage page 79). page 79).
Les oreilles de lanneau The lugs of the snap ring

darrêt seront orientées à must be oriented
lopposé de lorifice opposite the inlet port
dalimentation (X).
(X).
008 922 51 BOMAG 331

13.2 Travel motor
POCLAIN HYDRAULICS
x Monter un joint torique (143) x Install a new O-ring (143) 143

neuf enduit de graisse antioxydante coated with anti-oxidizing grease in
dans sa gorge. its groove.
x Placer la coiffe neuve (141) sur x Install a new cover (141) on the 141
le chanfrein d'entrée. entry chamfer.
x L'encliqueter à l'aide du x Click it into place using the

mandrin correspondant (voir corresponding mandrel (see tools
outillage page 83). page 83).
S'assurer que le bord Make sure that the outer

extérieur de la coiffe est en edge of the brake cover is
prise dans sa gorge. engaged in the groove.
x Monter un bouchon (142) neuf. x Install a new plug (142).

142
x Reposer le moteur. x Install the motor.
x Vérifier l'efficacité du frein x Check brake effectiveness.
332 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Frein MK09 Brake MK09
(Type 1: arbre court; type 2: arbre (Type 1: short shaft; type 2: long
long) shaft)
Demontage Disassembly
Pour tous types: For all types:
x Déposer le moteur. x Remove the motor 109
x Monter deux vis de fixation x Install two fixation screws

diamétralement opposées sur la diametrically opposite on the back
plaque de fixation (109). (M16x20 plate (109). (M16x80 cl10,9)
cl10,9)
x Démonter et éliminer les vis x Remove and discard screws

(127). (127).
127
x Démonter les deux vis de x Remove two fixation screws.

fixation.
008 922 51 BOMAG 333

13.2 Travel motor
POCLAIN HYDRAULICS
x Démonter la plaque arrière x Remove the back plate (109).

(109).
109
x Démonter le joint torique (129). x Remove the O-ring (129). 129
x Démonter la bague d'étanchéité x Remove the sealing ring (118).

(118). 118
x Démonter la rondelle élastique x Remove the spring washer

(108). (108).
108
x Retourner le moteur. x Turn the motor.

x Desserrer les vis de fixation x Loose the mounting screws
175
(175) de la plaque de fixation (171). (175) of the front fixation plate
171
(171).
334 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Démonter et éliminer les vis x Remove and discard the screws
(175). (175).
175
x Démonter la plaque de fixation x Remove the front fixation plate

moteur (171). (171).
171
x Démonter et éliminer le joint x Remove and discard the O-ring

torique (173). (173). 173
Pour type 1: For type 1:

x Démonter l'anneau d'arrêt (117) x Remove the snap ring (117) of 117
110
de l'arbre (110). the shaft (110).
Pour type 2: For type 2:

x Démonter l'anneau d'arrêt (117) x Remove the snap ring (117) of 110
de l'arbre (110). the shaft (110).
117
008 922 51 BOMAG 335

13.2 Travel motor
POCLAIN HYDRAULICS
Pour tous type: For all type:

x Extraire l'arbre (110) du moteur x Extract the shaft (110) of the
à l'aide de l'outil correspondant.(voir motor to the right tool.(see tools
outillage page 83) page 83)
x Eliminer le joint radial (172). x Discard the lip seal (172).
172
x Sortir l'arbre (110) du moteur. x Remove the shaft (110) with

bearing and piston assembled.
110
x Extraire la cale (105). x Extract the shim (105). 105
x Extraire les disques de frein x Extract the brake discs (103)

(103) et (104). and (104).
336 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Repérer la position du x Mark the position of the valving
couvercle (041) par rapport à la cover (041) in relation to the cam 026
came (026) et au corps de frein (026) and the brake body (101).
(101).
041
101
x Démonter les vis (102). x Remove the screws (102).
102
x Démonter le corps de frein x Remove the brake body (101).

(101).
101
x Eliminer le joint torique (114). x Discard the O-ring (114).

114
x Eliminer le joint torique (119) x Discard the O-ring (119).
008 922 51 BOMAG 337

13.2 Travel motor
POCLAIN HYDRAULICS

torique (111) de l'arbre (110). (111) of the shaft (110).
111
110
Pour le type 2: For type 2:

torique (113) de l'arbre (110). (113) of the shaft (110).
113
110
Pour tous types: All for types:

x Démonter le roulement de x Remove the bearing of shaft
l'arbre (110) à l'aide d'un maillet et (110) using a mallet and a tube
d'un tube en s'appuyant sur le while being pressed on the brake
piston de frein (107).(voir outillage piston (107).(see tools page 82)
page 82)
107
110
x Démonter le roulement (128) de x Remove the bearing (128) of

l'arbre (110). the shaft (110).
128
338 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Démonter le piston de frein x Remove the brake piston (107)
(107) de l'arbre (110). of the shaft (110).
! !
Attention à la surface de Be careful on the surface
frottement du joint à lèvre of friction of the lip seal

torique (106) du piston de frein (106) of the brake piston (107).
(107).
107 106
x Démonter et éliminer le contre x Remove and discard the seal

joint (115). (115).
115

(116). (116).
116
008 922 51 BOMAG 339

13.2 Travel motor
POCLAIN HYDRAULICS
Pour tous types: All for types:
x Monter le joint (116). x Install the O-ring (116).
116
x Monter le contre joint (115). x Install the seal (115).
115
x Monter le joint torique neuf x Install new O-ring (106) on the 106
(106) sur le piston. piston.
! !
Le joint doit être serré sur The ring should be tight on
le piston et non vrillé. the piston and not twisted.

x Monter le joint torique (111) de x Install the O-ring (111) of the
l'arbre (110). shaft (110).
111
110
Pour le type 2: For type 2:

x Monter le joint torique (113) de x Install the O-ring (113) of the
l'arbre (110). shaft (110).
340 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Nettoyer et dégraisser le x Clean and degrease the cover
couvercle (041). (041). 110
x Monter l'arbre (110). x Install the shaft (110).

041
x Monter le joint torique neuf x Install the new O-ring (114) on

(114) sur le corps de frein. the body brake.
114
x Remonter le joint (172) après x Install the lip seal (172) after 172
l'avoir nettoyer ou changer si clean or change if necessary.
nécessaire.
Pour le type 1 / for type 1:

Attention de ne pas 117
! !
Take care not to let the
faire tomber l'arbre shaft fall
x Monter l'anneau d'arrêt (117) x Install the snap ring (117) on

sur l'arbre. the shaft.
x S'assurer de l'impossibilité de x Verify the snap ring position
tourner l'anneau d'arrêt and ensure it cannot be turned
manuellement. manually.
x Dégraisser les taraudages. x Degrease thread holes.
Pour le type 2 / for type 2:
117
008 922 51 BOMAG 341

13.2 Travel motor
POCLAIN HYDRAULICS
x Retourner le moteur. x Return the motor.

x Essuyer la face de liaison en faisant x Wipe the mating face with a
des mouvements vers l’extérieur à l’aide moist lint-free rag, stroking the
d’un chiffon humide ne présentant pas brake housing from the inside to the
de particules détachables. outside.
x Dégraisser la face de liaison x Degrease the mating face
à laide dalcool isopropylique. using isopropyl alcohol.
x Monter le joint (119) sur le x Install the O-ring (119) on the

couvercle. cover.
119
x Appliquer un cordon continu de x Place a continuous bead of

pâte étanche LOCTITE 510 sur la adhesive LOCTITE 510 on the
surface de fixation du couvercle retaining face of the valving cover
(041) (voir outillage page 79). (041) (see tools page 79).
Cordon de pâte étanche Largeur du cordon: 3 à 5 mm

Bead of LOCTITE 510 [0.12 to 0.2].
Width of bead: 3 à 5 mm
[0.12 to 0.2].
342 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Monter en place le corps de x Install the body brake (101).
frein (101).
114
x Monter les vis de préfixation x Install new prefixation screws

114
neuves (102). (102).
x Serrer progressivement les vis x Tighten gradually screws to the

au couple correspondant (voir right torque (see table page 85).
tableau page 85).
x Huiler et monter un disque à x Lubricate and install an external

denture extérieure (103). teeth disc (103).
103
x Aligner le retour de fuite du x Align the feed port of the cover

couvercle (041) avec les dents du (041) with teeth discs (103).
disque (103).
008 922 51 BOMAG 343

13.2 Travel motor
POCLAIN HYDRAULICS
x Alternativement huiler et monter x Alternately lubricate and install

un disque à denture intérieure an internal teeth disc (104).
(104).
104
x S'assurer que les trous des x Check to be sure to align the

disques (104) sont alignés. holes in the discs (104).
x Monter le piston de frein (107) x Install the brake piston (107) in

107
dans le corps de frein (101). the brake body (101).
x Monter la rondelle élastique x Install the spring washer (108) 108

(108) sur le piston de frein (107). on the brake piston (107).
x Monter la faux chapeau. x Install the shimming plate.

(outillage de montage à réaliser (mounting special tool page 82)
page 82)
344 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Appliquer une force F et x Using a press apply the
alimenter le frein en pression (voir compressive force F and supply the
tableau ci-dessous). pressure to the brake (see table
here below).
TAILLE COURSE EFFORT F (N) NBRE DE DISQUES* PRESSION DE RÉGLAGE

SIZE STROKE FORCE F [LBF] NUMBER OF DISCS* SETTING PRESSURE
mm in N lbf 103 104 bar PSI
+0.3 +0.012
F08 0.65 -0.2
0.025 -0.008
100000 22481 12 11 14 203
x Mesurer la course du piston. x Measure the brake piston

stroke through the holes in the
shimming plate.
x Mesurer par l'intermédiaire des x Measure the stroke at least in two
trous qui sont dans le faux chapeau opposite points and to determine the
et déterminer la cale a monter. shim you have to install.
X= course théorique - course X= theoric stroke – measured

mesurée stroke
x Enlever le faux chapeau. x Remove the shimming plate.
x Démonter la rondelle élastique x Remove the spring washer 108

(108) sur le piston de frein (107). (108) on the brake piston (107).
008 922 51 BOMAG 345

13.2 Travel motor
POCLAIN HYDRAULICS
x Démonter le piston de frein x Remove the brake piston (107)

107
(107) dans le corps de frein (101). in the brake body (101).
x Monter le calage (105). x Install the shims (105).

105
x Monter le piston de frein (107) x Install the brake piston (107) in

107
dans le corps de frein (101). the brake body (101).
x Monter la rondelle élastique x Install the spring washer (108) 108

x Monter le roulement (128) dans x Install the bearing (128) in the

le faux chapeau. shimming plate.
128
346 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Monter le faux chapeau (voir x Install the shimming plate (see
outillage page 82). tools page 82).
x Appliquer une force F pour x Apply the compressive force F

placer le roulement sur l'arbre. with a press to install bearing on the
shaft.
x Démonter le faux chapeau. x Remove the shimming plate.

x Le roulement est installé dans x The bearing is installed in its
sa position. position.
x Positionner manuellement la x Position manually sealing ring

bague d'étanchéité (118) dans la (118) in the rear plate (109), after
plaque arrière (109), après l'avoir greased it. 118
graissée.
x Mettre en butée la bague à x Mount the sealing ring using a

l'aide d'un mandrin (voir outillage mandrel (see tools page 80).
page 80).
008 922 51 BOMAG 347

13.2 Travel motor
POCLAIN HYDRAULICS
x Monter le joint torique (129) sur x Install O-ring (129) on the rear 129
la plaque arrière. plate.
x Monter la plaque arrière (109) x Install the rear plate (109) on 109
sur le corps de frein (101). the brake body (101).
x Appliquer une force F=20000 N x Apply the compressive force

[4496.4 lbf] sur la plaque arrière F=20000 N [4496.4 lbf] with a 127
(109). press on the rear plate (109).
x Placer les vis (127) x Install screws (127).
x Serrer les vis au couple x Tight the screws to the right

correspondant (voir tableau page torque (see table page 85).
85).
x Monter le joint torique (173) sur x Install the O-ring (173) on the 173
la plaque de fixation (171). fixation plate (171).
±

348 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Graisser la plaque de fixation x Grease the radial lip groove in
(171). the fixation plate (171).
Quantité: 55 cm3 Quantity: 3.36 cu.in3
x Monter la plaque de fixation x Install the fixation plate (171).

(171). 171
x Dégraissé avec de l'alcool x Degrease with alcohol isopropyl

isopropylique et enduire les vis and coat the news screws (175)
175
neuves (175) de LOCTITE 262. with LOCTITE 262.
x Serrer les vis (175) au couple x Tight screws (175) to the right
correspondant (voir tableau page torque see table page 85).
85).
008 922 51 BOMAG 349

13.2 Travel motor
POCLAIN HYDRAULICS
Moteur MK08 remplacement de MK08 motor Replacing of

la bague détanchéité (118) the sealing ring (118)
x Disposer le moteur sur le bloc x Place the motor on the cylinder

cylindre. block.
x Soulever l'anneau expansif x Lift the locking ring (117), using

(117), à l'aide de deux tournevis. two screwdriver.
117
x Démonter l'anneau expansif x Remove the locking ring (117).

(117).
117
x Décoller à l'aide d'un tournevis x Remove the sealing ring (118)

pointu la bague d'étanchéité (118), from its housing, using a pointed
de son logement. screwdriver.
Ne pas rayer la portée Do not scratch the
!
de la bague d'étanchéité sealing ring contact
sur le corps de frein et
sur le piston de frein. ! surface on the brake
body and on the brake 118
piston.
350 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Extraire et éliminer la bague x Extract and discard the sealing
d'étanchéité (118). ring (118).
118
removed.
x Graisser la bague d’étanchéité x Grease the new sealing ring

(118) neuve et la positionner. (118) and position it.
118
x Monter la bague d'étanchéité x Install the sealing ring coated

graissée à l'aide du mandrin grease using the corresponding
correspondant. mandrel.
x Monter l'anneau expansif (117) x Install the locking ring (117),

en s’assurant de sa mise en place making sure that it is correctly
dans sa gorge. seated in its groove.
x Reposer le moteur. x Reinstall the motor.
117
008 922 51 BOMAG 351

13.2 Travel motor
POCLAIN HYDRAULICS
Remplacement de Replacing of the reinforced

l'étanchéité renforcée Seal.
MOTEURS MK05 MK08 MK05 MK08 motors

x Disposer le moteur x Place the motor vertically on the
verticalement, en appui sur le corps brake body.
de frein.
x Décoller la tôle de protection x Remove the protective plate

(171) et la démonter. (171) and disassemble it.
171
x Extraire et éliminer le joint à x Extract and discard the lip seal

lèvre (172). (172).
172

d'étanchéité (027). ring (027). 027

! de la bague d'étanchéité
dans la came ! sealing ring contact
surface in the cam.
352 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
removed.
.
x Graisser les lèvres, puis mettre x Grease the lips, and install the
en place la bague d’étanchéité sealing ring (027).
(027).
027
x Monter la bague d'étanchéité à x Install the sealing ring using the

l'aide du mandrin correspondant correct mandrel. (see tools 81).
(voir outillage 81).
x Nettoyer et contrôler l’état de la x Clean and check the condition

tôle de protection (171), la of the protective plate (171), replace
remplacer si nécessaire. it if necessary.
face et du logement du joint à lèvre of the lip seal face and housing
(172) sur la came (026), ainsi que la (172) on the cam (026) and the face
face du bloc-cylindres (011). of the cylinder block (011).
x Monter le joint à lèvre (172). x Install the lip seal (172).
x Graisser la zone (A) entre la x Grease the area (A) between

came (026) et la tôle de protection the cam (026) and the protective 1 7 2
0 2 6
(171) (réf. graisse: voir outillage plate (171) (grease refer: see tools A
page 79). page 79). 1 7 1
x Monter la tôle de protection x Install the protective plate (171).
(171). x Reinstall the motor. 0 2 7
x Reposer le moteur.
0 1 1
008 922 51 BOMAG 353

13.2 Travel motor
POCLAIN HYDRAULICS
MOTEUR MK09 MK09 MOTOR

x Desserrer les vis de fixation x Unscrew the mounting screws
171
(175) de la plaque de fixation (175) of the back plate (171). 175
moteur (171).
x Démonter et éliminer les vis x Disassemble and discard the

(175). screws (175).
175
x Démonter la plaque de fixation x Remove the fixation plate (171).

moteur (171).
171

torique (173). (173). 173
x Eliminer le joint radial (172). x Discard the lip seal (172).
172
354 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Démonter l'anneau d'arrêt x Remove the snap ring (174).
(174). 174
x Enlever l'anneau d'arrêt (174). x Extract the snap ring (174). 174

d'étenchéité (027). ring (027). 027

! de la bague d'étanchéité
dans la came ! sealing ring contact
surface in the cam.
008 922 51 BOMAG 355

13.2 Travel motor
POCLAIN HYDRAULICS
removed.
x Graisser les lèvres de la bague x Grease the lips of the sealing 027
d'étanchéité (027). ring (027).
x Positionner manuellement la x Position manually the sealing 027

bague d'étanchéité (027). ring (027).
x Monter la bague d'étanchéité x Install the sealing ring (027)

(027) à l'aide du mandrin using a right mandrel (see tools
correspondant (voir outillage page page 81).
81)
x Monter l'anneau d'arrêt (174) en x Install the snap ring (174),

s'assurant de sa mise en place making sure that it is correctly
dans sa gorge. seated in its groove.
174
356 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Montrer le joint à lèvre (172). x Install the lip seal (172). 172
x Monter le joint torique (173) sur x Install the O-ring (173) on the 173
la plaque renforcée (171). reinforced plate (171).
x Graisser la plaque renforcée

(171).
Quantité: 55 cm3
x Grease the reinforced plate
(171).
Quantity: 55 cu.in3
±
±
x Monter la plaque renforcée x Install the reinforced plate

(171). (171).
171
x Dégraisser avec de l'alcool x Degrease with alcohol isopropyl 175

isopropylique enduire les vis and coat the news screws (175)
neuves (175) de LOCTITE 262. with LOCTITE 262.
008 922 51 BOMAG 357

13.2 Travel motor
POCLAIN HYDRAULICS
x Serrer les vis (175) au couple x Tighten screws (175) to the

correspondant (voir tableau right torque (see table page 85).
correspondant 85).
358 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
MOTEURS MK11 MK18 MKE18 MK11 MK18 MKE18 motors

x Disposer le moteur x Place the motor vertically on the
verticalement, en appui sur le corps brake body.
de frein.
x Décoller la tôle de protection x Use a screwdriver to separate

(171) à l'aide d'un tournevis. the protective plate (171).
171
x Puis démonter la tôle (171). x And disassembly the protective

plate (171). 171
x Extraire et éliminer le joint à x Extract and discard the lip seal

172
lèvres (172). (172).
008 922 51 BOMAG 359

13.2 Travel motor
POCLAIN HYDRAULICS
x Desserrer les vis de fixation x Unscrew the mounting screws

174
(175) du porte-joint (174). (175) of the seal support (174).
175
x Démonter et éliminer les vis x Disassemble and discard the

(175). screws (175).
175
x Démonter le porte joint (174). x Remove the seal support (174).
174

torique (173). (173). 173

d'étanchéité (027 pour MK11) ou ring (027 for MK11) or (078 for 027
(078 pour MK18 MKE18). MK18 MKE18).
360 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Graisser les lèvres de la bague x Grease the lips of the sealing
d'étanchéité (027 pour MK11) ou ring (027 for MK11) or (078 for
(078 pour MK18 MKE18). MK18 MKE18).
027
x Positionner manuellement la x Position manually the sealing

bague d’étanchéité. ring.
x Monter la bague d'étanchéité à x Mount the sealing ring, using

l'aide du mandrin correspondant the correct mandrel. (see tools page
(voir outillage page 79) ou en 79), or using the seal support (174),
utilisant le porte joint (174), et 4 vis and 4 new screws (175).
neuves (175).
x Monter puis serrer x Install and gradually tighten the

progressivement les vis (175), mounting screws (175) to obtain the
jusqu'au contact du porte-joint avec contact between the bearing
le palier. support and the seal support.
x Desserrer les vis et démonter le x Unscrew the screws and

porte-joint. remove the seal support.
008 922 51 BOMAG 361

13.2 Travel motor
POCLAIN HYDRAULICS
x Vérifier le positionnement de la x Check the locating of the

bague d'étanchéité (027) puis sealing ring (027) and install a new
monter un joint torique neuf (173). O-ring (173).
173
027
x Monter le porte-joint (174). x Install the seal support (174).
174
x Dégraisser les taraudages, puis x Degrease the internal threads,

monter des vis (175) neuves then install the new screws (175)
enduites de LOCTITE 243 (voir coated with LOCTITE 243 (see
outillage page 79). tools page 79).
x Serrer les vis (175) au couple x Tighten to the right torque the
correspondant (voir tableau page screws (175) (see table page 85).
85).

tôle de protection (171), la of the protective plate (171), replace
remplacer si nécessaire. it if necessary.
face et du logement du joint à of the lip seal face and housing
lèvres (172) sur la came (026), ainsi (172) on the cam (026) and the face
que la face du bloc-cylindres (011), of the cylinder-block (011), and coat
puis enduire de graisse with anti-oxidizing grease (see tools
antioxydante (voir outillage page page 79) the top of the sealing
79) le dessus du porte joint. support.
362 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Toute trace de graisse, All traces of grease, in

! dans les trous taraudés
doit être supprimée. ! the threaded holes must
be removed
x Monter le joint à lèvres (172). x Install the lip seal (172).
172
x Monter la tôle de protection x Install the protective plate (171).

