Bw141ad-4 SM PDF

Service - Manual
BW 141 AD-4 / BW 151 AD-4

BW 151 AC-4 / BW 161 ADCV
S/N 101 920 00 ....
S/N 101 920 01 ....
S/N 101 920 10 ....
Tandem Vibratory Roller
Catalogue number.
008 910 92 01/2008
Table of Contents
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 24
Maintenance 29
2.1 General notes on maintenance 30
2.2 Fuels and lubricants 31
2.3 Fuels, lubricants and filling capacities 33
2.4 Running-in instructions 34
2.5 Maintenance chart 35
Technical data 37
3.1 Technical data 38
Connection overview 45
4.1 Connection overview 46
Tests and adjustments 49
5.1 Special tools, tests and adjustments 50
5.2 Adjusting the angle sensor on travel control lever 54
5.3 Checking the rotation speeds 56
5.4 Pressure tests in the travel circuit 58
5.5 Checking / adjusting the neutral positions of the travel pump 60
5.6 Check the setting of the high pressure relief valves in the travel circuit 63
5.7 Pressure tests in the vibration circuit 65
5.8 Check the setting of the high pressure relief valves in the vibration circuit 66
5.9 Checking / adjusting the vibrator shaft speeds 68
5.10 Check the leakage rate of the vibration motor 69
5.11 Pressure test in steering circuit 70
Flushing and bleeding 73
6.1 Special tools for flushing 74
6.2 Flushing - general 79
6.3 Flushing schematic for front drum drive 82
6.4 Flushing the front drum drive 83
6.5 Flushing schematic for rear drum drive system 87
6.6 Flushing the rear drum drive 88
6.7 Flushing schematic for wheel drive motors, AC-machines 92
6.8 Flushing the rear wheel drive on AC machines 93
6.9 Flushing schematic for vibration drive on AD-machines 97
6.10 Flushing schematic for vibration circuit on AC-machines 98
6.11 Flushing the vibration circuit 99
6.12 Bleeding the travel circuit 103
6.13 Bleeding the vibration circuit 105
Fundamental electrics 107
7.1 Understanding circuit diagrams 108
7.2 Terminal designations 113
7.3 Current and voltage 117
7.4 CAN-Bus 120
008 910 92 BOMAG 3

Table of Contents
7.5 Resistance 121

7.6 Series / parallel connection 123
7.7 Ohm's law 125
7.8 Electrical energy 125
7.9 Formula diagram 126
7.10 Metrology 127
7.11 Diodes, relays, fuses 129
7.12 Batteries 132
7.13 Three-phase generator 135
7.14 Electric starter 143
7.15 Telemecanique switch 146
7.16 Inductive proximity switches 149
7.17 Angle sensor with current output 150
7.18 Plug connectors 151
7.19 Deutsch plug, series DT and DTM 152
7.20 Plugs and terminals in spring clamping technology 158
Special tools, electrics 161
8.1 Special tools, electrics 162
Electronic modules 171
9.1 BEM, BOMAG Evib-meter 173
9.2 Electrics module A03 231
9.6 Heating/air conditioning control 298
Speedometer Module 305
10.1 Speedometer module 306
Service Training 309
11.1 Service Training 311
Engine 429
12.1 General information on diesel engine 430
12.2 Operation side 432
12.3 Exhaust side 433
12.4 Lubrication oil circuit 434
12.5 Oil pressure switch and low oil pressure circuitry 437
12.6 Coolant temperature switch 438
12.7 Three-phase generator 439
12.8 Fuel circuit 441
12.9 Fuel supply 442
12.10 Injection system 443
12.11 Injection pump replacement during service 445
12.12 Injection valve replacement during service 451
12.13 Checking / repairing injection valves 452
12.14 Fuel filter 457
12.15 Checking the compression 459
12.16 Boost fuel and minus balancing solenoid valve 460
12.17 Engine shut-down solenoid 462
4 BOMAG 008 910 92