(171). x Reinstall the motor.
x Reposer le moteur
171
008 922 51 BOMAG 363

13.2 Travel motor
POCLAIN HYDRAULICS
MK05 MK11 Remplacement MK05 MK11 Replacement of

de lensemble bloc- the cylinder-block - cam
cylindres - came assembly
Si le moteur n’est pas freiné : Motor without brake :

x Démonter les vis de fixation x Remove the mounting screws
(066), décoller le flasque (061), (066), separate the flange (061)
puis éliminer le joint torique (063) and discard the O-ring (063)
x Puis passer à la page 79. x Then go to the page 79.
$ $
$
$ !
$ "
$ #
Si le moteur est freiné. Motor with brake.
x Extraire le bouchon (142), x Extract the plug (142), discard

éliminer la coiffe (141) et le joint the cover (141) and the O-ring
torique (143). (143). 141
142
143
x Comprimer la rondelle élastique x Compress the spring washer

(108) à l’aide du mandrin (voir (108) using the mandrel (see tools
outillage page 79), en plaçant page 79). This is done by placing the
l’ensemble sous une presse (effort F) assembly under a press (F force).
x Démonter l’anneau d’arrêt (109) x Remove the snap ring (109)
à l’aide d’une pince à anneau using internal snap ring pliers (see
d’arrêt intérieur. (voir outillage page tools page 79).
79).
x Extraire : x Extract :
x la rondelle élastique (108). x the spring washer (108).

108
364 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Le piston de frein (107). x The brake piston (107). 107
x Le calage (115), x The shims (115),

x Les disques de frein (103) et x The brake discs (103) and
(104). (104).
103 104
115
x Éliminer le joint torique (106). x Discard the O-ring (106).
106
x Placer l’ensemble sous la x Place the whole under the press

presse et chasser l’arbre de frein and press out the brake shaft (110).
(110).
Enlever l'anneau On the MK11 motor

élastique (116) sur le remove the snap ring
moteur MK11. (116).
008 922 51 BOMAG 365

13.2 Travel motor
POCLAIN HYDRAULICS

111
110
-
x Démonter les vis (102). x Remove the screws (102). 102
x Décoller le corps de frein (101). x Separate the brake body (101).

101
x Éliminer le joint torique (114) x Discard the O-ring (114) on

sur moteur MK05 ou (059) sur MK05 motor or (059) on MK11 114
moteur MK11. motor.
366 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
042
x Déposer le couvercle équipé x Remove the valving cover

(040). assembly (040) 040
045
008 922 51 BOMAG 367

13.2 Travel motor
POCLAIN HYDRAULICS
x Contrôler l’état de surface de la x Check the condition of the

glace (047) au niveau de sa portée valving surface (047) on its mating
sur le bloc-cylindres (011). face with the cylinder block (011).
1
047
011
x Huiler les surfaces de contact x Oil the contact surfaces

entre le bloc-cylindres (011) et la between the cylinder block (011)
glace (047). and the valving (047).
011
x Graisser puis monter un joint x Grease and install a new O-ring

torique (045) neuf sur le couvercle (045) on the valving cover (041). 041
distributeur (041).
045
x Mettre en place avec le x Install the cylinder block - cam

couvercle équipé (040), l’ensemble assembly (010) with the valving
bloc-cylindre-came (010). cover assembly (040).
Orientation pour moteur MK05 : MK05 motor orientation : 1
Orifices (1) vers soi, bouchon (032) Ports (1) toward you, plug (032) to 040
à gauche. the left.
032
010
368 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Orientation pour moteur MK11 : MK11 motor orientation :
1 040
Orifices (1) vers soi, bouchon (032) Ports (1) toward you, plug (032) to
à droite. the right.
032
010
x Monter, puis serrer les vis de x Install and tighten to the right
fixation (042) au couple torque the mounting screws (042)
correspondant (voir tableau page 85). (see table page 85). 042
Moteur MK05 MK05 Motor
040
Moteur MK11 (vis classe 12.9). MK11 Motor (screws class 12.9).
Moteur non freiné : Motor without brake:

torique (063) neuf dans la plaque (063) in the end cover (061).
de fermeture (061).
x Monter la plaque de fermeture sur x Install the end cover on the
le couvercle équipé (040). valving cover assembly (040).
x Monter, puis serrer les vis de x Install and tighten to the right $
$ $
préfixation (066) au couple torque the pre-retaining screws $ !

$ "
correspondant. (066). $ #
Moteur freiné : Motor with brake:
x Contrôler l’état des cannelures du x Check the condition of the 101
corps de frein (101). brake body (101) splines.

x Nettoyer et dégraisser le corps x Clean and degrease the brake
de frein (101), body (101).
x Graisser, puis monter un joint x Grease and install a new O-ring
torique neuf (114) pour moteur (114) for MK05 motor or (059) for
MK05 ou (059) pour moteur MK11. MK11 motor. on the brake body
sur le corps de frein (101). (101).
008 922 51 BOMAG 369

13.2 Travel motor
POCLAIN HYDRAULICS
x Déposer un cordon continu de x Place a continuous bead of

colle (LOCTITE JS 510) sur la face adhesive (LOCTITE JS 510) on the
de fixation du couvercle (041). retaining face of the valving cover
(041).
041
x Placer rapidement (maximum x Quickly (maximum 10 minutes)

10 minutes) le corps de frein (101) place the brake body (101) on the
sur le couvercle équipé (040), distribution valve assembly (040).
101
x Monter et serrer les vis de x Install and tighten to the right

préfixation (102) au couple torque the pre-retaining screws
correspondant (voir tableau page (102) (see table page 85).
85).
102
x Contrôler l’état des cannelures x First check the condition of the

de l’arbre de frein, brake shaft splines.
370 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Monter sur l’arbre de frein x Install a new O-ring (111) on
(110), un joint torique (111) neuf, the brake shaft (110) and then, 111
puis à la presse, effectuer le using the press, install the brake
montage de l’arbre de frein (100) shaft (100) in the cylinder block
dans le bloc cylindre (011). (011).
Max. force 70000 N

! Effort maxi 7000 DAN
! [15737.4 lbf]
Replacer l'anneau On the MK11 motor

élastique (116) sur replace the snap ring
moteur MK11 (116).
x Huiler les disques de frein x Oil the brake discs and then
puis monter alternativement : install alternately :
x MK05 F04 : un disque intérieur x MK05 F04 : one internal disc
(104), puis un disque extérieur (104) then one external disc (103). 104
(103).
x MK05 F07 : un disque extérieur x MK05 F07 : one external disc
(103), puis un disque intérieur (103) then one internal disc (104).
103
(104).
x Disposer le calage (115) sur le x Place the shims (115) on the

dernier disque, la cale la plus last disc, with the thickest shim
épaisse côté piston. towards the piston.
x Nettoyer et s’assurer de la x Clean and check the property of

propreté des gorges de l’anneau the snap ring (109) and cover (141)
d’arrêt (109) et de la coiffe (141), grooves, the piston (107), the spring 106 107
ainsi que celle du piston (107), de la washer (108), the snap ring (109)
rondelle élastique (108), de l’anneau and the surface condition of the
d’arrêt (109) et de l’état de surface de piston seal face.
la portée du joint de piston.
Toute trace de rouille,
! !
All traces of rust, mud
boue, eau doit être or water must be 109 108
supprimée removed
x Enduire de graisse anti- x Coat with anti-oxidizing grease

oxydante (réf. AUTO-TOP 2000 (part number AUTO-TOP 2000
origine AGIP, couleur vert fluo) les manufactured by AGIP, fluorescent
gorges de l’anneau d’arrêt (109), de green color) the snap ring (109) and
la coiffe (141), le dessus du piston cover (141) grooves, the top of the
de frein (107), la rondelle élastique brake piston (107), the spring
(108), l’anneau d’arrêt (109), et la washer (108), the snap ring (109),
portée du joint de piston de frein and the brake piston sealing
dans le corps de frein (101). surface in the brake body (101).
008 922 51 BOMAG 371

13.2 Travel motor
POCLAIN HYDRAULICS
x Graisser et monter un joint x Grease and install a new O-ring

torique (106) neuf sur le piston de (106) on the brake piston (107).
frein (107).
x Monter le piston. x Install the piston.
Attention au passage du
! !
Take care when passing
joint sur la gorge de the ring over the snap
lanneau darrêt (109) ring groove (109)
x Monter, puis comprimer la x Install and compress the spring

rondelle élastique (108) à l’aide du washer (108), using the correct
mandrin correspondant (voir outillage mandrel (see tools page 79) by
page 79), en plaçant l’ensemble sous placing the whole under a press.
une presse.
x Install the snap ring (109), using
x Monter l’anneau d’arrêt (109) à
internal snap ring pliers (see tools).
l’aide d’une pince à anneau d’arrêt
intérieur (voir outillage). x Install an O-ring (143) coated
x Monter un joint torique (143) with anti-oxidizing grease in its
neuf enduit de graisse anti- groove.
oxydante dans sa gorge.
x Placer une coiffe (141) neuve x Place a new cover (141) on the
sur le chanfrein d’entrée. entry chamfer. 141
x et l’encliqueter à l’aide du x and click it into place using the

mandrin. (voir outillage page 79). mandrel (see tools page 79).
x S’assurer que le bord extérieur x Make sure that the outer edge
de la coiffe est en prise dans sa of the cover is engaged in its
gorge (l’excédent de graisse doit groove (excess of grease should
apparaître à ce niveau). appear at this point).
372 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Monter un bouchon neuf (142). x Install a new plug (142).
142
008 922 51 BOMAG 373

13.2 Travel motor
POCLAIN HYDRAULICS
MK09 Remplacement de MK09 Replacement of the

lensemble bloc-cylindres - cylinder-block - cam assembly
came
x Effectuer les opérations x Do operations described in

décrites à la rubrique "démontage" chapter "replacement of the brake
du chapitre "Remplacement du joint piston O-ring – Brake MK09" page
de piston de frein – Frein MK09" 23.
page 23.

042
x Démonter le couvercle (041) et x Remove the distribution cover

le nettoyer. (041) and cleaned it.
041
x Eliminer le joint torique (045). x Discard the O-ring (045).
045
374 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Monter le joint torique (045). x Install the O-ring (045).
045
x Placer le couvercle (041) sur le x Install the distribution cover

nouveau bloc cylindres came. assembly (041) on the new 041
cylinders bloc cam.
x Placer les vis de fixation (042) x Install the fixing screws (042) 042
dans le couvercle (041). into the cover (041).
x Serrer les vis au couple x Tight screws to the right torque

correspondant (voir tableau page (see table page 85).
85).
Effectuer les opérations décrites à Do operations described in

la rubrique "remontage" du chapitre chapter "replacement of the
"remplacement du joint de piston de brake piston O-ring – brake
frein – frein MK09" page 30. MK09" page 30.
008 922 51 BOMAG 375

13.2 Travel motor
POCLAIN HYDRAULICS
MK18, MKE18 : Remplacement MK18, MKE18: Replace-

du bloc-cylindres ou de la came ment of cylinder-block or
cam
x Repérer la position du palier x Mark the position of the bearing
(071) par rapport à la came (026) et support (071) in relation to the cam
au couvercle distributeur (041). (026) and to the valving cover
(041).
x Disposer le moteur en appui sur x Place the motor on the bearing

le palier. support.
x Démonter les vis (042) x Remove the screws (042)
042
x Puis déposer le couvercle x Then remove the valving cover

(041), repérer la position de la glace (041), mark the position of the
par rapport au couvercle (moteur à valving in relation to the valving
2 cylindrées). cover (dual displacement motor).
x Déposer la came (026), le bloc x Remove the cam (026), the 010
cylindre équipé puis éliminer les cylinder bloc assembly and discard
joints (027). the seals (027). 026
376 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Contrôler l’état de la came, des x Check the condition of the cam,
cannelures de l’arbre. and the shaft splines.
x Monter le bloc cylindre sur x Place the cylinder block on the

l’arbre (090), les pistons enfoncés shaft (090) with the pistons pushed
dans leur alésage. into their bores.
x Monter des joints neufs (027) x Install new, lubricated seals
graissés dans leur logement. (027) in their housing.
x Monter la came (026) suivant x Install the cam (026) in line with
les repères établis au démontage. the marks made during disassembly.
x Huiler la face d’appui de la x Lubricate the valving/cylinder-
glace sur le bloc-cylindres. block-mating surface.
x Mettre en place le couvercle x Install the valving cover

équipé suivant les repères établis assembly in line with the marks
au démontage. made during disassembly.
x Visser sans serrer 2 vis (042) x Screw without tightening two

diamétralement opposées. screws (042) diametrically opposite.
008 922 51 BOMAG 377

13.2 Travel motor
POCLAIN HYDRAULICS
x Visser puis serrer les vis de x Screw and tighten the mounting
fixation (042).(Vis classe 12.9 screws (042).(Screws class 12.9
voir tableau page 84) voir table page 84)
x Moteur freiné remonter le frein. x Motor with brake reassemble

(voir page 79) the brake (see page 79)
x Moteur non freiné : x Motor without brake :
torique (063) (063)
x Monter la plaque de fermeture x Install the end cover (061) on
(061) sur le couvercle équipé (040). the valving cover assembly (040).
x Monter, puis serrer les vis de x Install and tighten the fixing 066 061
fixation (066). screws (066).
378 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Remplacement de la glace Replacement of the valving
(047) MK05 - MK08 - MK09 (047) MK05 – MK08 – MK09
x Effectuer les opérations décrites à la x Do operations described in
rubrique "démontage" du chapitre "MK09 chapter "MK09 Replacement of the
Remplacement de l'ensemble bloc cylindres cylinder-block – cam assembly"
– cames"¨page 64 page 64.
Pour les moteurs MK08 For MK08 MOTORS
.
x Démonter la glace (047). Remove the valving (047).
047
Pour le moteur MK05-09 For the MK05-09 motor
x Démonter la glace (047). x Remove the valving (047).

047
047
x Démonter la rondelle élastique x Remove the spring washer

(051). (051).
051
008 922 51 BOMAG 379

13.2 Travel motor
POCLAIN HYDRAULICS
x Extraire et éliminer les contre- x Extract and discard the back-up 048-1
joints (048-1). rings (048-1).
048-1
x Extraire et éliminer les joints x Extract and discard the O-rings

toriques (048-2). (048-2).
048-2
048-2
x Huiler et monter les joints x Lubricate and install new O-
toriques (048.2) neufs dans le rings (048.2) into the cover.
couvercle.
048.2
380 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Huiler et monter les contre- x Lubricate and install new 041
joints (048.1) neufs dans le backing ring (048.1) in the cover
couvercle (041), en déformant les (041), ensuring the back up rings
contre-joints un minimum. are twisted as little as possible.
048.1
UNIQUEMENT MK09 ONLY MK09

x Retourner le couvercle, monter x Return the cover; lubricate and
le joint torique (126) neuf dans le install the new O-ring (126) on the
couvercle. cover.
126
x Huiler et monter le contre- x Lubricate and install new

joints(125) neuf, en déformant les backing ring (125) in the cover,
contre-joints un minimum. ensuring the back up rings are
twisted as little as possible.
125
TOUS LES MK ALL MK

x Monter les goupilles (050) sur le x Install the locating pins (050) on
couvercle. the cover.
050
x Régler la hauteur des goupilles x Adjust the height locating pins

(50). (50).
050
008 922 51 BOMAG 381

13.2 Travel motor
POCLAIN HYDRAULICS
mm in
Hauteur des 0 0.16 0
4
goupilles -0.3 -0.012
0
4 -0,3
x Monter la rondelle élastique x Install the spring washer (051).

(051).
Pour les moteurs MK08 For MK08 MOTORS
.
x Monter la glace (047) dans le x Install the valving (047) into the
041
couvercle (041). cover (041). 047
x Monter le joint torique (045) du x Install the O-ring (045) of the

couvercle. cover.
045
382 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Pour le moteur MK05-09 For the MK05-09 motor
x Monter la glace (047) dans le x Install the valving (047) into the
couvercle (041). cover (041). 041
047
x Monter le joint torique (045) du x Install the O-ring (045) of the 045
couvercle. cover.

décrites à la rubrique "remontage" chapter "MK09 replacement of the
du chapitre "MK09 Remplacement cylinder-block – cam assembly"
de l'ensemble bloc cylindres – section " reassembly" page 65
came" page 65.
008 922 51 BOMAG 383

13.2 Travel motor
POCLAIN HYDRAULICS

(047) MK11-MK18 (047) MK11-MK18

décrites à la rubrique "démontage" chapter "replacement of the
du chapitre "remplacement du bloc cylinders bloc assembly (010)"
cylindre équipé (010)" page .66 section "disassembly" page 66
Mark location to the

REPÉRER LE POSITION DE
valving (047) in relation
!
LA GLACE (047) PAR
! RAPPORT AU COUVERCLE
(041) (MOTEUR À DEUX
to the valving cover
(041) (Dual
displacement motor).
CYLINDRÉES).
x Déposer la glace (047) du x Separate the valving (047) from

couvercle (041) en faisant levier au the cover (041) by levering at the
niveau des doigts d'indexage ou de indexing pins or at the flange.
la collerette.
! !
Protéger la glace de Protect the valving from
toute poussière. dusts.
x Extraire les ressorts (052). x Remove the springs (052).

x Extraire et éliminer les joints et x Remove and discard the seals
contre joints (048) du couvercle and back-up rings (048) from the
(041). cover (041).
Toute trace de rouille, All traces of rust, mud,

supprimée. ! and water must be
removed.
x Huiler, puis monter des joints x Lubricate and install new seals
toriques et contre joints neufs (048) and back-up rings (048), ensuring 048
en déformant les contres joints au the back up rings are twisted as
minimum. little as possible.
x Placer les ressorts (052) dans x Place the springs (052) in their
leur logement préalablement rempli housings, previously filled with
de graisse. grease.
x Huiler les portées de joints de la x Lubricate the faces of the seals
glace (047). of the valving (047).
x Enfoncer la glace (047) dans le x Press the valving (047) into the
couvercle (041). cover (041).
384 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Respecter le sens de Respect the assembly
! !
montage de la glace sense of the valving
(047) par rapport au (047) in relation to the
Ne pas forcer lors du Do not force when
! !
montage de la glace installing the valving
(047) dans le couvercle (047) into the cover
(041). (041).
Montage glace version 1C Valving assembly type

single displacement motor
x Pas de sens de montage x No particular assembly sense.

particulier.
041 047
Montage glace version 2C Valving assembly type Dual

displacement motor
x Mettre la lettre choisie indiquant x Place the chosen letter indicate
le sens de rotation en face du tiroir the rotation sense in front of the
de pilotage (053). displacement change spool (053).
POSITIONNEMENT DE LA GLACE VALVING POSITIONING

G/L Gauche G/L Left
041
0 5 3
R 047
L
053
R A 3 2 2 7
053
008 922 51 BOMAG 385

13.2 Travel motor
POCLAIN HYDRAULICS
D/R Droite D/R Right
047
0 5 3 041
R L
053
R A 3 2 2 8
053
x Si il n'y a pas de lettre, réaliser x If there is no letter, do the

l'indexage suivant les repères indexing according to the marks
établis au démontage. made during disassembly.
x Effectuer les opérations décrites x Do operations described in chapter

à la rubrique "remontage" du "replacement of the cylinders block"
chapitre "remplacement du bloc section "reassembly" page 67.
cylindre "page 67
Cas des moteurs SE02 et S05 : Situation of SE02 and S05 motors :
Moteur SE02 :
SE02 Motor :
G/L Gauche D/R Droite
G/L Left D/R Right
6 9 5 9
Moteur S05 :
S05 Motor : G/L Gauche D/R Droite
G/L Left D/R Right
053
6 9 4 8
386 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Remplacement du capteur Replacing of the sensor

(option) (optional)
MK05 MK08
x Débrancher le connecteur x Disconnect the connector (161.3) 0 2 6

(161.3) ou les fils de raccordement or the cables connecting to the 1 6 6
au circuit électrique suivant modèle. electrical circuit, according to the 1 6 5
model applied. 0 1 1
x Démonter la vis (165), puis x Remove the screw (165), and
extraire le capteur (161) avec le extract the sensor (161) with its
support (166) support. (166).
Remontage Reassembly 1 6 7
1 6 1
x S’assurer de la propreté de la x Make sure that the seal 1 6 3
portée de joint (164) sur le mounting surface (164) on the
couvercle distributeur (041). valving cover (041) is clean.
1 6 4
x Monter la rondelle frein (163) x Install the new brake washer
neuve et le joint (164) neuf sur le (163) and the new seal (164) on the
capteur (161) équipé de sa pastille sensor (161) fitted with its adjusting
de réglage (167). sticker (167).
x Engager le capteur équipé dans x Push the sensor assembly into
MK11 MK18 MKE18
le support (166) jusqu’à ce que le the support (166) until the seal
joint (164) soit dans son logement. (164) is in its housing.
x Enfoncer le capteur dans le x Push the sensor into the valving
couvercle distributeur (041) jusqu’à cover (041) until it comes in contact
venir en contact avec le bloc with the cylinder block (011), the
cylindre (011), l’encoche du capteur notch of the sensor should be
doit être orientée vers le centre du oriented towards the center of the
moteur. motor.
x Monter et serrer la vis (165) x Install and tighten the screw
(165)
35 ± 3 N.m
35 ± 3 N.m
25.8 ± 2.2 lbf.ft
25.8 ± 2.2 lbf.ft
x Rebrancher le connecteur ou x Reconnect the connector or the

les fils de raccordement au circuit cables connecting to the electrical
électrique. circuit.
008 922 51 BOMAG 387

13.2 Travel motor
POCLAIN HYDRAULICS
Remplacement du nouveau Replacing of the new

capteur sensor
388 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Récapitulatif outillage. Tooling inventory

Outillage standard Standard tools
x Clé hexagonale pour vis six pans creux Hex key (Allen) 4..5 6 8 10 12 14
x Clé dynamométrique Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
x Clé dynamométrique Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
x Clé dynamométrique Torque wrench 160 à 800 N.m [120 to 600 lbf.ft]
x Tournevis Screwdriver
x Chasse goupille Drift punch
x Maillet Mallet
x Pinceau standard Standard brush
x Extracteur Extractor
Internal retaining
x Pince à anneau d’arrêt intérieur
ring pliers
Couleur vert fluo / fluorescent green color

Anti-oxidizing
x Graisse anti-oxydante AUTO-TOP 2000 AGIP
grease
Couleur bleu / blue color MOBIL XHP 222
x Frein filet Frein filet Couleur bleu / Blue color LOCTITE 243
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
Tools for mechanical
Outillage de défreinage mécanique
release.
Ø 1 6 .5
A = 2 0 0 (F 0 5 F 0 8 )
[0 .6 4 ]
A = 2 8 0 (F 1 1 F 1 8 F 2 1 )
6 0 x 3 0 5 0 x 5
008 922 51 BOMAG 389

13.2 Travel motor
POCLAIN HYDRAULICS
Outillage à réaliser Special tools

x Tube pour immobiliser le x Tube to immobilize the
moteur. motor.
[1 .6 " d ia ]
Ø 4 0
Ø 2 0
[0 .7 8 " d ia ]
5 5
[2 .1 6 "]
1 5 0 0
[6 0 "]
x Boulon pour comprimer de la x Bolt to compress the spring Vis CHC M12x150 classe 12.9 filetée sur
rondelle élastique (108). washer (108). toute la longueur avec écrou Hh12.
CHC screw M12x150 class 12.9 threaded
on the whole length with nut Hh12.
C Moletage
E Milling
MX
D dia
ØD
F
x Mandrin pour comprimer x Mandrel to compress the
la rondelle élastique. spring washer.
ØA / A dia
ØB / B dia
ØA ØB C ØD E F G
mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch]
F05 M12 125 [4.92] 115 [4.52]

151 [5.94] 159 [6.25] 50 [1.96] 10 [0.39] 20 [0.78]
F08 125 [4.92] 115 [4.52]
F11
M16
F18 190 [7.48] 180 [7.08] 180 [7.08] 205 [8.07] 215 [8.46] 50 [1.96] 10 [0.39]
F21
390 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
C Moletage
E Milling
MX
D dia
ØD
x x
F
Mandrin pour remonter la Mandrel for
coiffe de frein. reassembling the brake cover.
ØA / A dia
ØB / B dia
ØA ØB C ØD E F G
F05 M12 125 [4.92] 115 [4.52]

151 [5.94] 159 [6.25] 50 [1.96] 10 [0.39] 20 [0.78]
F08 125 [4.92] 115 [4.52]
F11
M16
F18 190 [7.48] 180 [7.08] 180 [7.08] 205 [8.07] 215 [8.46] 50 [1.96] 10 [0.39]
F21
C Moletage
E Milling
MX
D dia
ØD
x Mandrin pour remonter x Mandrel for
F
la bague d’étanchéité (027) reassembling the sealing
ou (078) ring (027) or (078)
ØA / A dia
ØB / B dia
ØA ØB C ØD E F G
mm [in] mm [in] mm [in] mm [in] mm [in] mm [in] mm [in]
MK05 162 [6.37] 175 [6.88] 100 [3.93] 35 [1.37] 10 [.39] 10 [.39] 25 [.98]
MK08 192 [7.55] 198 [7.79] 100 [3.93] 35 [1.37] 10 [.39] 10 [.39] 25 [.98]
MK09 193 [7.56] 202 [7.95] 100 [3.93] 35 [1.37] 10 [.39] 10 [.39] 25 [.98]
MK11 238 [9.37] 248 [9.76] 100 [3.93] 35 [1.37] 10 [.39] 10 [.39] 25 [.98]
MK18
MKE18
238 [9.37] 248 [9.76] 100 [3.93] 35 [1.37] 10 [.39] 10 [.39] 25 [.98]
008 922 51 BOMAG 391

13.2 Travel motor
POCLAIN HYDRAULICS
x Mandrin pour x Mandrel for

démontage du roulement disassembly of the bearing
x Faux chapeau pour x The shimming plate for

calage du frein ou le shimming or bearing shaft
montage du roulement assembly
392 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
x Mandrel for
x Mandrin pour
disassembly of the shaft
démontage de l'arbre (110)
(110)
008 922 51 BOMAG 393

13.2 Travel motor
POCLAIN HYDRAULICS
Couples de serrage Standard tightening

standards torques
en N.m ± 10% in [lbf.ft] ± 10%
(Suivant norme DIN 912) (According to the standard DIN 912)
Taille 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
394 BOMAG 008 922 51

Travel motor 13.2
POCLAIN HYDRAULICS
Résumé des couples de

Tightening torque summary
serrage
Plaque de fixation 35±3.5 N.m 26±2.6 lbf.ft

Back plate MK09
côté frein MK09
Screw (127) page 29
Vis (127) page 29
Plaque de fixation 355±3.5 N.m 262±26 lbf.ft

Front plate MK09
côté moteur MK09
Screw (175) page 31
Vis (175) page 31 et
and 40
40
Reinforced tightness. 14 ± 1.4 N.m 10.3±1.4 lbf.ft

Étanchéité renforcée.
screws (175)
Vis (175) Page 52
Page 52
Distribution équipée : Valving cover 120±12 N.m 88.4±9 lbf.ft

MK05 assembly: MK05
Vis (042) Page 59 Screw (042) page 59
Corps de frein Brake body 14±2 N.m 10.3±1.4 lbf.ft

Vis de préfixation Pre-retaining screw
(102) MK05 MK08 (102): MK05 MK08
Page 60 Page 60
End cover
Plaque de fermeture 14±2 N.m 10.3±1.4 lbf.ft
MK05 motor without
moteur non freiné
brake
MK05 0 6 1
0 6 6
Screw (066) page 0 6 3
Vis (066) page 60 0 6 5

0 6 4
60
Cover MK08 295±30 N.m 218±22 lbf.ft

Couvercle MK08
Screw (042) page
Vis (042) page 59
59
Valving cover
Distribution équipée : assembly: MK11 355±35 N.m 262±26 lbf.ft
MK11 MK18 MKE18 MK18 MKE18
Vis (042) page 83 Screw (042) page
83
008 922 51 BOMAG 395

13.2 Travel motor
POCLAIN HYDRAULICS
End cover
Plaque de fermeture 150±2 N.m 110.6±1.4 lbf.ft
MK11 MK18 MKE18
moteur non freiné
motor without
MK11 MK18 MKE18
brake:
Page 83
Page 83
Cover MK09 230±23 N.m 170±17 lbf.ft

Couvercle MK09
Screw (042) page
Vis (042) page 59
59
Body brake MK09 35±3.5 N.m 26±2.6 lbf.ft

Corps de frein MK09
Screw (102) page
Vis (102) page 62
62
396 BOMAG 008 922 51

Travel motor 13.2
France (Head office) France

POCLAIN HYDRAULICS INDUSTRIE SAS POCLAIN HYDRAULICS France SAS
B.P. 106 B.P. 106
60411 VERBERIE CEDEX 60411 VERBERIE CEDEX
FRANCE Tel.: 33 / (0) 3 44 40 77 57
Tel.: 33 / (0) 3 44 40 77 77 Fax: 33 / (0) 3 44 40 77 91
Fax: 33 / (0) 3 44 40 77 91 FRANCE
AGENCE DE LYON
Tel. : 33 / (0) 4 78 56 67 44
Fax : 33 / (0) 4 78 56 67 12
China Czech republic

POCLAIN HYDRAULICS BEIJING LTD POCLAIN HYDRAULICS SRO
2nd Floor M2 Building East Kírova 186
No. 1 Jiu Xian Qiao Dong Road 61900 BRNO
Chao Yang District ESKÁ REPUBLIKA
BEIJING 100016 Tel.: 42 / 0 5 43563121
CHINA Fax: 42 / 0 5 43217818
Tel.: 86 / 10 6438 6618
Fax: 86 / 10 6438 7427
Germany Italia
POCLAIN HYDRAULICS GMBH POCLAIN HYDRAULICS SRL
Bergstrasse 106 Via Remesina int, 190
64319 PFUNGSTADT 41012 CARPI (MODENA)
DEUTSCHLAND ITALIA
Tel.: 49 / (0) 6157 9474 0 Tel.: 39 / 059 655 0528
Fax: 49 / (0) 6157 9474 74 Fax: 39 / 059 655 0544
Japan Netherlands
POCLAIN HYDRAULICS KK POCLAIN HYDRAULICS BENELUX BV
5-4-6 Kugenumashinme Penningweg 32C
FUJISAWA 251 4879 AM ETTEN-LEUR
JAPAN NEDERLAND
Tel.: 81 / 466 50 4400 Tel.: 31 / (0) 76 5021152
Fax: 81 / 466 50 4422 Fax: 31 / (0) 76 5012279
Spain & Portugal Sweden

POCLAIN HYDRAULICS SPAIN S.L. POCLAIN HYDRAULICS AB
Gran Via Carlos III n°84 1°3a Lövängsvägen 8
08028 BARCELONA Box 2086
ESPAÑA 19402 Upplands Väsby
Tel.: 34 / 9 3 409 54 54 SWEDEN
Fax: 34 / 9 3 490 21 79 Tel.: 46 / 8 590 88050
Fax: 46 / 8 590 74110
United Kingdom USA

POCLAIN HYDRAULICS LTD POCLAIN HYDRAULICS INC.
Nene Valley Business Park Oundle P.O. Box 801
PETERBOROUGH, Cambs PE8 4HN 1300 N. Grandview Parkway
ENGLAND Sturtevant, WI 53177
Tel.: 44 / 1832 273773 USA
Fax: 44 / 1832 274990 Tel.: 1 / (262) 321 0676
Fax: 1 / (262) 321 0703
and a worldwide network of more than 100 distributors and partners
POCLAIN HYDRAULICS Industrie

B.P. 106
60411 Verberie Cedex – France
Tel.: 33 / (03) 44 40 77 77
Fax: 33 / (03) 44 44 77 99
008 922 51 BOMAG 397

13.2 Travel motor
398 BOMAG 008 922 51

13.3 Wheel drive
008 922 51 BOMAG 399

13.3 Wheel drive
400 BOMAG 008 922 51

Wheel drive 13.3
Moteurs hydrauliques
MS
Hydraulic motors
Réparations
Repairs
02 03 05 08 11 18
MS
MSE
Dépannage
Trouble shooting
Interventions
Maintenance
Réparations
Repairs
5767
Pièces de rechange
Spare parts
5763 5765
0549 5766 0545
5764
0550 0547
Ref : 677777845L POCLAIN HYDRAULICS Industrie

B.P. 106
REPAR MS2-18 F/GB 60411 VERBERIE CEDEX - FRANCE POCLAIN HYDRAULICS
Tel.: 33 3 44 40 77 77
Rev : B - Avr 01
Fax: 33 3 44 40 77 99
Certifié ISO 9001
008 922 51 BOMAG 401

13.3 Wheel drive
POCLAIN HYDRAULICS
Ce document s'adresse aux constructeurs des machines qui intè- This document is provided to machine manufacturers integrating
grent les produits POCLAIN-HYDRAULICS. II préconise les proces- POCLAIN-HYDRAULICS products.. It suggests processes that
sus que les constructeurs peuvent mettre en oeuvre pour réparer ces manufacturers may utilize to repair products after the warranty period.
produits à l'issue de la période de garantie.
It is recommended that all operations be performed by technicians
Il est recommandé que toutes les opérations soient effectuées par trained accordingly. The technicians should read and understand the
des techniciens ayant bénéficié de la formation adéquate. Les tech- information given in this document and be authorized by the machine
niciens doivent avoir lu et compris les informations figurant dans ce manufacturer.
document et avoir été habilités par le constructeur de la machine. It is essential that the technicians comply with safety instructions to
Ces techniciens devront impérativement observer les directives de prevent injury.
sécurité et de protection contre les accidents.
Ce document inclut des remarques importantes concernant la sécuri- This document includes major safety warnings announced in this way:
té. Elles sont mentionnées de la manière suivante:
! Remarque de sécurité.
! Safety warning.
Ce document inclut également des instructions essentielles au fonc- Additionally, this document includes instructions essential to product
tionnement du produit ainsi que des informations générales. Elles function as well as those providing general information. Both are an-
sont mentionnées de la manière suivante: nounced similar to the following examples:
Instruction essentielle. Essential instruction.
Information générale. General information.
POCLAIN HYDRAULICS est concepteur de produits que ses clients POCLAIN HYDRAULICS designs products that are integrated by its
intègrent aux machines qu'ils conçoivent. De ce fait, POCLAIN HY- customers in the machines they design. Subsequently POCLAIN
DRAULICS ne peut être tenu pour responsable des conséquences HYDRAULICS disclaims liability for consequences of improper inte-
liées à la mauvaise intégration de ses produits, ni des conséquences gration of its products and of improper set-up of adjustable devices.
pouvant résulter du mauvais paramétrage de leurs dispositifs régla- In the same way, POCLAIN HYDRAULICS may not be liable for in-
bles. De la même manière, POCLAIN HYDRAULICS ne peut être complete or improper operating and maintenance instructions pro-
tenu pour responsable d'instructions d'utilisation et de maintenance vided to the end user by the machine manufacturer nor for failures
erronées ou incomplètes qui auraient été communiquées par les resulting from operations performed by any person using these sug-
constructeurs de machines aux utilisateurs finaux ni d'incidents gested procedures.
qu'aurait engendrés quiconque ayant appliqué les processus préco-
nisés dans ce document. A re-certification of the machine may be required for every change in
Toute modification de paramétrage des dispositifs réglables peut né- set-up of adjustable devices.
cessiter une nouvelle homologation des machines.
In order to offer the best quality service, POCLAIN HYDRAULICS
Dans le but d’offrir le meilleur service, POCLAIN HYDRAULICS re- recommends to its customers to have applications approved by PO-
commande à ses clients de lui faire approuver chaque application. CLAIN HYDRAULICS.
L'ouverture des produits conduit à la perte de la garantie. N'utilisez Opening of products voids the warranty contract.
que des pièces de rechange d'origine POCLAIN HYDRAULICS. Le Use only POCLAIN HYDRAULICS genuine spare parts. Using parts
montage de pièces d'origine différente pourrait nuire au fonctionne- from different sources could reduce the performance of the product
ment du composant et du système et à la sécurité. and pose a safety hazard..
Soucieux d’améliorer ses fabrications, POCLAIN HYDRAULICS se In accordance with its policy of continuous improvement, POCLAIN
réserve le droit d’apporter sans préavis, toutes les modifications qu’il HYDRAULICS reserves the right to modify the specifications of all
jugerait utile aux produits décrits dans ce document. products described herein without prior notice.
Ce document contient des sections en langue Française et des sec- This document contains sections written in French and sections
tions imprimées en italique constituant leur traduction en langue An- printed in italics composing the English translation of the French sec-
glaise. En cas de contestation, les sections en langue Française fe- tions. The French sections will be the reference in case of dispute.
ront foi. Les mesures sont exprimées en unités métriques. Les All measures are expressed in metric units. Converted values to
correspondances à d’autres systèmes de mesure (notamment anglo- other systems (notably US and UK) are given for reference only.
saxons) sont données à titre indicatif.
Les illustrations ne sont pas contractuelles The illustrations for information only.
© POCLAIN HYDRAULICS Industrie 1998. © POCLAIN HYDRAULICS Industrie 1998.
La marque POCLAIN HYDRAULICS est la propriété de POCLAIN The trademark POCLAIN HYDRAULICS is the property of POCLAIN
HYDRAULICS S.A. HYDRAULICS S.A.
Ce document est la propriété de POCLAIN HYDRAULICS Industrie. This document is the property of POCLAIN HYDRAULICS Industrie.
Il est strictement confidentiel. Il ne doit pas être utilisé, reproduit, co- It is strictly confidential. It must not be used, duplicated, copied or
pié ou divulgué à un tiers en totalité ou en partie sans notre accord disclosed to a third party in full or in part without our prior written con-
écrit préalable. sent.
FACOM est une marque déposée de FACOM SA. FACOM is FACOM SA registered trademark.
LOCTITE est une marque déposée de LOCTITE SA. LOCTITE is LOCTITE SA registered trademark.
AUTO-TOP est une marque déposée de AGIP SPA. AUTO-TOP is AGIP SPA registered trademark.
2 REPAR MS2-18 F/GB 677777845L
402 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Sommaire Contents
SECURITE ET QUALITE................................................4 SAFETY AND QUALITY ................................................4

AVANT TOUTE INTERVENTION .............................................4 BEFORE SERVICING ...........................................................4
DURANT L'INTERVENTION ...................................................4 DURING SERVICING............................................................4
APRES INTERVENTION........................................................4 AFTER SERVICING..............................................................4
IDENTIFICATION DU COMPOSANT ........................................5 IDENTIFICATION OF THE COMPONENT ..................................5
DEPANNAGE..................................................................6 TROUBLE SHOOTING...................................................7
INTERVENTIONS ...........................................................8 MAINTENANCE..............................................................8

REMPLACEMENT DU MOTEUR .............................................8 REPLACING THE MOTOR .....................................................8
DEFREINAGE MECANIQUE ..................................................9 MECHANICAL BRAKE RELEASE ............................................9
DESACTIVATION DU FREINAGE MECANIQUE DES MOTEURS A MECHANICAL BRAKE DEACTIVATION OF THE MOTORS WITH
PALIERS DYNA+. ............................................................10 DYNA+ BEARING SUPPORT .............................................10
CONTROLE DE L'EFFICACITE DE FREIN DE PARKING. ..........11 CHECKING THE PARKING BRAKE EFFICIENCY. ....................11
REPARATIONS. ...........................................................12 REPAIRS. .....................................................................12
REPARATION DU FREIN. ...................................................12 REPAIR OF THE BRAKE.....................................................12
REPARATION DU PALIER (070) .........................................27 BEARING SUPPORT (070) REPAIR .......................................27
REMPLACEMENT DU PALIER DYNA +................................44 REPLACEMENT OF THE DYNA + BEARING SUPPORT..........44
REMPLACEMENT DES MACHOIRES DE FREIN ......................50 The big chamfers oriented towards bearing support .48
REMPLACEMENT DE LA CAME (026) ..................................57 REPLACING THE BRAKE SHOES.........................................50
REMPLACEMENT DU BLOC CYLINDRE EQUIPE (010) ...........58 REPLACEMENT OF THE CAM (026) ....................................57
REMPLACEMENT DE LA GLACE (047). ...............................59 REPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)58
REMPLACEMENT DU JOINT (045) DE LA PLAQUE DE REPLACEMENT OF THE VALVING (047)..............................59
FERMETURE. ...................................................................62 REPLACEMENT OF THE END COVER O-RING (045) .............62
REMPLACEMENT DU CAPTEUR (OPTION) ...........................64 REPLACING THE SENSOR (OPTIONAL) ...............................64
RECAPITULATIF OUTILLAGE ....................................66 TOOLING INVENTORY................................................66
RESUME DES COUPLES DE SERRAGE ...................69 TIGHTENING TORQUE SUMMARY ............................69
LISTE DES PIECES......................................................73 SPARE PARTS LIST ....................................................73

MOTEURS AVEC PALIER DYNA + .......................................75 MOTOR WITH DYNA+ BEARING SUPPORT ........................75
MOTEURS A 1 CYLINDREE ................................................76 SINGLE DISPLACEMENT MOTORS ......................................76
MOTEURS A 2 CYLINDREES ..............................................78 DUAL DISPLACEMENT MOTORS .........................................78
677777845L REPAR MS2-18 F/GB 3
008 922 51 BOMAG 403

13.3 Wheel drive
POCLAIN HYDRAULICS
Sécurité et Qualité Safety and Quality

Avant toute intervention Before servicing
• Prendre toutes les dispositions de sécurité nécessai- • Be extremely careful to prevent personal injury and
res (hommes et matériel) en se conformer aux ré- to avoid damage to material. Comply with all safety
glementations de sécurité en vigueur. regulations.
• Engager le frein de parking et immobiliser la ma- • Apply the parking brake and prevent the machine
chine avec des cales. from rolling with tire blocks.
• Stopper le générateur d'énergie (moteur) du système • Stop the hydraulic system power source (engine)
hydraulique et déconnecter l'alimentation électrique. and disconnect the battery.
• Le cas échéant, délimiter le périmètre de sécurité. • If necessary, block off the safety area.
• Nettoyer l'extérieur des composants pour en retirer • Wash dirt and grease from exterior of the compo-
toute trace de boue et de graisse. nents.
• Attendre le refroidissement et la dépressurisation complète • Await the complete cooling down and depressurization of
du système hydraulique (décharger les accumulateurs). the hydraulic system (accumulators must be purged).
L'huile chaude ou sous pression peut provo- Hot or pressurized hydraulic fluid may cause se-
! quer des brûlures graves avec infection.
Consulter un médecin en cas d'accident. ! rious burns & infections to the human body.
Consult a physician in case of accident.
Durant l'intervention During servicing

• Certains composants sont très lourds. Les soutenir • Some hydraulic components are very heavy. Se-
au moyen d'un dispositif de levage de capacité adé- cure them with a lifting device of adequate capacity
quate pour les déposer du châssis. when removing from the machine frame.
• La propreté est essentielle au fonctionnement des com- • Cleanliness is essential to functioning of the hydrau-
posants hydrauliques. La plupart des pièces peuvent être lic components. Most of the parts may be cleaned with a
nettoyées au moyen d'un solvant propre. clean solvent.
• Durant les manutentions, protéger toutes les surfaces • During handling, protect all sensitive surfaces from
sensibles contre les chocs (centrages, parties frottantes, ap- shocks (piloting and interface surfaces, thrust & bear-
puis, portées des joints et des roulements, etc...). ings surfaces, seal races, etc...)
• Nettoyer ces surfaces avant remontage. • Clean up these surfaces before reassembling.
• Toujours remonter des joints neufs en éliminant • Always install new O-rings, seals & gaskets discard-
systématiquement les joints démontés. Nous recom- ing the old ones. We recommend lubricating all seals
mandons de graisser tous les joints avant montage. prior to assembly.
• Huiler toutes les surfaces frottantes en y déposant • Lubricate all surfaces which have relative motion
un film de fluide hydraulique propre qui assurera une lu- between parts by coating them with a film of clean hy-
brification correcte lors du premier (re)démarrage.
draulic fluid to assure lubrication at first start.
• Ne jamais chauffer le fluide hydraulique qui peut
• Never heat hydraulic fluid, as it may flame at high
s'enflammer à haute température. Certains solvants
temperature. Some solvents are also flammable.
sont également inflammables. Ne pas fumer durant l'in-
Do not smoke during servicing.
tervention.
Après intervention After servicing
Réinstaller les composants et remettre le système hy- Reinstall the components and restart the hydraulic sys-
draulique en service selon les instructions figurant dans tem according to instructions defined in the following
les documents suivants: documents:
• INSTALLATION MS F/GB (ref. 677777844K) • INSTALLATION MS F/GB (ref. 677777844K)
• INSTALLATION CIRCUITS F/GB (ref. 677777831V) • INSTALLATION CIRCUITS F/GB (ref. 677777831V)
! Ne pas surtarer les soupapes de sécurité.

! Do not overset relief valves.
4 REPAR MS2-18 F/GB 677777845L
404 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Identification du composant Identification of the component
MS18-2-D11-F19-2A10-K000
B
D
000143896J
C
001 40712
0349
A : Désignation commerciale : A: Commercial description:

Ex : MSE18-2-D11-F19-2A10-K000 E.g : MSE18-2-D11-F19-2A10-K000
B : Code :Code Article B: Code:Part number.

Ex : 000143896J E.g : 000143896J
C : Série :Numéro de fabrication C: Series: Manufacturing batch number.

Ex : 001 E.g : 001
D : Num : Numéro d’ordre chronologique D: Num: Chronological serial number.

Ex : 40712 E.g : 40712
Le Code article et le numéro d’ordre doi- The part number and the chronological
vent être indiqués pour toute commande serial number must be specified to order
de pièces de rechange. spare parts.
677777845L REPAR MS2-18 F/GB 5
008 922 51 BOMAG 405

13.3 Wheel drive
POCLAIN HYDRAULICS
Dépannage
DETERIORATION → LIMAILLE → DETECTION PAR LES FILTRES → PREVENTIF……
Pannes Causes Remèdes

Ronronnement Palier usagé Procéder au remplacement du
régulier palier
À vide
Desserrage des fixations,
Vibrations Resserrer au couple
des tuyauteries
MOTEUR BRUYANT
Contrôler le tarage et l'état de
Pression de gavage trop
Claquement la soupape de contre-
faible
En charge pression.
Fuites internes trop impor- Remplacer le bloc cylindre et
Cavitation
tantes la distribution
Le moteur n'est pas ali- Contrôler l'entraînement de la

menté pompe et son alimentation
Le circuit ne monte pas en Contrôler l'état de la soupape
LE MOTEUR NE pression de sécurité (régulateur)
TOURNE PAS Fuites internes trop impor- Remplacer le bloc cylindre et
tantes la distribution
Contrôler le circuit de pilotage
Le frein reste serré du frein
Le débit de la pompe est Contrôler la vitesse d'entraî-

insuffisant nement et l'état de la pompe
LE MOTEUR NE
TOURNE PAS A SA Fuites internes trop impor- Vérifier l'état du bloc cylindre
VITESSE NORMALE tantes et de la distribution
EN CHARGE
La pression de fonction- Contrôler le tarage de la sou-
nement est trop basse pape de sécurité (régulateur)
LE MOTEUR Le débit est irrégulier Contrôler le débit de la pompe

TOURNE IRREGU- Vérifier l'état du bloc cylindre
LIEREMENT Fuites trop importantes
et de la distribution
Pression carter trop élevée Vérifier le circuit de drainage,

et l'état du filtre
FUITES D'HUILE EX- Joints détériorés Remplacer les joints
TERNES
Contrôler le serrage des vis
Montage défectueux d'assemblage, des vis de
purge et raccordements
6 REPAR MS2-18 F/GB 677777845L
406 BOMAG 008 922 51

Wheel drive 13.3
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 un-
ions
677777845L REPAR MS2-18 F/GB 7
008 922 51 BOMAG 407

13.3 Wheel drive
POCLAIN HYDRAULICS
Interventions Maintenance
Remplacement du moteur Replacing the motor
Dépose Removal
• Éliminer la pression dans le circuit d'alimentation. • Release the pressure in the supply circuit.
• Débrancher la tuyauterie de drainage au niveau du • Disconnect the drain line at the tank level to avoid
réservoir afin d'éviter le siphonnage de celui-ci. its siphoning.
• Débrancher et boucher les tuyauteries ou flexibles • Disconnect and plug the pipes or hoses connected
raccordés sur le moteur. to the motor.
• Débrancher le connecteur du capteur tachy • Disconnect the speed sensor.
• Démonter les vis de fixation, puis déposer le mo- • Disconnect the mounting screws, and remove the
teur. motor.
• Vidanger le carter. • Drain the casing.
Repose Installation
Reprendre les opérations de dépose dans l'ordre in- Execute the removal operations in the reverse order.
verse.
Veuillez vous reporter aux documentations suivantes: Please refer to the following documentation brochures:
• INSTALLATION MS F/GB (ref: 677777844K) • INSTALLATION MS F/GB (ref: 677777844K)
• INSTALLATION CIRCUITS F/GB (réf: . 677777831V) • INSTALLATION CIRCUITS F/GB (réf: . 677777831V)
8 REPAR MS2-18 F/GB 677777845L
408 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Défreinage mécanique Mechanical brake release

(sauf moteur avec palier DYNA+) (except motor with DYNA+ bear-
ing support)
Dans certains cas de dépannage, il In certain service situations, it may

peut être nécessaire que le moteur be necessary to release the motor
soit défreiné. brake.
• Extraire et éliminer le bouchon • Extract and release the plug 142

(142) de la coiffe de frein. (142) from the brake cover.
6499
• Serrer la vis dans le piston • Tighten the screw in the piston
6556
• Puis serrer l'écrou jusqu'à ce • And tighten the nut until the mo-
que l'arbre du moteur tourne libre- tor shaft turns freely.
ment.
6555
Freins Brakes Effort N Force [lbf] Couple équivalent N.m Equivalent torque [lbf.ft] Ecrou Nut
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
!
Après le défreinage, monter un bouchon After brake release, mount a new plug
! (142) neuf. (142).
677777845L REPAR MS2-18 F/GB 9
008 922 51 BOMAG 409

13.3 Wheel drive
POCLAIN HYDRAULICS
Désactivation du freinage mécanique des Mechanical brake deactivation of the mo-

moteurs à paliers DYNA+. tors with DYNA+ bearing support
• Se reporter aux brochures caractéristiques pour obtenir • See the characteristics brochures to obtain the nec-
les volumes nécessaires pour défreiner et pour freiner. essary volumes to release the brake or to brake.
Cette opération peut être nécessaire lors du montage This operation can be necessary to do during the mo-
du moteur ou dans certains cas pour déplacer une ma- tor’s assembly or to move a machine during a break-
chine lors d'un dépannage. down.
• Dévisser et démonter la soupape d'irrigation des • Unscrew and remove the irrigation valve of the mo-
moteurs à palier DYNA+.(D+). tors with DYNA+ bearing support (D+).
• Monter en lieu et place l'obturateur M18x1.5 équipé. • Install the M18x1.5 plug assembly (Part number
(Code article 003037414M). 003037414M).
• À l'aide d'une tuyauterie flexible, relier les orifices de • Using a flexible piping, connect the break release
défreinage (X) des paliers DYNA+ à une pompe ma- ports (X) of DYNA+ bearing supports to a manual
nuelle (M) équipée d'un réservoir (0.5 l [30.5 cu.in] pump (M) equipped with a tank (0.5 L [30.5 cu.in]
minimum), ainsi qu'une soupape de sécurité (S) tarée minimum), as well as a safety valve (S) calibrated at
à 30 bar [435 PSI] maxi, d'une vanne de vidange (V), 30 bar [ 435 PSI ] maximum, a blow off valve (V), a
d'un clapet anti-retour en sortie de pompe et d'un check valve at the pump output and a manometer
manomètre (M) (0-100 bar [0 – 1450 PSI]). (M) (0-100 bar [ 0 – 100 bar [1450 PSI ]).
• Actionner la pompe à main (M) pour désactiver le • Activate the hand pump to release the mechanical
frein mécanique. brake.
• Pour réactiver le frein mécanique, actionner la • To reactivate the mechanical brake, activate the
vanne de vidange (V), puis procéder aux opérations blow off valve (V), then execute the operations in
inverses. the reverse order.
• Après l'intervention, remonter les soupapes d'irriga- • After the intervention, reinstall the irrigations valves.
tions.
R 1
0 .5 l m in i P
[3 0 .5 c u .in ]
M
S
V
3 0 b a r
[4 3 5 P S I]
R 1 X D
7852
10 REPAR MS2-18 F/GB 677777845L
410 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Contrôle de l'efficacité de frein de parking. Checking the parking brake efficiency.
! !
Pour un engin roulant, effectuer ce test sur un For a rolling machine, make the test on a
sol horizontal. horizontal ground.
Pression de pilotage du frein: mini 12 bar Pilot brake pressure : Minimum 12 bar [174 PSI]
Maxi 30 bar. Maximum 30 bar [435 PSI]
• S'assurer que la pression d'alimentation du frein est • Make sure that the brake supply pressure is zero,
nulle,
• Effectuer la purge du frein par la vis (112) située au • Purge the brake using the screw (112) located at
niveau le plus haut, the highest level,
• Alimenter le moteur jusqu'à la pression de tarage, • Supply the motor up to the setting pressure.
• L'arbre du moteur ne doit pas tourner sinon il est • The motor shaft must not turn, otherwise it is nec-
nécessaire de procéder au remplacement du frein: essary to replace the brake :
! Ne pas roder les freins multidisques. ! Do not run multidisc brakes in.
677777845L REPAR MS2-18 F/GB 11
008 922 51 BOMAG 411

13.3 Wheel drive
POCLAIN HYDRAULICS
Réparations. Repairs.
Réparation du frein. Repair of the brake.
(sauf moteur avec palier DYNA+) (except motor with DYNA+ bear-
ing support)
Prévoir la fourniture de la Plan to supply a cover
! !
coiffe(141) car elle sera (141) as it will be de-
détruite au démontage. stroyed during disas-
sembly.
• Déposer le moteur. • Remove the motor.

• Mettre le moteur en appui sur le • Place the motor on the bearing
support palier. support.
! !
Protéger les goujons en Protect the studs by re-
remontant les écrous installing the nuts
• Démonter et éliminer la coiffe • Remove and discard the brake

de frein.(141) cover.(141) 141
6500
• Extraire et éliminer le joint tori- • Extract and discard the O-ring 143
que (143). (143).
6501
• Comprimer la rondelle élastique • Compress the spring washer

(108): (108).
• À l'aide du mandrin et de l'ex-
tracteur (voir outillage page 66) (fig • Using a mandrel and an extrac-
6502) tor (see tools page 66) (fig 6502)
• À l'aide du mandrin et d'une vis • Using a mandrel and a screw
de classe 12.9 (voir outillage page class 12.9 (see tools page 66)
66) • Using a mandrel and a press 6502
• À l'aide du mandrin et d'une (fig 6503). Respect the force F (see
presse (fig 6503). Respecter la table page 9)
force F (voir tableau page 9)
Mark the mounting direc-

Repérer le sens de mon- tion of the snap ring.
tage de l'anneau élastique.
6503
12 REPAR MS2-18 F/GB 677777845L
412 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Démonter l'anneau d'arrêt (109) • Remove the snap ring (109) us-
à l'aide d'une pince à anneaux d'ar- ing internal snap ring pliers. (see
rêt intérieur.(voir outillage 66) tools 66)
• Extracteur et pince (fig 6504 et • Extractor and pliers (fig 6504 6504 6505
6505) and 6505)
• Presse et pince (fig 6506 et • Press and pliers (fig 6506 and
6507) 6507)
6506 6507
Ne pas mettre le palier en If you use the press do
! appui sur les goujons lors
de la mise sous la presse.
! not place the bearing
support on the studs.
• Extraire la rondelle élastique • Extract the spring washer (108).

(108).
108
6508
• Extraire le piston de frein (107). • Extract the brake piston (107)
6513
• Eliminer le joint torique (106). • Discard the O-ring (106).

106
6511
• Démonter et éliminer les vis • Remove and discard the screws
(102). (102). 102
7145
677777845L REPAR MS2-18 F/GB 13
008 922 51 BOMAG 413

13.3 Wheel drive
POCLAIN HYDRAULICS
• Démonter le corps de frein • Remove the brake housing

101
(101). (101).
7146
• Extraire le calage (105) et les • Extract the shims (105) and the
103-104
disques de frein (103-104). brake discs (103-104).
6647
• Si le moteur est à 2 cylindrées, • If motor with dual displacement

démonter le tiroir de changement de (two speed) : remove the two speed
cylindrée (053). shift spool (053).
053
7147
• Eliminer le joint torique (045). • Discard the O-ring (045).

045
7148
• Si le moteur est à deux cylin- • If motor with dual displacement,

drées, éliminer le joint (057). discard the O-ring (057).
057
7149
14 REPAR MS2-18 F/GB 677777845L
414 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Remontage. Reassembly.
Avant le remontage, il est impératif Before reassembling, it is necessary

de s'assurer de la propreté de tou- to ensure that all parts, the surface
tes les pièces, des portées de joint conditions of the piston seal and the
et des gorges. grooves are clean.

! !
All traces of rust, mud,
boue, eau doit être sup- water must be removed.
primée.
S’assurer également que le corps Also make sure that the brake
de frein présente bien des chan- housing has proper chamfers
freins dans les trous de passage around the mounting screws
des vis de fixation sur le corps de holes.
frein.
Enduire de graisse anti-oxydante Coat with anti-oxidizing grease (see

(voir outillage page 66), les gorges, tools page 66), the grooves, the top
le dessus du piston de frein, la ron- of the brake piston, the spring
delle élastique, l'anneau d'arrêt, et washer, the snap ring and the piston 7150
la portée du joint de piston dans le seal contact surface in the brake
corps de frein. housing.
Montage du corps de frein : Brake housing mounting :
st
De type 1 : collé 1 type : glued
nd
De type 2 : non collé 2 type : not glued
rd
De type 3 : à fixation à billes 3 type : balls fixing
Type 1 Type 1
• Contrôler l’absence de colle sur • Check there is no dried glue on
la face de liaison du couvercle. the mating face of the valving
Eliminer toute trace de colle à l’aide cover. Scrape off all glue residues
d’une spatule. with a blade.
NE PAS TOILER LA FACE DE DO NOT FILE OR EMERY THE

LIAISON AFIN DE CONSERVER SA MATING SURFACE AS THE
RUGOSITE ORIGINALE. ORIGINAL SURFACE FINISH MUST
BE MAINTAINED
• Essuyer la face de liaison en • Wipe the mating face with a lint-

faisant des mouvements vers free moist rag, stroking the valving
l’extérieur à l’aide d’un chiffon hu- cover from the inside to the outside.
mide ne présentant pas de particu-
les détachables. 7152
• Dégraisser la face de liaison à • Degrease the mating face us-
l’aide d’alcool isopropylique. ing isopropyl alcohol.
• Contrôler l’absence de colle sur • Check there is no dried glue on

la face de liaison du corps de frein. the mating face of the brake hous-
Éliminer toute trace de colle à l’aide ing. Scrape off all glue residues of
d’une spatule. the brake housing.
NE PAS TOILER LA FACE DE DO NOT FILE OR EMERY THE

LIAISON AFIN DE CONSERVER SA MATING SURFACE AS THE
RUGOSITE ORIGINALE. ORIGINAL SURFACE FINISH MUST
BE MAINTAINED.
677777845L REPAR MS2-18 F/GB 15
008 922 51 BOMAG 415

13.3 Wheel drive
POCLAIN HYDRAULICS
• Essuyer la face de liaison en • Wipe the mating face with a

faisant des mouvements vers moist lint-free rag, stroking the
l’extérieur à l’aide d’un chiffon hu- brake housing from the inside to the
mide ne présentant pas de particu- outside .
les détachables.
• Dégraisser la face de liaison à • Degrease the mating face us-
l’aide d’alcool isopropylique. ing isopropyl alcohol.
7154
LE DEGRAISSAGE TERMINE, LES

AFTER DEGREASING, DO NOT
MAINS ET LES DOIGTS DE
TOUCH THE MATING SURFACES
L’OPERATEUR DE DEVRONT
WITH HANDS NOR FINGERS.
PLUS ETRE EN CONTACT AVEC
LES FACES A ASSEMBLER.
• Déposer un film d’activateur • Using a clean brush apply a film

Loctite 7471 (voir tableau page 66) of Loctite 7471 activator (see table
à l’aide d’un pinceau propre sur la page 66) on the valving cover sur-
surface du couvercle qui doit être en face which should be in contact with
contact avec le corps de frein, et at- the brake housing, and wait 2 min-
tendre 2 minutes. utes.
NE PAS APPLIQUER D’ACTIVATEUR SUR DO NOT APPLY ANY ACTIVATOR ON

L’ARBRE. THE SHAFT.
7151
• Monter le joint torique neuf • Install the new O-ring (045), and
(045) et si le moteur est à 2 cylin- if motor with dual displacement, in- 045
drées, le joint (057) neuf. stall the new O-ring (057).
057
DO NOT TOUCH THE MATING
NE PAS TOUCHER LA SURFACE
SURFACE AFTER COATING IT
RECOUVERTE D’ACTIVATEUR.
WITH THE ACTIVATOR.
7155
• Déposer sur le corps de frein un • Place a continuous bead of

cordon continu d’adhésif LOCTITE LOCTITE 638 glue (see page 66)
638 (voir page 66) suivant la ligne on the brake housing following the
moyenne des centres de trous de median line of the mounting screw
passage des vis de fixation (voir hole centers (see drawing).
dessin).
• Veiller à raccorder les cordons • Make sure the bead of glue is
sans discontinuité. continuous (no gaps).
7156
NE JAMAIS DEPOSER
NEVER APPLY THE ACTIVATOR
D’ACTIVATEUR SUR LA FACE
ON THE SAME SURFACE AS THE
RECEVANT LE CORDON ADHE-
BEAD OF GLUE.
SIF.
16 REPAR MS2-18 F/GB 677777845L
416 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Ligne moyenne des centres de

Largeur du cordon : trous de passage des vis de fixa-
5 à 10 mm [0.2 to 0.4 in] tion
Width of bead : Median line of the mounting
5 à 10 mm [0.2 to 0.4 in] screws centerline.
Absence d'adhésif dans la gorge

No adhesive in the groove.
LES OPERATIONS SUIVANTES THE FOLLOWING STEPS MUST

DOIVENT ETRE EFFECTUEES AU BE ACHIEVED IN 10 MINUTES
MAXIMUM 10 MINUTES APRES MAXIMUM AFTER THE GLUE AP-
LE DEPOT DU CORDON. PLICATION.
Type 1 et 2 Type 1 et 2
• Présenter les pièces à assem- • Position the parts to be assem-
bler en montant quelques vis neu- bled by installing some new screws
ves (classe 12.9) (cl 12.9)
7157
• Monter et serrer toutes les vis • Install and tighten all new
neuves (102) au couple préconi- screws (102) to the required 057
sé.(voir page 69). torque.(see page 69)
7158
677777845L REPAR MS2-18 F/GB 17
008 922 51 BOMAG 417

13.3 Wheel drive
POCLAIN HYDRAULICS
Type 1 Type 1
LA LIAISON COLLEE DEMEURE FRAGILE DURANT UNE THE GLUED CONNECTION REMAINS FRAGILE SIX HOURS
PERIODE DE 6 HEURES APRES COLLAGE. AFTER BEING GLUED.
Durant cette période : During this time :
NE PAS CHOQUER les pièces collées, AVOID ANY SHOCK to the glued parts,
NE PAS UTILISER OU TESTER le frein ou le DO NOT USE OR TEST the brake nor the mo-
moteur. tor
Type 3 Type 3
• Monter les 6 billes (123) sur le • Install the 6 balls (123) on the 0 7 1
L o g e m e n t d e s b ille s
couvercle (041). cover (041). B a lls H o u s in g
1 2 3
1 0 1
8155
0 4 1
• Monter un joint torique neuf • Install a new O-Ring (045) in the

(045) dans le couvercle (041). cover (041).
0 4 1
0 4 5
1 1 0
18 REPAR MS2-18 F/GB 677777845L
418 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Assembler le corps de frein • Install the brake housing (101) •

(101) sur le couvercle (041) en pre- on the cover 041). Take care to
nant soin de présenter les loge- place the housings in front of the
ments en face des billes (123). balls (123).
• Monter et serrer toutes les vis • Install and tighten all the screws
(102) au couple préconisé. (102) to the required torque :
1 0 1
1 0 2
1 2 3
8157
0 4 5
677777845L REPAR MS2-18 F/GB 19
008 922 51 BOMAG 419

13.3 Wheel drive
POCLAIN HYDRAULICS
REGLAGE DU FREIN. ADJUST THE BRAKE.
TOUTE TRACE DE ROUILLE, ALL TRACES OF RUST, MUD,

BOUE, EAU, COLLE, DOIT ETRE WATER OR GLUE, MUST BE RE-
SUPPRIME. MOVED.
• Monter le calage de compensa- • Install the torque reduction

tion de couple (115) suivant version shims (115) according to the ver-
(voir dessin 6736). sion (see drawing 6736).
• Huiler les disques neufs (utiliser • Oil the new discs (use hydraulic
du fluide hydraulique). fluid).
• Commencer par monter un dis- • Start by installing one external

que extérieur (103), puis un disque brake disc (103), then one internal
intérieur (104), puis alternativement brake disc (104), then alternately
(103) et (104). (103) et (104).
104
103
• Le dernier disque à monter est • The last brake disc must be an
un disque extérieur (103). external disc (103).
7159
1 0 3 1 0 4 1 0 4 1 0 3
1 0 1
1 0 6
1 1 5
1 0 9
1 0 5
1 0 8
1 0 7
1 1 0
1 4 2
1 0 2
1 1 1 .4 1 4 1
1 1 1 .3
1 1 1 .1
1 4 3
+ 0 ,1
0 0
1 1 1
6 7 3 6
20 REPAR MS2-18 F/GB 677777845L
420 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
REP. ITEM DÉSIGNATION DESCRIPTION

101 Corps de frein Brake housing
102 Vis de fixation Mounting screw
103 Disque de frein extérieur External brake disc
104 Disque de frein intérieur Internal brake disc
105 Calage Shims
106 Joint de piston de frein Brake piston O-ring
107 Piston de frein Brake piston
108 Rondelle élastique Spring washer
109 Anneau d'arrêt Snap ring
115 Calage de compensation de couple Torque reduction shim
141 Chapeau de frein Brake cover
142 Bouchon Plug
143 Joint torique O-ring
• Enduire de graisse antioxydante • Coat the piston seal contact

(réf. AUTO-TOP 2000 origine AGIP surface in the brake housing with
ou Mobil XHP222) la portée du joint anti-oxidizing grease (ref. AGIP
de piston dans le corps de frein AUTO-TOP 2000 or Mobil XHP222).
(101).
• Monter un joint torique (106) • Install a new O-ring (106) on the
neuf sur le piston (107). piston (107). 107
The ring should be tight

!
Le joint doit être serré sur
le piston et non vrillé. ! on the piston and not
twisted.
106
7160
• Monter le piston de frein (107) • Install the brake piston (107) in

dans le corps de frein (101). the brake body (101). 107
Attention au passage du Be careful when pass-

! joint sur la gorge de l'an-
neau d'arrêt.
! ing the seal over the
snap ring groove.
101 7161
• Monter la rondelle élastique • Install the spring washer (108)

108
7162
677777845L REPAR MS2-18 F/GB 21
008 922 51 BOMAG 421

13.3 Wheel drive
POCLAIN HYDRAULICS
• Appliquer l’effort F (voir tableau • Using a press or an extractor

ci-dessous) à l’aide de la presse ou (FACOM U20B) apply the compres-
avec l’extracteur (FACOM U20B) sive force F (see table here below) 109
pour monter l’anneau d’arrêt (109). to install the snap ring (109).
6505
• Alimenter le frein en pression • Supply the pressure to the

(voir tableau ci-dessous) et mesurer brake (see table here below) and
la course du piston à l’aide d’un measure the brake piston stroke us-
comparateur. ing a dial gauge.
7163
• Calculer alors la valeur pour le • Calculate the shimming (105)

calage (105) afin de respecter la value in order to respect the stroke
course C indiquée dans le tableau C indicated in the table here below.
ci-dessous.
TAILLE COURSE EFFORT F (N) NBRE DE DISQUES* PRESSION DE REGLAGE

SIZE STROKE FORCE F [LBF] NUMBER OF DISCS* SETTING PRESSURE
mm in N lbf 103 104 bar PSI
BRAKE WITH SINTERED DISCS
FREINS A DISQUES FRITTES
+0.32 +0.012
F02 MSE02 0.65 0.025 10 10
-0.14 -0.005
+0.32 +0.012
F04 MSE02 0.75 0.029 50000 11200 14 14 17 246
-0.14 -0.005
+0.32 +0.012
F02 MS02 0.65 0.025 11 10
-0.14 -0.005
+0.4 +0.016
F05 0.55 0.021 11 11 14 203
-0.3 -0.012
+0.4 +0.016
F05 0.55 0.021 70000 15700 11 11
-0.3 -0.012
+0.4 +0.016
F07 0.8 0.031 15 15
-0.3 -0.012
+0.32 +0.016 17 246
F11 0.65 0.025 10 10
-0.25 -0.012
+0.35 +0.016 100000 22500
F18 1 0.039 17 17
-0.25 -0.012
F03 095 +0.32 0.037 +0.012 50000 1124 21 19

NI-
FREINS A DISQUES
-0.14 -0.005
+0.45 +0.018
F04 0.87 0.034 70000 1573 19 18
NITRURES
WITH
-0.25 -0.01
TRIDED DISCS
+0.4 +0.016 17 246

F09 0.85 0.033 90000 2023 19 18
-0.3 -0.012
+0.42 +0.017
BRAKE
F12 0.90 0.035 20 19

-0.3 -0.012
+0.35 +0.014
100000 2250
F19 1.4 -0.25
0.055 -0.01
33 32
*Dans certains cas, on peut réparer un frein équipé d'ori- *In certain cases it's possible to repair a brake system
gine en disques frittés avec des disques nitrurés. Pour equipped with genuine sintered discs with nitrided discs.
connaître l'ordre spécifique du montage des disques, pren- To know the specific order of brake discs mounting,
dre contact avec les services techniques de POCLAIN contact POCLAIN HYDRAULICS technical depart-
HYDRAULICS. ments.
22 REPAR MS2-18 F/GB 677777845L
422 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Appliquer à nouveau l’effort F • Reapply the compressive force

pour dégager l’anneau d’arrêt (109). F to remove the snap ring (109).
109
6505
• Démonter la rondelle élastique • Remove the spring washer

(108). (108).
108
6508
• Démonter le piston de frein • Remove the brake piston (107).

(107).
107
6509
• Installer le calage nécessaire • Install the proper shimming

(105) sur le dernier disque de frein, (105) on the last disc, the thickest 105
la cale la plus épaisse côté piston shim towards the brake piston.
de frein.
MINIMIZE THE NUMBER OF

MINIMISER LE NOMBRE DE CA-
SHIMS OF THICKNESS 0.2 mm
LES D’EPAISSEUR 0.2 mm
[0.0079 inch]
7164
• Remonter le piston de frein • Reinstall the brake piston (107),

(107), la rondelle élastique (108). the spring washer (108). 108
108
7162
677777845L REPAR MS2-18 F/GB 23
008 922 51 BOMAG 423

13.3 Wheel drive
POCLAIN HYDRAULICS
• Appliquer l’effort F pour monter • Apply the compressive force F

l’anneau d’arrêt (109) et relâcher to install the snap ring (109) and re-
l’effort. lease the compressive force.
109
6505
• Alimenter à nouveau le frein en • Supply the pressure to the

pression pour vérifier la course du brake piston again to check the pis-
piston de frein. ton stroke.
7163
• Monter un joint torique neuf • Install a new O-ring (143) 143

(143) enduit de graisse anti- coated with antioxidizing grease
oxydante (voir outillage page 66) (see tool page 66 ) in its groove.
dans sa gorge.
6515
• Placer la coiffe neuve (141) sur • Install a new cover (141) on the
le chanfrein d’entrée. entry chamfer. 109
6516
• L’encliqueter à l’aide du man- • Click it into place using the cor-

drin correspondant (voir outillage responding mandrel (see tools page
page 66). 66).
S’ASSURER QUE LE BORD EX- MAKE SURE THAT THE OUTER

TERIEUR DE LA COIFFE EST EN EDGE OF THE BRAKE COVER IS
PRISE DANS SA GORGE. ENGAGED IN THE GROOVE
6517
24 REPAR MS2-18 F/GB 677777845L
424 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Monter un bouchon neuf (142). • Install a new plug (142).

142
6518
• Reposer le moteur. • Install the motor.
ATTENDRE SIX HEURES APRES

WAIT SIX HOURS AFTER GLUING
LE COLLAGE AVANT DE SOLLICI-
BEFORE USING THE BRAKE OR
TER LE FREIN OU D’UTILISER
ENGAGING THE POWER FUNC-
LES FONCTIONS DE PUISSANCE
TIONS OF THE MOTOR
DU MOTEUR.
• Vérifier l’efficacité du frein. • Check brake effectiveness.
677777845L REPAR MS2-18 F/GB 25
008 922 51 BOMAG 425

13.3 Wheel drive
POCLAIN HYDRAULICS
5767
8144
0 7 8
Etanchéité TYPE 1 : 0 7 8 Etanchéité TYPE 2 : Etanchéité TYPE 3 :
Bague d’étanchéité Bague d’étanchéité joint glace
faciale à lèvre radiale à lèvre Sealing TYPE 3:
Sealing TYPE 1: Sealing TYPE 2: Mechanical seal
Facial lip seal 3 1 5 9
Radial lip seal 0 8 5 3 1 3170
7 0
0 7 9 3 1 6 0
26 REPAR MS2-18 F/GB 677777845L
426 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Réparation du palier (070) Bearing support (070) repair

(Type 1, 2 et 3, sauf moteur MS02 (Type 1, 2 et 3, except MS02 motor
avec palier "1340".et palier DYNA with1340 DYNA+ bearing support)
+)
• Déposer le moteur. • Remove the motor.

• Disposer le moteur en appui sur • Place the motor on the brake or
le frein ou sur la plaque de fermeture on the end cover (motor without
(moteur sans frein) brake)
6519
• Repérer la position de la came • Mark the position of the cam 070

(026) par rapport au couvercle dis- (026) in relation to the valving cover
tributeur (040). (040).
025
040
6519
• Démonter les vis (042). • Remove the screws (042).
042
6520
• Démonter le palier (070), en uti- • Remove the bearing support

lisant un palan. (070), using a lifting tackle.
070
6521
677777845L REPAR MS2-18 F/GB 27
008 922 51 BOMAG 427

13.3 Wheel drive
POCLAIN HYDRAULICS
• Déposer la came (026). • Remove the cam (026).

026
6524
• Eliminer le joint torique (027) du • Discard the O-ring (027) from the
couvercle (041). valving cover (041). 027
041
6525
• Eliminer le joint torique (027) du • Discard the O-ring (027) from the
support palier (071). bearing support (071) 027
071
6522
• Installer le palier posé sur • Position the bearing support

l’arbre (090) sous une presse ou sur placed on the shaft (090) under a
un support pour éviter tout effort sur press or on a support to avoid any
les goujons. force on the studs.
090
7925
• Comprimer les roulements à • Compress the roller bearings us-

l’aide d’un mandrin, Effort F (voir ta- ing a mandrel, force F (see table
bleau page 72), puis démonter page 72), then remove the snap ring
l’anneau d’arrêt (077) à l’aide d’une (077) using external snap ring pliers 077
pince à anneaux d’arrêt extérieurs (see tools page 66).
(voir outillage page 66).
6838
28 REPAR MS2-18 F/GB 677777845L
428 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Relâcher l’effort F de la presse, • Release the press force F and

puis enlever le mandrin. remove the mandrel.
• Démonter la bague d’appui • Remove the thrust ring (076) 075
(076) et les cales de réglage (075) and the shims (075)
!
REPERER L’ORDRE DE MON-
!
MARK THE MOUNTING ORDER OF
TAGE DES CALES (075) THE SHIMS (075)
6844
6839
• Fixer sur le support palier la • Fix a right contact plate on the

plaque d’appui correspondante. bearing support.
6840
• Positionner la plaque d’appui • Position the contact plate on the

sur des supports sous la presse. supports under the press.
DISPOSER SOUS LE PALIER UN PLACE UNDER THE BEARING
! !
MATERIAU SOUPLE (BOIS) POUR SUPPORT A PLIANT MATERIAL
AMORTIR LA CHUTE DE L’ARBRE

(WOOD)TO ABSORB THE SHAFT
DOWNFALL
6841
• Chasser l’arbre (090) • Press out the shaft (090)
CHAUFFER LEGEREMENT LA IF NECESSARY, HEAT SLIGHTLY

BAGUE INTERIEURE DU ROULE- THE INNER RING OF THE
! MENT SI NECESSAIRE. LE ROU-

LEMENT SERA DETRUIT PEN- ! ROLLER BEARING. THE BEAR-
ING WILL BE DESTROYED BY
DANT CETTE OPERATION THIS OPERATION
6842
PAR MESURE DE SECURITE, SE AS A SAFETY MEASURE, STAY
! !
TENIR ELOIGNE DU MONTAGE APART FROM THE ASSEMBLY
PENDANT LA DESCENTE DE DURING THE SHAFT FALLING
L’ARBRE DOWN
Dans le cas de TYPE 3: If TYPE 3 :

• Extraire la partie (078.2) du joint • Using a flat screwdriver remove
glace (côté support-palier) à l’aide the part (078.2) of the mechanical
d’un tournevis plat. seal (on the bearing support side).
7873
0 7 8 .2
Pour tous types For all types :
• Démonter la bague intérieure du • Remove the internal bearing

roulement (074.1) cage (074.1)
6843
677777845L REPAR MS2-18 F/GB 29
008 922 51 BOMAG 429

13.3 Wheel drive
POCLAIN HYDRAULICS
• Extraire la bague extérieure du • Extract the bearing outer race

roulement (074.2). Utiliser un ex- (074.2) using a two legs extractor
tracteur à deux branches à prise ex- (see tools page 66) and a cutting
térieure (voir outillage page 66) et tool lying flat to have a central sup-
074.2
un burin posé à plat pour obtenir un port point for the extractor.
point d’appui centrale. Finir Finish extracting the race using a
d’extraire la bague à l’aide d’un jet casing and a hammer.
et d’un marteau. 6844
Pour tous types sauf TYPE 3 : All types except TYPE 3 :

• Chasser l’ensemble d’étanchéité • Press out the sealing assembly
(072). (072). 072
ATTENTION DE NE PAS ENDOM-
! !
BE CAREFUL NOT TO DAMAGE
MAGER LE LOGEMENT DE LA
THE SEAL’S HOUSING
BAGUE ETANCHE.
6846
• Eliminer l’ensemble d’étanchéité • Discard the sealing assembly

(072). (072). 072
6847
• Extraire la bague extérieure du • Extract the bearing outer race

roulement (073) (voir outillage page (073) (see tools page 66).
073
66). Finish extracting the race using a
Finir d’extraire la bague à l’aide d’un casing and a hammer.
jet et d’un marteau
6845
Dans le cas du TYPE 3 : If TYPE 3 :

• Extraire la partie (078.1) du joint • Remove the part (078.1) of the
glace à l’aide d’un tournevis plat. mechanical seal using a flat screw-
driver.
0 7 8 .1
5767
Pour tous types : For all types :

• Détruire cage à rouleaux du • Destroy the bearing cage (073)
roulement (073) à l’aide d’un burin using a cutting tool by sectioning it
073
en la sectionnant en quatre points in four points above the rollers.
au-dessus des rouleaux.
DO NOT DAMAGE THE SEAL
! !
NE PAS ENDOMMAGER LA POR-
CONTACT SURFACE ON THE 6848
TEE DE JOINT SUR L’ARBRE
SHAFT
NE JAMAIS TRONÇONNER DANS NEVER TRUNCATE IN THE
! L’ATELIER POUR EVITER TOUTE

POLLUTION ! WORKSHOP TO PREVENT POL-
LUTION
30 REPAR MS2-18 F/GB 677777845L
430 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Ecarter la cage avec un tournevis et • Separate the cage using a

éliminer cage et rouleaux. screwdriver then discard the 078
cage and the rollers.
Pour tous types sauf TYPE 3 All types except TYPE 3 :
• Palier équipé de la bague • If bearing support fitted with
d’étanchéité type 1 (078). Découper type 1 seal (078), cut it using a cut-
celle-ci à l’aide d’un burin. L’extraire ting tool. Extract it using a flat 6849
avec un tournevis plat. screwdriver.
• Palier équipé de la bague • If bearing support fitted with
d’étanchéité type 2 (078). Ecraser type 2 seal (078), use a flat chisel.
celle-ci à l’aide d’un burin plat.
Pour tous types : All types :

• Extraire la bague intérieure du • Extract the bearing inner race 074
roulement (074) (voir outillage). (074) (see tools).
CHAUFFER LEGEREMENT SI NE-

IF NECESSARY HEAT SLIGHTLY.
! !
CESSAIRE : LA BAGUE
THE LIP SEAL (078) WILL BE
D’ETANCHEITE (078) SERA DE-
DESTROYED BY THIS OPERATION
TRUITE PAR CETTE OPERATION
6850
Pour TYPE 1 : TYPE 1:

• Extraire le déflecteur (079) à • Extract the deflector (079) with
l’aide d’un tournevis plat. a flat screwdriver. 079
6851
677777845L REPAR MS2-18 F/GB 31
008 922 51 BOMAG 431

13.3 Wheel drive
POCLAIN HYDRAULICS
Remontage. Reassembly
(TYPE 1 ou 2) (TYPE 1 or 2)
• Contrôler la portée de la bague • Check the lip seal (072) contact

d’étanchéité (072) sur l’arbre (090) surface on the shaft (090), the
l’état des cannelures, la portée de la splines conditions, the lip seal (078)
bague (078) sur le palier (071). contact surface on the bearing sup-
port (071)
• Monter la bague d’étanchéité • Install the lip seal (072) in the
(072) dans le support palier à l’aide bearing support using the right
du mandrin correspondant voir outil- mandrel – see tools.
lage.
ENLEVER LE RESSORT POUR
! !
TAKE OFF THE SPRING TO POSI-
POSITIONNER LA BAGUE ETAN-
TION THE LIP SEAL (072)
CHE (072)
• S'assurer visuellement que la • Check visually that the lip seal

bague soit bien en place au fond de is properly placed in the bottom of 7878
son logement. its groove
• Monter la bague extérieure du • Install the bearing outer race
roulement (074) dans le corps du (074) in the bearing support housing
support palier en la mettant en bu- up to the stop (see tools page 66)
tée. (voir outillage page 66).
• Contrôler visuellement la bonne • Check visually the right position
position de la bague dans son lo- of the race in its groove.
gement.
7836
• Retourner le support palier et • Return the bearing support and

l’équiper de la bague extérieure du install the bearing outer race (073)
109
roulement (073) en la mettant en up to the stop (see tools page 66)
butée (voir outillage page 66).
NE PAS OUBLIER DE REMONTER
! !
DO NOT FORGET TO INSTALL
LE RESSORT DE LA BAGUE
THE LIP SEAL SPRING.
D’ETANCHEITE.
• Contrôler visuellement la bonne • Check visually the right position 7837

position de la bague dans son lo- of the race in its groove.
gement.
• Enduire de graisse (LG EP2) la • Coat with grease (LG EP2) the
bague extérieure du roulement bearing external race (073). 073
(073)
7832
32 REPAR MS2-18 F/GB 677777845L
432 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Enduire de graisse (LG EP2) les • Coat with grease (LG EP2) the
lèvres de la bague d’étanchéité lips of the lip seal (072).
(072).
072
7933
• Enduire de graisse (LG EP2) le • Coat with grease (LG EP2) the
roulement (073). bearing (073).
073
7931
• Monter le roulement (073) (voir Install the bearing (073) (see tools
outillage page 65) dans sa bague page 65) inside its external race.
extérieure.
073
7930
677777845L REPAR MS2-18 F/GB 33
008 922 51 BOMAG 433

13.3 Wheel drive
POCLAIN HYDRAULICS
MONTAGE TYPE 1 : TYPE 1 ASSEMBLY:
• Monter la bague (078) à l’aide • Install the seal (078) using a tef-
d’une plaque de téflon de diamètre lon plate with upper diameter and a
supérieur et d’un maillet jusqu’au mallet up to the contact of the plate
contact de la plaque sur le support with the bearing support, then finish
palier et finir le montage à la main. the assembly manually.
7875
• Enduire de graisse (LG EP2) les • Coat with grease (LG EP2) the 078
lèvres de la bague type 1. (078) lips of the type 1 seal.(078)
7927
• Monter le déflecteur (079) sur • Install the deflector (079) on the

l’arbre (090). shaft (090) 079 090
7877
MONTAGE TYPE 1 : TYPE 1 ASSEMBLY :

(1) (1 )
• Enduire de graisse (LG EP2) les • Coat with grease (LG EP2) the
lèvres (1) de la bague type 2 (078). lips (1) of the type 2 seal (078).
7 8 7 2
• Monter manuellement la bague • Install manually the type 2 seal 0 7 8

type 2 (078) dans le support palier (078) into the bearing support up to
et mettre en butée sur le roulement the stop on the bearing (074)
(074).
ATTENTION AU SENS DE MON- BE CAREFUL ABOUT THE TYPE 2
! TAGE
2.(078)
DE LA BAGUE TYPE
! SEAL
TION.
(078) MOUNTING DIREC-
! !
LES LEVRES NE DOIVENT PAS SE THE LIPS SHOULD NOT TURN IN-
RETOURNER VERS L’INTERIEUR. SIDE. 3 1 3159
5 9
34 REPAR MS2-18 F/GB 677777845L
434 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
DANS TOUT LES CAS : ALL CASES :
• Sous une presse, poser l’arbre • Under press, place the shaft on
sur un support pour éviter tout effort a support to avoid any force on the
sur les goujons. studs.
7840
• Positionner le support palier sur • Install the bearing support on

l’arbre the shaft
ATTENTION AU PASSAGE DES TAKE CARE WHEN PASSING THE
! CANNELURES SUR LA BAGUE

D’ETANCHEITE (072). ! SPLINES THROUGH THE LIP SEAL
(072).
7843
• Positionner le roulement (074) • Install the bearing (074) in its

dans sa bague extérieure. outer race
074
7844
• Appliquer l’effort F (voir tableau • Using the right mandrel (see

page 69) sur le roulement (074) à tools page 65) press with F force
090
l’aide du mandrin correspondant (see table page 69) on the bearing
(voir outillage page 65). (074)
7845
• Relâcher l’effort F (voir tableau • Release the F force (see table

page 69) jusqu'à obtenir page 69) up to 20 000 N [4500 Ibf]
20 000 N.[4500 lbf].et s’assurer de and check the bearings position by
la mise en place des roulements par turning the bearing support (mini-
la rotation du palier (5 tours mini à mum 5 rev. to the right and left)
droite et à gauche) • Using a mandrel press again
• Appliquer à nouveau l’effort F with F force (see table page 69) on
(voir tableau page 69) sur le roule- the bearing (074)
ment (074) à l’aide d’un mandrin.
7846
677777845L REPAR MS2-18 F/GB 35
008 922 51 BOMAG 435

13.3 Wheel drive
POCLAIN HYDRAULICS
• Relâcher l'effort F, et monter la • Release the F force, and install

bague d’appui (076) the thrust ring (076)
076
7847
• Monter l’anneau d’arrêt (077) en • Remove the snap ring (077) us-
utilisant une pince à anneaux d’arrêt ing external snap ring pliers 077
extérieurs
7848
• Appliquer l’effort F (voir tableau • Apply the F force (see table

page 69) sur le roulement (074), page 69) on the bearing (074), then
puis mesurer le jeu entre la bague measure the clearance between the
d’appui (076) et l’anneau d’arrêt thrust ring (076) and the snap ring
(077). (077).
• Déterminer le calage (075) afin • Determine the shimming (075)
d'obtenir le couple de rotation (C) in order to obtain the rotational
correspondant (voir tableau page torque (C) (see table page 69) (Ap-
69). (valeur approximative du ca- proximate shimming value = meas-
lage = mesure + S) ure + S). 7849
• Relâcher l’effort F. Démonter • Stop the F force. Remove the

l’anneau d’arrêt (077) et la bague snap ring (077) and the thrust ring
(076). (076).
• Monter le calage (075) • Install the shimming (075)
LA CALE LA PLUS EPAISSE DOIT THE THICKEST SHIM SHOULD BE
! ETRE
MENT
MONTEE COTE ROULE-
! MOUNTED TOWARDS THE BEAR-
ING
• Remonter la bague (076). • Install the thrust ring (076). 7850

• Monter l’anneau d’arrêt (077) • Install the snap ring (077) (the
(l'angle vif opposé à la bague d'ap- sharp corner opposite to the thrust
pui (076)) en utilisant l’effort F initial ring (076) using the initial F force
(voir tableau page 69) (see table page 69).
S’ASSURER : CHECK : 074 075 076 077
• De l'impossibilité de tourner la • that it is not possible to turn the
bague (076) d’appui manuellement. thrust ring (076) manually
• Visuellement que le diamètre de • visually that the snap ring (077)
l’anneau d’arrêt (077) n'est pas plus diameter is not larger then the thrust
grand que celui de la bague d’appui ring (076) diameter.
(076).
2050
36 REPAR MS2-18 F/GB 677777845L
436 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
ETANCHEITE RENFORCEE REINFORCED SEALING
• Equiper le support de la bague • Install the lip seal on its support

d'étanchéité à l'aide du mandrin using the right mandrel (see tools
correspondant (voir outillage page page 66)
66).
ENLEVER LE RESSORT POUR
! !
TAKE OFF THE SPRING TO POSI-
POSITIONNER LA BAGUE ETAN-
TION THE LIP SEAL (072) 7880
CHE (072)

position de la bague d'étanchéité. of the lip seal.
7881
• Appliquer un cordon de Loctite • Coat with Loctite 542 (see tools

542 (voir outillage page 63) sur le page 63) the external diameter of
diamètre extérieur du support équi- the lip seal support assembly.
pé de la bague d'étanchéité.
7882
• Monter le support équipé à • Using a mandrel (see tools

l'aide du mandrin (voir outillage page 66) install the lip seal support
page 66) dans le support palier. assembly into the bearing support.
7878

position du support équipé dans le of the lip seal support assembly in
support palier the bearing support
! !
NE PAS OUBLIER D'ESSUYER DO NOT FORGET TO CLEAN THE
L'EXCEDENT DE LOCTITE. LOCTITE EXCESS
7885
677777845L REPAR MS2-18 F/GB 37
008 922 51 BOMAG 437

13.3 Wheel drive
POCLAIN HYDRAULICS
• Remonter le ressort de la bague • Reinstall the lip seal spring.

d'étanchéité.
7886
• Appliquer un cordon de loctite • Coat with Loctite 542 (see tools

542 (voir outillage page 63) sur le page 63) the back-up ring support.
support de contre-joint.
7887
• Monter le support de contre- • Using a mandrel (see tools

joint à l'aide du mandrin (voir outil- page 66) install the back-up ring
lage 66) support
! !
ATTENTION AU SENS DE MON- BE CAREFUL ABOUT THE
TAGE. MOUNTING DIRECTION.
• Essuyer l'excédent de Loctite. • Clean the Loctite excess.

7884
• Monter le joint torique. • Install the O-ring.
7888
• Monter le contre-joint. • Install the back-up ring.
7889
38 REPAR MS2-18 F/GB 677777845L
438 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Remontage (TYPE 3) Reassembly (TYPE 3)

• Contrôler les portées de joint et • Check the lip seal contact sur-
l’état des cannelures. face and the splines conditions.
SHAFT PART EXCEPT IF THERE
! !
ARBRE NU SAUF SI DEFLECTEUR
IS A DEFLECTOR WITH TYPE 1
AVEC UNE BAGUE TYPE 1
SEAL
7830
• Monter les éléments de la partie • Install the first component of the

er
(78.1) du joint glace. Ici 1 élé- mechanical seal part (78.1) 090
ment.
7831
ème
• Ici 2 élément. • Install the second component
7833
• Vérifier le positionnement du • Check visually at four points the

joint (085) visuellement en quatre seal’s positioning (085).
points.
7834
• Positionner la bague intérieure • Install the bearing inner race 073

du roulement (073) sur l’arbre (073) on the shaft
7835
677777845L REPAR MS2-18 F/GB 39
008 922 51 BOMAG 439

13.3 Wheel drive
POCLAIN HYDRAULICS
• Monter la bague extérieure du • Install the bearing outer race

roulement (074) dans le corps du (074) into the bearing support hous-
support palier, en la mettant en bu- ing up to the stop. (see tools page
tée.(voir outillage page 66) 66)
7836
• Retourner le support palier et • Turn the bearing support and

monter la bague extérieure du rou- install the bearing outer race (073) 073
lement (073) en la mettant en butée. up to stop.
7837
• Positionner la partie (78.2) du • Place the mechanical seal part

joint glace sur l’outil (voir outillage (78.2) on the tool (see tools page 078.2
page 66). 66)
7838
• Monter le joint glace sur le pa- • Install the mechanical seal on

lier. the bearing support.
• Vérifier que le joint soit bien po- • Check visually at four points the
sitionné visuellement en quatre seal’s positioning.
points.
7839
• Poser l’arbre sur un support • Place the shaft on a support to

pour éviter tout effort sur les gou- avoid any force on the studs
jons
S’ASSURER QU’IL N’Y AIT AU- MAKE SURE THERE ARE NO IM-
! CUNE IMPURETE SUR LES DEUX

PARTIES DU JOINT GLACE ! PURITIES ON THE TWO PARTS OF
THE MECHANICAL SEALS
7840
40 REPAR MS2-18 F/GB 677777845L
440 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Huiler une des portées du joint • Lubricate one of the sealing sur-
glace. faces
7841
• Appliquer un film huile sur le • Apply an oil film on the seal

joint.
! !
PROCEDER AVEC PRECAUTION, BE CAREFUL NOT TO CUT
RISQUE DE COUPURE. YOURSELF
7842
• Positionner le support palier sur • Position the bearing support on

l’arbre the shaft
7843
• Positionner le roulement (074). • Position the bearing (074)

074
7844
• Puis suivre les instructions dé- • Then follow the mounting in-
crites de la page 35 à la page 36 structions on pages 35 - 36 about
concernant le calage du palier. the bearing support shimming.
677777845L REPAR MS2-18 F/GB 41
008 922 51 BOMAG 441

13.3 Wheel drive
POCLAIN HYDRAULICS
Remontage du palier sur le moteur. Reassembling of the bearing

support on the motor.
Avant le remontage, il est impératif de Before reassembling it is necessary

s'assurer de la propreté de la gorge. to ensure that the groove is clean

! !
boue, eau doit être sup- water must be removed
primée.
• Monter un joint torique neuf • Install a new O-ring (027) coated 027
(027) enduit de graisse anti- with anti-oxidizing grease (see tools
oxydante (voir outillage page 66) page 66) in the groove of the bear-
dans la gorge du support palier ing support (071).
(071).
071
6523
• Monter un joint torique neuf • Install a new O-ring (027) coated

(027) enduit de graisse anti- with anti-oxidizing grease (see tools
oxydante (voir outillage page 66) page 66) in the groove of the valv-
dans la gorge du couvercle (041). ing cover (041).
041
6525
• Monter la came (026) sur le cou- • Install the cam (026) on the valv-
vercle, suivant les repères établis ing cover, in line with the marks 026
au démontage. made during disassembly.
The big chamfers ori-

! !
Gros chanfreins orientés
ented towards bearing
côté palier
support
• Centrer la came à l'aide de deux • Center the cam using two 6526
vis (042) diamétralement opposées. screws (042) diametrically opposite.
42 REPAR MS2-18 F/GB 677777845L
442 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Monter le palier en utilisant un • Install the bearing support, using

palan. a lifting tackle.
Pour les moteurs paliers For shaft motors the

les orifices doivent être ports must be perpen-
! perpendiculaires à l'axe
de fixation du moteur. (Fig
! dicular to the mounting
axis of the motor. (Fig
6527) 6527)
6521
6527
• Monter et serrer les vis de fixa- • Install and tighten the mounting
tions (042) au couple indiqué. (voir screws (042) to the right torque.
tableau page 71). (see table page 71).
042
6520
• Reposer le moteur. • Install the motor.
677777845L REPAR MS2-18 F/GB 43
008 922 51 BOMAG 443

13.3 Wheel drive
POCLAIN HYDRAULICS
Remplacement du palier Replacement of the DYNA +

DYNA + bearing support.
Démontage. Disassembly.
Les étapes suivantes sont impé- The following steps are manda-
ratives si le joint (045) fuit sinon tory if there are leaks on the seal
commencer le démontage des vis (045) level, if not start removing
(042) page 45 the screws (042) page 45
• Disposer le moteur en appui sur • Place the motor on the bearing
le palier et desserrer les vis (066). support and unscrew the screws 066
(066).
7666
• Démonter les vis (066) puis la • Remove the screws (066) and 065
plaque de fermeture (065). the end cover (065).
7667
• Démonter le tiroir (053) • Remove the valve spool (053).

053
7668
• Éliminer le joint torique (057). • Discard the O-ring (057).

090
7669
44 REPAR MS2-18 F/GB 677777845L
444 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS

045
7670
• Desserrer les vis (042). • Unscrew the screws (042).

042
7671
• Démonter le couvercle (040) • Remove the valving cover (040)

équipé de la glace. equipped with the valving.
Repérer la position de la Mark the location of the

! glace (047) par rapport au
couvercle (041). ! valving (047) in relation to
the valving cover (041).
6758
• Démonter la came (025). • Remove the cam (025). 025
7672
• Démonter le bloc cylindre équi- • Remove the cylinders block

pé (010). assembly (010). 010
7673
677777845L REPAR MS2-18 F/GB 45
008 922 51 BOMAG 445

13.3 Wheel drive
POCLAIN HYDRAULICS

027
7674
46 REPAR MS2-18 F/GB 677777845L
446 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Remontage. Reassembly.
• Avant le remontage, il est impé- Before reassembling it is necessary

ratif de s'assurer de la propreté de to ensure that the groove is clean
la gorge.

!
! boue, eau doit être sup-
primée.
water must be removed
• Monter un joint torique (027) • Install a new O-ring (027) in the

neuf dans la gorge du support palier groove of the bearing support (071).
(071).
! !
Monter le joint sans Install the O-ring without
l’enduire de graisse. greasing it.
7674
Les 2 étapes suivantes ne sont The 2 following steps are not 027
pas nécessaires si la plaque de necessary if the end cover (065)
fermeture (065) n’a pas été dé- was not removed.
montée.
• Install a new O-ring (027)
• Monter un joint torique neuf coated with anti-oxidizing grease
(027) enduit de graisse anti- (see tools page 66) in the groove of
oxydante (voir outillage page 66) the valving cover (041).
dans la gorge du couvercle (041).
7670

(057) enduit de graisse anti- coated with anti-oxidizing grease
oxydante (voir outillage page 66) (see tools page 66) in the groove of
dans la gorge du tiroir (053). the valve spool (053).
7669
• Monter le bloc cylindre équipé • Install the cylinders-block as-

010
(010). sembly (010).
7673
677777845L REPAR MS2-18 F/GB 47
008 922 51 BOMAG 447

13.3 Wheel drive
POCLAIN HYDRAULICS
• Monter la came (025). • Install the cam (025).
The big chamfers ori-

!
Gros chanfreins orientés
côté palier ! ented towards bearing
support 025
7672
• Huiler avec du fluide hydrauli- • Lubricate with hydraulic fluid the

que le dessus du bloc-cylindres. top of the cylinder-block.
7675
• Monter le couvercle équipé sur • Install the valving cover assem-

l'ensemble. Utiliser les 2 piges de bly on the unit. Use 2 positioning
positionnement. pins.
7676
• Monter et serrer au couple les • Install and tighten the screws

vis (042). (042). 042
Puis retirer les piges de positionne- Then remove the positioning pins.
ment.
7671
Les 3 étapes suivantes ne sont The 3 following steps are not

pas nécessaires si la plaque de necessary if the end cover was 053
fermeture n’a pas été démontée. not removed.
• Monter le tiroir (053). • Install the valve spool (053).
7668
48 REPAR MS2-18 F/GB 677777845L
448 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Monter la plaque de fermeture • Install the end cover (065).

(065). 065
7667
• Monter et serrer au couple les • Install and tighten the screws

vis (066).(voir tableau page 69) (066).(see table page 69) 066
7666
677777845L REPAR MS2-18 F/GB 49
008 922 51 BOMAG 449

13.3 Wheel drive
POCLAIN HYDRAULICS
Remplacement des mâchoi- Replacing the brake shoes.

res de frein
Avant démontage il est possible de Before disassembling it is possible

contrôler visuellement l'usure des to make a visual checking of the
garnitures de frein par les trous de brake pads wear via the inspection
visite. ports.
2055
Le remplacement des mâ- The same repairs should

choires et des tambours be made on each motor of
! doit être effectué sur cha-
que moteur d'un même
! the same axle when re-
placing shoes and brake
essieu drums.
• Débloquer les écrous de fixation • Loosen the wheel rim retaining

de la jante. nuts.
• Lever l'engin à proximité de la • Raise the machine on the side of
jante à déposer. the wheel rim to be removed.
• Déposer la jante (pneu). • Remove the wheel rim (tyre).
• Desserrer le frein mécanique. • Release the mechanical brake.
• Extraire le tambour (096) • Extract the drum (096).
Contrôler l'état de la sur- Check the friction sur-

face de frottement du face condition of the
tambour qui ne doit com- drum which should
show no deep scratches
!
porter aucune rayure pro-
fonde (0,2 mm maxi) ni
d'usure anormale sinon
! (deeper than 0,2 mm
[0.0078 in]) nor abnormal
096
procéder à son rempla- wear. Otherwise, the

brake drum should be 6528
cement. (Ra 1,6 à 3,2)
replaced. (Ra 1.6 to 3.2)
50 REPAR MS2-18 F/GB 677777845L
450 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Démonter le ressort de rappel • Remove the return spring

(154.a). (154.a).
154.a
6529
6530
• Démonter les ressorts de main- • Remove the retention springs

tien (154.b). (154.b). 1
154.b
2
6531
• Libérer les mâchoires du méca- • Release the brake shoes from

nisme de réglage . the regulating mechanism.
6532
• Démonter les ressorts de rappel • Remove the return springs

(154.c). (154.c).
154.c
6533
677777845L REPAR MS2-18 F/GB 51
008 922 51 BOMAG 451

13.3 Wheel drive
POCLAIN HYDRAULICS
• Déposer la mâchoire (154.1) • Remove the brake shoe (154.1)
154.1
6534
• Déposer la mâchoire (154.2) en • Releasing the mechanical brake

libérant le levier de freinage méca- control lever from its cable, remove
nique de son câble. the brake shoe (154.2)
154.2
6535
6536
52 REPAR MS2-18 F/GB 677777845L
452 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Dépoussiérer l'ensem- Remove all dust from the
! !
ble, s'assurer de l'étan- whole assembly. Make
chéité du cylindre de sure there are no leaks at
roue. the wheel cylinder.
Contrôler l'état de la surface de frot- Check the friction surface condition

tement du tambour qui ne doit com- of the drum which should show no
porter aucune rayure profonde (su- deep scratches (deeper than 0.2 6549
périeure à 0.2 mm) ni d'usure mm) [0.0078in] nor abnormal wear.
anormale sinon procéder à son Otherwise, the brake drum should
remplacement. be replaced.
• Monter la mâchoire (154.2), en • Attaching the control lever on

accrochant le levier de commande the brake cable (098), install the
sur le câble de frein (098). brake shoe (154.2)
098
154.2
6536
6535
677777845L REPAR MS2-18 F/GB 53
008 922 51 BOMAG 453

13.3 Wheel drive
POCLAIN HYDRAULICS
• Monter la plaque de renvoi sur • Mount the return plate on the

la mâchoire (154.2) brake shoe (154.2)
6537
6538
• Monter la mâchoire (154.1) • Install the brake shoe (154.1)
154.1
6539
• Positionner les mâchoires sur le • Position the brake shoes on the

mécanisme de réglage. regulating mechanism.
6532
• Monter les ressorts de rappel • Install the return springs (154.c)

(154.c)
154.c
6533
54 REPAR MS2-18 F/GB 677777845L
454 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Mettre en place les mâchoires • Install the brake shoes in the

dans le mécanisme de réglage regulating mechanism
6532
• Monter les ressorts de maintien • Install the retention springs

(154.b) (154.b)
1
154.b
2 6531
• Monter le ressort de rappel • Install the return spring (154.a)

(154.a)
154.a
6530
• Mesurer le diamètre D de frot- • Measure the brake drum friction

tement du tambour puis celui des diameter D and that of the brake
mâchoires en place shoes, which have been installed.
Diamètre D diameter
6529
677777845L REPAR MS2-18 F/GB 55
008 922 51 BOMAG 455

13.3 Wheel drive
POCLAIN HYDRAULICS
• Ajuster le diamètre des mâchoi- • Adjust the brake shoes diame-

res pour obtenir le jeu entre garni- ter to obtain correct clearance be- 1 5 6 .4
ture et tambour à l'aide de la roue tween the brake padding and the
dentée (156.1) pour les freins équi- 1 5 6 .2 1 5 6 .3
drum using the adjusting wheel
pés d'un dispositif de réglage mé- (156.1) for brakes equipped with
canique ou des deux roues dentées mechanical adjustment system or
(156.2 et 156.3) pour les freins two adjusting wheels (156.2 and
équipés d'un dispositif de rattrapage 156.3) for brakes equipped with a a
de jeu automatique. Dans ce cas, automatic clearance adjustment. In
l'action sur les roues dentées doit this case, the adjusting wheels 6540
être symétrique (a). Dégager légè- should be adjusted symmetrically
rement le levier (156.4) pour per- (a). Release the lever slightly
mettre cette opération. (156.4) to enable this operation to
take place.
Diamètre tambour (mm)

Drum diameter [in] Jeu total (mm)
Freins 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]
• Monter le tambour, contrôler sa • Install the drum, check that it

libre rotation. can turn freely.
6528
• Purger le cylindre de roue si né- • Bleed the wheel cylinder, if nec-

cessaire. essary.
• Remonter la jante. • Install the wheel rim.
Voir brochure INSTALLATION • See brochure INSTALLATION
MS F/GB (ref. 677777844K) MS F/GB (ref 677777844K)
56 REPAR MS2-18 F/GB 677777845L
456 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Remplacement de la came Replacement of the cam

(026) (026)
Effectuer les opérations décrites à Do operations described in chapter

la rubrique "démontage" du chapitre "replacement of the bearing sup-
"remplacement du palier" page 27 port" section "disassembly" page 27
Effectuer les opérations décrites à la Do operations described in chapter

rubrique "remontage" du chapitre "replacement of the bearing sup-
"remplacement du palier" page 28. Il port" section "reassembly" page
est nécessaire de respecter la position 28.The angular position of the cam
angulaire de la came dans le cas des must be respected on dual dis-
moteurs à 2 cylindrées dont le rapport placement motors with a displace-
de cylindrée est différent de 2 ment ratio different from 2.
Exemple : Moteur MS18, cylindrées Example : Motor MS18 with dis-

1747-1049-698 placement 1747-1049-698.
3 3
Petite cylindrée : 698 cm lettre P Small displacement : 698 cm
[42.59 cu.in] letter P
3 3
Moyenne cylindrée : 1 049 cm lettre M Medium displacement : 1049 cm
[64.01 cu.in] letter M.
La lettre P ou M doit être située The letter P or M must be located in
dans l’axe et vers le tiroir de chan- the axis and towards the displace-
gement de cylindrée, le trou borgne ment change spool, with the blind
côté fixation de la came sur le pa- hole towards the fixing of the cam
lier. on the bearing support.
M P
M P
MS08
MSE08
A R A R
MS18
MSE18
P M
M P
A R A R
MS11
MSE11
P M 2035
677777845L REPAR MS2-18 F/GB 57
008 922 51 BOMAG 457

13.3 Wheel drive
POCLAIN HYDRAULICS
Remplacement du bloc cy- Replacement of the cylin-

lindre équipé (010) ders block assembly (010)
Effectuer les opérations décrites à Do operations described in chapter

la rubrique "démontage" du chapitre "replacement of the bearing sup-
"remplacement du palier" page 27 port" section "disassembly" page 27
• Après avoir démonter la came, • After removing the cam, re-

démonter le bloc cylindre. move the cylinders block.
6541

(027)
6542
• Monter le bloc cylindre équipé • Install the cylinders block as-

(010) sembly (010) 010
6541
• Effectuer les opérations décrites • Do operations described in

à la rubrique "remontage" du chapi- chapter "replacement of the bearing
tre "remplacement du palier" page support" section "reassembly" page
28. 28.
58 REPAR MS2-18 F/GB 677777845L
458 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS

(047). (047).
• Effectuer les opérations décrites • Do operations described in

à la rubrique "démontage" du chapi- chapter "replacement of the cylin-
tre "remplacement du bloc cylindre ders bloc assembly (010)" section
équipé (010)" page 58. "disassembly" page 58.
Mark location to the

Repérer le position de la valving (047) in relation
!
glace (047) par rapport au
couvercle (041) (moteur à ! to the valving cover
(041) (Dual displace-
deux cylindrées). ment motor).
• Déposer la glace (047) du cou- • Separate the valving (047) from

vercle (041) en faisant levier au ni- the cover (041) by levering at the
veau des doigts d'indexage ou de la indexing pins or at the flange.
collerette.
2031
! !
Protéger la glace de Protect the valving from
toute poussière. dusts.
• Extraire les ressorts (052). • Remove the springs (052).

• Extraire et éliminer les joints et • Remove and discard the seals
contre joints (048) du couvercle and back-up rings (048) from the
(041). cover (041).
! !
boue, eau doit être sup- All traces of rust, mud,
primée. water must be removed.
• Huiler, puis monter des joints • Lubricate and install new seals
toriques et contre joints neufs (048) and back-up rings (048), ensuring
048
en déformant les contres joints au the back up rings are twisted as little
minimum. as possible.
1135
• Placer les ressorts (052) dans • Place the springs (052) in their
leur logement préalablement rempli housings, previously filled with
de graisse. grease.
• Huiler les portées de joints de la • Lubricate the faces of the seals
glace (047). of the valving (047).
• Enfoncer la glace (047) dans le • Press the valving (047) into the
677777845L REPAR MS2-18 F/GB 59
008 922 51 BOMAG 459

13.3 Wheel drive
POCLAIN HYDRAULICS
Respecter le sens de Respect the assembly
! !
montage de la glace sense of the valving
(047) par rapport au (047) in relation to the
Ne pas forcer lors du Do not force when in-
!
montage de la glace
(047) dans le couvercle ! stalling the valving (047)
into the cover (041).
(041).
Montage glace version 1C. Valving assembly type sin-

gle displacement motor.
• Pas de sens de montage parti- • No particular assembly sense.

culier.
041 047 2031
Montage glace version 2C. Valving assembly type Dual

displacement motor.
• Mettre la lettre choisie indiquant • Place the chosen letter indicate
le sens de rotation en face du tiroir the rotation sense in front of the
de pilotage (053). displacement change spool (053).
POSITIONNEMENT DE LA GLACE VALVING POSITIONING

G/L Gauche G/L Left
041
0 5 3 047
R L 053
6758
R 053 A 3 2 2 7
60 REPAR MS2-18 F/GB 677777845L
460 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
D/R Droite D/R Right
047
041
0 5 3
R L
6757
R 053 A 3 2 2 8
• Si il n'y a pas de lettre, réaliser • If there is no letter, do the indexing

l'indexage suivant les repères établis according to the marks made during
au démontage. disassembly.
• Effectuer les opérations décrites • Do operations described in chapter

à la rubrique "remontage" du chapi- "replacement of the cylinders block"
tre "remplacement du bloc cylindre section "reassembly" page 58.
"page 58.
Cas des moteurs SE02 et S05 : Situation of SE02 and S05 motors :
Moteur SE02 :
SE02 Motor :
G/L Gauche D/R Droite
G/L Left D/R Right
6959
6 9 5 9
Moteur S05 :
S05 Motor : G/L Gauche D/R Droite
G/L Left D/R Right
053
6 9 4 8
6948
677777845L REPAR MS2-18 F/GB 61
008 922 51 BOMAG 461

13.3 Wheel drive
POCLAIN HYDRAULICS
Remplacement du joint Replacement of the end

(045) de la plaque de ferme- cover O-ring (045)
ture.
• Disposer le moteur en appui sur • Place the motor on the bearing

le palier (écrou montés pour proté- support (fitted with nuts for studs
ger les goujons) protection)
• Démonter les vis (066) • Remove the screws (066)
066
6543
• Démonter la plaque de ferme- • Remove the end cover

ture
6544
• Eliminer le joint torique (045) • Discard the O-ring (045)

045
6545
• Eliminer le joint torique (057) si • Discard the O-ring (057) if the 057
le moteur est un 2 cylindrées motor has 2-displacement
6546
62 REPAR MS2-18 F/GB 677777845L
462 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
• Monter un joint torique (045) • Install a new O-ring (045).

neuf.
045
6547
• Monter un joint torique (057) • Install a new O-ring (057) if the 057
neuf si le moteur est un 2 cylindrées motor has 2-displacement. If not go
sinon passer à l'étape suivante to the next section
6548
• Monter la plaque de fermeture • Install the end cover
6544
• Monter et serrer les vis (066) au • Install and tighten the screws
couple correspondant (voir tableau (066) to the right torque (see table 066
page 71) page 71)
6543
677777845L REPAR MS2-18 F/GB 63
008 922 51 BOMAG 463

13.3 Wheel drive
POCLAIN HYDRAULICS
Remplacement du capteur Replacing the sensor (op-

(option) tional)
• Débrancher le connecteur • Disconnect the connector

(161.3) (161.3) 161.3
6550
• Desserrer et démonter la vis • Unscrew and remove the screw

(165) (165) 165
6551
• Extraire le capteur (161) avec le • Extract the sensor (161) with its
166
support (166) support (166)
161
6552
64 REPAR MS2-18 F/GB 677777845L
464 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
S'assurer de la propreté Make sure that the seal
! !
de la portée de joint mounting surface (164)
(164) sur le couvercle on the valving cover
distributeur (041) (041) is clean
• Monter la rondelle frein (163) • Install the new brake washer

neuve et le joint (164) neuf sur le (163) and the new seal (164) on the
capteur (161) équipé de sa pastille sensor (161) fitted with its adjusting
de réglage (167) sticker (167).
• Engager le capteur équipé dans • Push the sensor assembly into
le support (166) jusqu'à ce que le the support (166) until the seal (164)
joint (164) soit dans son logement is in its housing
6552
• Enfoncer le capteur dans le • Push the sensor into the valving

couvercle distributeur (041) jusqu'à cover (041) until it comes in contact
venir en contact sur le bloc cylindre with the cylinders block (011).
(011).
2064
l'encoche du capteur doit être orien- the notch of the sensor should be
tée vers le centre du moteur. oriented towards the center of the
motor. 1 5 ° m a x i
1 5 ° m a x i
6558
• Monter et serrer la vis (165) au • Install and tighten the screw

165
couple de serrage correspondant (165) to the right torque (see table
(voir tableau page 38). page 38).
6551
• Rebrancher le connecteur • Reconnect the connector

(161.3) (161.3) 161.3
6550
677777845L REPAR MS2-18 F/GB 65
008 922 51 BOMAG 465

13.3 Wheel drive
POCLAIN HYDRAULICS
Récapitulatif outillage Tooling inventory

Outillage standard Standard tools
• Clé hexagonale pour Hollow head
5 6 8 10 12 14
vis six pans creux wrench
• Clé hexagonale pour
Hex head wrench 13 17 19 22 24
tête hexagonale
• Clé dynamométrique FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Clé dynamométrique FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Clé dynamométrique FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]
Auto-top 2000
Anti-oxidizing Couleur vert fluo / fluorescent
• Graisse anti-oxydante origine AGIP ou Mo-
grease green color
bil XHP 222
du commerce
• Alcool isopropylique isopropyl alcohol
commercial
du commerce
• Pinceau standard Standard brush
commercial
• Activateur LOCTITE 7471 T Activator
Anaerobic adhe-
• Adhésif anaérobie LOCTITE 638
sive
• Adhésif LOCTITE 542 Adhesive
• Pince à anneau Internal snap ring

FACOM 499.32
d’arrêt intérieur pliers
0761
• Extracteur
FACOM U 20 B Extractor
6553
• Extracteur FACOM U.52T Extractor

• Clé hexagonale pour
Hex head wrench 13 17 19 22 24
tête hexagonale
• Clé dynamométrique FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Clé dynamométrique FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Clé dynamométrique FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]
66 REPAR MS2-18 F/GB 677777845L
466 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Outillage à réaliser Special tools

Ø A
Ø B
F
E
G
• Mandrin pour remonter
• Mandrel for reassembling the
la coiffe de frein ou pour
brake cover or to compress the
comprimer la rondelle
spring washer. Ø C
élastique
Ø D
0759
ØA ØB ØC ØD E F G
F02
110 [4.3] 100 [4.3] 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] 195 [7.67] 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
[0 .9 8 " d ia ]
Tube pour immobiliser le

Tube to immobilize the motor
Ø 2 5
moteur Ø
[0 .6 2 " d ia ]
1 6
5 5
[2 .1 6 "]
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
Outillage pour défreinage F 0 2 F 1 1
Tools for mechanical brake release F 0 3
mécanique. F 1 2
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
677777845L REPAR MS2-18 F/GB 67
008 922 51 BOMAG 467

13.3 Wheel drive
POCLAIN HYDRAULICS
Mandrin pour roulement de palier et Mandrel for bearing support and

bague d'étanchéité sealing ring
Taille de moteurs ØA ØB L
Size of motors mm in mm in mm in
MS02 45 1.78 55 2.16 110 4.33
MSE02
MS05
60 2.36 70 2.75 120 4.72
MSE05
MS08
75 2.95 85 3.35 140 5.51
MSE08
MS11
85 3.35 95 3.74 160 6.3
MSE11
MS18
100 3.94 110 4.33 200 7.87
MSE18
Tolérances générales : ± 0.25 mm General tolerances : ± 0.001 in
Tube Ø 5x10
pipe 0.197 dia x
0.393
Outillage pour montage joint-glace Tools for mechanical seal mounting
Taille de moteurs ØA ØB ØC
Size of motors mm in mm in mm in
MS05
101 3.97 94 3.70 88 3.46
MSE05
MS08
150 5.9 142 5.6 135 5.31
MSE08
MS11
155 6.1 148 5.82 139.5 5.49
MSE11
MS18
169 6.65 162 6.38 155 6.1
MSE18
Tolérances générales : ± 0.25 mm General tolerances : ± 0.001 in
68 REPAR MS2-18 F/GB 677777845L
468 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Mandrin pour les bagues extérieures

Mandrel for bearing outer race : Ø1
des roulements de palier :
Ø2
Ø 1 for bearing 073
Ø 1 pour roulement 073
Ø 2 for bearing 074
Ø 2 pour roulement 074
50 mm
[1.97 in]
Taille de moteurs Ø1 Ø2
Size of motors mm in mm in
MS02 C 75 2.95 75 2.95
MS02
89 3.5 84 3.3
MSE02
MS05C
89 3.5 89 3.5
MSE05C
MS05
109 4.29 99 3.9
MSE05
MS08C
119 4.68 109 4.29
MSE08C
MS08
139 5.47 124 4.88
MSE08
MS11C
MSE11C 129 5.07 124 4.88
MS11
159 6.26 139 5.47
MSE11
MS18C
159 6.26 144 5.67
MSE18C
MS18
189 7.44 169 6.65
MSE18
Résumé des couples de

Tightening torque summary
serrage
Remplacement du Replacement of the 145±14 N.m 107±10 lbf.ft

palier (070) MS02 bearing support (070)
MS05 MS08 MS02 MS05 MS08
Vis (042) Page 43 Screw (042) page 43

palier (070) MS11 bearing support (070)
MS18 Vis (042) MS11 MS18
Page 43 Screw (042) page 43
677777845L REPAR MS2-18 F/GB 69
008 922 51 BOMAG 469

13.3 Wheel drive
POCLAIN HYDRAULICS

palier DYNA + DYNA + bearing
Page 48 support page 48
End cover MS02

Plaque de fermeture
MS05 49±5 N.m 36±4 lbf.ft
MS02 MS05 moteur
motor without brake
non freiné
Screw (066) page 63
Vis (066) page 63
DYNA+ bearing sup-
Palier DYNA+ page49)
port page 49)
Plaque de fermeture 86±9 N.m 63.4±6 lbf.ft

End cover MS08
MS08 moteur non
motor without brake
freiné
Screw (066) page 63
Vis (066) page 63
Plaque de fermeture End cover MS11 210±21 N.m 155±15 lbf.ft

MS11 MS18 moteur MS18
non freiné motor without brake
Vis (066) page 63 Screw (066) page 63
Corps de frein sur 85+(0/-16) N.m 63 (+0/-12) lbf.ft

rake housing on
couvercle (MS02
alving (MS02 MS05)
MS05)
crews (102) page 17
Vis (102) page 17
Corps de frein sur rake housing on 145+(0/-30) N.m 107 (+0/-22) lbf.ft
couvercle (MS08) alving (MS08)
Vis (102) page 17 crews (102) page 17
Corps de frein sur 355+(0/-70) N.m 262 (+0/-52) lbf.ft

rake housing on
couvercle (MS11
alving (MS11-MS18)
MS18)
crews (102) page 17
Vis (102) page 17
Remplacement du Replacing the sensor. 35 ± 3.5 N.m 26±2.6 lbf.ft

capteur. screws (165)
Vis (165) Page 65 Page 65
70 REPAR MS2-18 F/GB 677777845L
470 BOMAG 008 922 51

Wheel drive 13.3
POCLAIN HYDRAULICS
Couples de serrage Standard tightening

standard en N.m ± 10% torques in [lbf.ft] ± 10%
(Suivant norme DIN 912) (According to the standard DIN 912)
Taille 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
677777845L REPAR MS2-18 F/GB 71
008 922 51 BOMAG 471

13.3 Wheel drive
POCLAIN HYDRAULICS
Tableau de valeur pour réparation palier Table of repair support bearing values.
Standard Industriel Graisse

Moteurs Types Standard Industrial Grease
Motors Types F (N) S(mm) C (N.m) F (N) S C N.m (cm3)
F [lbf] S[in] C [lbf.ft] F [lbf] mm C [lbf.ft] [cu.in]

MS02 1..0 20000 [4496.4] 0 4 [2.9] 30 [1.83]
45000 [10117] 0,10 [0.0039] 10 [7.3]
MSE02 13.0 - - - - - - -
MS05 1..0 0,12 [0.0047] 25000 [5620.5] 60 [3.66]
70000 [15737.4] 23 [16.9] 0 9 [6.6]
MSE05 13.0 0,18 [0.0070] 18000 [4046.7] 25 [1.52]
MS08 1..0 0,15 [0.0059] 40000 [8992.8] 90 [5.49]
100000 [22482] 31 [22.8] 0 12 [8.8]
MSE08 13.0 0,20 [0.0078] 28000 [6295] 30 [1.83]
MS11 1..0 0,17 [0.0066] 45000 [10117] 65 [3.96]
120000 [26978.4] 37 [27.2] 0 12 [8.8]
MSE11 13.0 0,25 [0.0098] 31000 [6969.4] 25 [1.52]
1..0 [13489.2
MS18 13.0 60000 180 [10.98]
170000 [38219.4] 0,20 [0.0078] 70 [51.6] ] 0 28 [20.6]
MSE18 42000 150 [9.15]
14.0 [9442.4]
1..0 73 [53.8] 75000 [16861.5 29 [21.3] 150 [9.15]

13.0 60 [44.2] 52000 ] 24 [17.6] 140 [8.54]
MS25 210000 [47212.2] 0,20 [0.0078] 0
[11690.6
]
1..0 280000 [62949.6] 0,25 [0.0098] 108 [95.8] [13489.2 43 [31.7] - -
MS35 60000 0
13.0 170000 [38219.4] 0,20 [0.0078 75 [55.3] ] 30 [22.1] 180 [10.98]
1..0 320000 [71942.4] 0,30 [0.0118] 120 [88.4] [16861.5 48 [35.3] -
MS50 75000 0
13.0 210000 [47212.2] 0,20 [0.0078] 110 [81.1] ] 44 [32.4] 150 [9.15]
1..0 350000 [78687] 0,30 [0.0118] 208 [153] 100000 [22482] 83 [61.2]
MS83 13.0 250000 [56205] 0,20 [0.0078] 180 [132.7 75000 [16861.5 0 72 [53] - -
]
1..0 350000 [78687] 0,30 [0.0118] 170 [125.3] 100000 [22482] 68 [50.1]
MS125 0 - -
.4.. 250000 [56205] 0,20 [0.0078] 180 [132.7] 75000 72 [53]
1. .0 : Palier Moteur Roue Standard 1. .0 : Standard wheel motor bearing support

Types 13.0 : Palier Moteur Roue Courte. Types 13.0 : Short wheel motor bearing support
4 .. : Palier Moteur Compact 4 .. : Compact wheel motor bearing support
Graisse (901) : ELF EPEXA RN 2 Grease (901) : ELF EPEXA RN 2
72 REPAR MS2-18 F/GB 677777845L
472 BOMAG 008 922 51

Wheel drive 13.3
China España & Portugal

POCLAIN HYDRAULICS BEIJING rep. office POCLAIN HYDRAULICS SPAIN S.L.
Unit A0808, Hui Bin Officies o o a
Gran Via Carlos III n 84 – 1 3
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
Česká Republika France
POCLAIN HYDRAULICS SRO POCLAIN HYDRAULICS France SAS

Kšírova 186 B.P. 106
61900 BRNO 60411 VERBERIE CEDEX
ČESKÁ REPUBLIKA FRANCE
Tel.: 420 5 43217830 Tel.: 33 3 44 40 77 77
Fax: 420 5 43217818 Fax: 33 3 44 40 77 91
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
Italia United Kingdom

POCLAIN HYDRAULICS SRL POCLAIN HYDRAULICS LTD
Via Remesina int, 190 Nene Valley Business Park
41012 CARPI (MODENA) Oundle
ITALIA PETERBOROUGH, Cambs PE8 4HN
Tel.: 390 59 65 50 528 ENGLAND
Fax: 390 59 65 50 544 Tel.: 44 1832 273773
Fax: 44 1832 274990
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
Tel.: 31 76 5021152 USA
Fax: 31 76 5012279 Tel.: 1 262 554 6739
Fax: 1 262 554 4860
POCLAIN HYDRAULICS INDUSTRIE S.A.S. au capital de 85 124 000 Francs

B.P. 106 Siège social: Route de Saint Sauveur
60411 VERBERIE CEDEX - France VERBERIE (OISE)
Tel.: 33 3 44 40 77 77 R.C.S. Senlis B 414 781 823
Fax: 33 3 44 40 77 99 Siret 414 781 823 00011
008 922 51 BOMAG 473

13.3 Wheel drive
474 BOMAG 008 922 51

13.4 Steering valve
008 922 51 BOMAG 475

13.4 Steering valve
476 BOMAG 008 922 51

Steering valve 13.4
Power Steering
Repair Information XCEL45
Steering Control
Units
001
008 922 51 BOMAG 477

13.4 Steering valve
Exploded View
37
38
40 39
41
Load Sense Relief Valves
(if included) Inlet Relief Valves
(if included)
31 32
29 30
26 27
28
12
13 11
15 14
16
18
25
17
24 Cylinder Relief Valves
23 (if included)
22
21
19 20
36
35
34
33 Inlet Check Valve
(if included)
1
2
6 5 4 3
7 Anti-Cavitation
8 Valves (if included)
9
2 Legend provided on Page 3

EATON XCEL45 Steering Control Units Repair Manual 001, December 2003
10
478 BOMAG 008 922 51
Steering valve 13.4
Exploded View Legend

1. Cap Screw (M10) 22. Seal*
2. End Cap 23. Bearing Race
3. Seal, O-ring, 77.5mm ID* 24. Needle Thrust Bearing
4. Anti-Cavitation Valve Components 25. Bearing Race
(if included): Spring 26. Spring
5. Anti-Cavitation Valve Components 27. Spacer
(if included): Plug 28. Sleeve
6. Anti-Cavitation Valve Components 29. Inlet Relief Valve Components (if
(if included): Ball 4mm included): Plug
7. Gerotor 30. Inlet Relief Valve Components (if
8. Plate included): O-ring 15mm ID
9. Drive 31. Inlet Relief Valve Components (if
10. Housing included): Spring
11. Cylinder Relief Valve Components 32. Inlet Relief Valve Components (if
(if included): Valve Seat included): Poppet
12. Cylinder Relief Valve Components 33. Inlet Check Valve (if included)
(if included): Ball 5mm 34. Ball 7mm
13. Cylinder Relief Valve Components 35. Roll Pin
(if included): Ball Holder 36. Spacer
14. Cylinder Relief Valve Components 37. Load Sense Relief Valve
(if included): O-ring Components (if included): Valve
15. Cylinder Relief Valve Components Seat
(if included): Spring 38. Load Sense Relief Valve
16. Cylinder Relief Valve Components Components (if included): Poppet
(if included): Plug 39. Load Sense Relief Valve
17. Pin Components (if included): Spring
18. Spool 40. Load Sense Relief Valve
19. Dust Seal Components (if included): O-ring
20. Gland Bushing 41. Load Sense Relief Valve
21. O-ring 42.3mm ID Components (if included): Plug
Replacement Part No. Description
Z331-07 Seal Kit (contains parts with *)
3
008 922 51 BOMAG 479

13.4 Steering valve
Disassembly
Cleanliness is extremely important when repairing a

steering control unit. Work in a clean area. Before
disconnecting lines, clean the port area of unit
thoroughly. Use a wire brush to remove foreign material
and debris from the external joints of the unit.
Note Meter (Gerotor) End
Although not all drawings 1. Clamp unit in vice,

show the unit in a vice, Gerotor end up. Clamp
we recommend that you lightly on edges of port
keep the unit in a vice face sides (see figure).
during disassembly. Use protective material
Follow the clamping on vice jaws. Housing
procedures explained distortion can result if
throughout the manual. jaws are over-tightened.
Matching Mark
2. Remove M10 cap

screws. Cap screw
3. Remove end cap.

End cap
4. Remove seal. Spacer
Seal
4
480 BOMAG 008 922 51

Steering valve 13.4
Disassembly
Gerotor
5. Remove Gerotor set.
6. Remove seal. Space
7. Remove drive spacer. Seal
8. Remove drive.
9. Remove spacer plate Drive

.
10. Remove seal from
housing.
Spacer Plate
11. Remove housing from
vice.
Seal
5
008 922 51 BOMAG 481

13.4 Steering valve
Disassembly
12. Carefully remove anti

cavitation check valves
and manual steering
check valve from bolts
holes, by tipping.
Caution 13. Carefully remove the

Do not cock spool-sleeve spool-sleeve assembly
assembly in housing. from housing in upright
Rotate spool- sleeve position.
assembly slowly when
removing it from housing. 14. Push pin from spool
sleeve assembly.
15. Remove the bearing Needle

race, needle thrust Thrust
Bearing Bearing Race
bearing and bearing race,
step by step from the
housing. Seal
16. Remove seal from

seal gland bushing
6
482 BOMAG 008 922 51

Steering valve 13.4
Disassembly
Note
There are different kinds 17. Push spool partially
of spool and sleeve set. from control end of
sleeve, then carefully
remove centering springs
Do not remove any from spool by hand (see
valves other than manual figure). Low input torque
steering check valve and unit uses four centering
anti-cavitation check springs and two spacers.
valves. All other valves Standard input torque unit
are factory preset and are uses six centering
non-serviceable springs.
Standard Springs
Low torque Springs 370/6
370/4+21626/2
7
008 922 51 BOMAG 483

13.4 Steering valve
Reassembly
Check all mating surfaces. If any parts have scratches

or burrs, the steering units must be replaced. Use of
parts with scratches or burrs can cause leakage and is
not recommended. Clean all metal parts in clean
solvent. Blow dry with air. Do not wipe dry with cloth or
paper towel because lint or other matter can get into the
hydraulic system and cause damage. Do not use grit
paper or file or grind these parts.
Note Meter (Gerotor) End

Lubricate all seals with
clean petroleum jelly 1. Assemble spool and
(Vaseline). A good sleeve carefully so that
service policy is to spring slots line up at the
replace all old seals same end. Rotate spool
with new seals. Do not while sliding parts
use excessive lubricant together.
on seals for Gerotor
section. Test for free rotation.
. Spool should rotate Matching
smoothly in sleeve with Mark
finger tip force applied at
splined end. Align spool
and sleeve by matching Matching
Mark
marks, if present.
Otherwise, align spring
slots in spool and sleeve
and stand parts on
bench.
2. Centering springs for

low input torque units
have four arched springs
with two flat spacers in
the center as shown in Standard
figure. Torque Springs
Low Torque
Centering springs for Springs
standard input torque
units have six arched
springs.
Position centering springs

so that the notches line
up, and arched center
sections are nested
together. Next, with
spring notches facing
sleeve, insert one end of
entire spring set into
spring installation tool.
8
484 BOMAG 008 922 51

Steering valve 13.4
Reassembly
3. Compress extended
. end of spring set and
push into spool-sleeve
assembly. Keep pressure
on spring ends while
withdrawing installation
tool and pushing forward
on springs at same time.
4. Center spring set in

spring slots. Seat springs
down evenly and flush
with upper surface of
spool and sleeve
5. Insert pin through

spool-sleeve assembly
until pin is within the
outside diameter of
sleeve.
Caution 6. Lubricate seal (see

Do not use any seal that parts list) before
falls freely into counter installation in seal gland
bore of seal gland bushing in housing. Use
bushing. proper seal-installation
tool, to make sure seal
enters seal gland bushing
without being cut or
nicked.
7. Install two bearing

races and needle thrust
bearing as shown in
figure.
9
008 922 51 BOMAG 485

13.4 Steering valve
Reassembly
Caution 8. Position spool-sleeve

While inserting spool assembly so that splined
sleeve assembly into end of spool enters open
housing, make sure parts end of housing first.
do not tilt out of position.
Push assembly gently
into place with slight
rotating action, keeping
pin from moving out and
getting stuck in the
internal groove.
Bring spool-sleeve
assembly entirely within
housing bore. With spool
sleeve assembly in this
flush position, check for
free rotation within
housing by turning
assembly with fingertip
force at splined end.
Note 9. Clamp housing in vice,

Check to insure that as shown in figure. Clamp
spool and sleeve are lightly on edges of
flush or slightly below 14 mounting area; do not
hole surface of housing. over-tighten jaws.
Clean upper surface of

housing by wiping with
palm of clean hand.
Clean each of the flat
surfaces of parts in
Gerotor section in a
similar way just before
reassembly. Do not use
cloth or paper to clean
surfaces.
10
486 BOMAG 008 922 51

Steering valve 13.4
Reassembly
10. Install 77.5 ID seal in

housing.
11. Install anti-cavitation

check valves and manual
steering check valve in
holes, as shown in figure.
12. Install spacer plate.

Align bolt holes in spacer
plate with tapped holes in
housing.
13. Rotate spool and

sleeve assembly until pin
is parallel with port face.
Install drive, making sure
drive is engaged with pin. A
To assure proper
alignment, mark drive as
shown in figure, reference
B. When marking drive,
note relationship of B
slotted end of drive to
splined end of drive
14. Lubricate and install C

77.5 ID seal in Gerotor
ring. The lubrication will D
hold seal in place.
15. Align star valleys with

pin. Note parallel
relationship of reference
lines A,B,C and D in
figure. Align bolts holes
without disengaging
Gerotor star from drive.
.
11
008 922 51 BOMAG 487

13.4 Steering valve
Reassembly
16. When used, install

drive spacer in Gerotor
star.
17. Lubricate and install

77.5 ID seal in Gerotor
ring.
18. Install end cap

aligning holes.
1
19. Install 7 dry cap
screws in end cap. Pre
tighten screws to 17Nm, 6 3
then torque screws to
35~45Nm in sequence
show in figure.
5
4
2 7
20. Check for proper

timing by turning the
spool clockwise and
feeling pressure in the R
port.
12
488 BOMAG 008 922 51

Steering valve 13.4
Eaton Eaton Eaton

14615 Lone Oak Road 20 Rosamond Road Eaton Fluid Power GmbH
Eden Prairie, MN 55344 Footscray Dr-Reckeweg-Str. 1
USA Victoria 3011 D-76532 Baden-Baden, Germany
Tel: 952 937-9800 Australia Tel: +49 (0) 7221 682-0
Fax: 952 974-7722 Tel: (61) 3 9319 8222 Fax: +49 (0) 7221 682-788
www.hydraulics.eaton.com Fax: (61) 3 9318 5714
© 2003 Eaton Corporation

All Rights Reserved
Document Number 001
December 2003
13
008 922 51 BOMAG 489

13.4 Steering valve
490 BOMAG 008 922 51

14 Circuit diagrams
008 922 51 BOMAG 491

492 BOMAG 008 922 51
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008 922 51 BOMAG 493

494 BOMAG 008 922 51

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Service - Manual

BW 135 AD-5 / BW 138 AD-5

Tandem Vibratory Roller

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6.8 Cleaning radiator and hydraulic oil cooler 108

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Flushing and bleeding 191

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This manual addresses the professionally qualified

Use only genuine BOMAG spare parts.

These safety regulations must be read and ap-

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l Use protective clothes like hard hat, safety boots

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Engine l The installation and use of non-genuine spare parts

Special safety regulations

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l Plug-in connectors on control units are only dust Battery

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Hydraulic system l Perform measurements at operating temperature of

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Assembly of radial seals

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Screws and nuts Strength classes, metric screws

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

Fig. 9 Identification of nuts in clock system

Strength class of Strength class of associated

Nuts for screw joints with limited load factor (04,

Nuts for screw joints without specified load factor

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Identification of UNF-threads Cotter pins

Studs and brake rods

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Tightening torques for screws with metric unified thread*

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2.1 Technical data

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- EC Machine Regulation edition 2006/42/EC

- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC

- Vibration Protection Regulation 2002/44/EC

Guaranteed sound power level:

Hand-arm vibration values

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Rated power ISO 14396 33.3 KW 33.3 KW

Water sprinkler system

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