Table of Contents
12.18 Air filter, differential pressure switch 463

12.19 Electric throttle control 465
12.20 Glow plugs 467
12.21 Engine monitoring 470
12.22 Engine 474
12.23 Check the engine oil level 476
12.24 Change the engine oil 476
12.25 Change the engine oil filter cartridge 477
12.26 Check condition of engine oil and hydraulic oil cooler, clean 478
12.27 Check, clean the water separator 478
12.28 Change the fuel pre-filter cartridge 479
12.29 Change the fuel filter cartridge 480
12.30 Check, adjust the valve clearance 480
12.31 Check, clean, change the combustion air filter 482
12.32 Special tools, Deutz engine (BFM 2011) 485
Air conditioning system 499
13.1 Physical basics 500
13.2 Refrigerant R134a 503
13.3 Compressor oil / refrigeration oil 504
13.4 Working principle of the air conditioning system 505
13.5 Monitoring devices 505
13.6 Description of components 506
13.7 Checking the compressor oil level 512
13.8 Checking the magnetic clutch 513
13.9 Inspection and maintenance work 514
13.10 Checking, tensioning, replacing the refrigerant compressor V-belt 514
13.11 Servicing the air conditioning (summer operation) 515
13.12 Drying and evacuation 518
13.13 Emptying in case of repair 518
13.14 Leak test 519
13.15 Filling instructions 520
13.16 Trouble shooting in refrigerant circuit, basic principles 523
13.17 Trouble shooting, refrigerant circuit diagram 527
13.18 Trouble shooting procedure 528
13.19 Steam table for R134a 538
Replacing the cab window panes 543
14.1 Assembly of window panes 544
14.2 Special tools 545
14.3 Auxiliary materials 546
14.4 Removing and installing the window pane 548
Frame cracks in front frame 553
15.1 Repair overview for welding the frame 554
15.2 Welding the frame 557
Replacing the travel control cable 561
16.1 Replacing the travel control cable 562
Drum 567
17.1 Special tools, drum (BW 141/151-4) 568
008 910 92 BOMAG 5

Table of Contents
17.2 Repair overview AD-drum 570

17.3 Removing and installing the drum 573
17.4 Dismantling the AD-drum 584
17.5 Dismantling, assembling the AD exciter unit 593
17.6 Assembling the drum 600
Oscillating articulated joint 621
18.1 Repair overview oscillating articulated joint 622
18.2 Removing - disassembling the oscillating articulated joint 625
18.3 Assembling the oscillating articulated joint 634
Vibration valve Y54/Y55 645
19.1 Vibration control valve, repair overview 646
Suppliers documentation 649
20.1 Travel pump 651
20.2 Vibration pump 689
20.3 Travel motor 747
20.4 Drum reduction gear 777
20.5 Vibration motor 829
20.6 Wheel drive 851
Circuit diagrams 901
21.1 Hydraulic diagram 920 100 51 903
21.4 Wiring diagram 920 100 04 915
21.5 Wiring diagram 920 100 05 947
21.6 Wiring diagram 920 100 06 981
21.7 Wiring diagram 920 100 07 1017
Supplement to circuit diagram 1055
22.1 Control elements, old design 1056
22.2 Control elements, new design 1058
22.3 Control elements, cabin 1060
22.4 Monitoring module A15, old design 1061
22.5 Monitoring module A15, new design 1063
22.6 Machine 1064
6 BOMAG 008 910 92

1 General
008 910 92 BOMAG 7

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

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

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

this manual, in the operating instructions as well
as the applicable accident prevention regulations.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
8 BOMAG 008 910 92

Safety regulations 1.2
Important notes ● Mark a machine that is defective or being repaired
1.2 Safety regulations
by attaching a clearly visible warning tag to the

These safety regulations must be read and ap- steering wheel.
plied by every person involved in the repair of this
machine. The applicable accident prevention in-
● On machines with articulated joint keep the articu-
lated joint locked during work.
structions and the safety regulations in the oper-
ating and maintenance instructions must be ● Use protective clothes like hard hat, safety boots
additionally observed. and gloves.
Repair work shall only performed by appropriately

● Keep unauthorized persons away from the machine
trained personnel or by the after sales service of during repair work.
BOMAG. ● Tools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
Any suggestions, safety precautions and warn-
safe condition.
ings in this section are intended as a mnemonic
aid for well trained and experienced expert me- ● Use only safe and approved lifting gear of sifficient
chanics. This manual should not be considered a load bearing capacity to remove and install parts or
bible on workshop safety. components from and to the machine.
Workshop equipment and facilities as well as the

● Be careful with cleansing agents. Do not use easily
use and waste disposal of solvent, fluids, gases inflammable or harmful substances, such as gaso-
and chemicals are subject to legal regulations, line or paint thinners for cleaning.
which are intended to provide a minimum on safe- ● Cleaning or repair work on the fuel tank is very dan-
ty. It is obviously your own responsibility to know gerous. Do not smoke or allow any ignitable sparks
and adhere to these regulations. or open fire in the vicinity when cleaning or repairing
This manual contain headers like "Note", "Attention", a tank. .
"Danger" and "Environment", which must be strictly ●
When performing welding work strictly comply with
complied with in order to avoid dangers for health and the respective welding instructions.
for the environment.
Precautions and codes of conduct for
Danger
! welding work
Paragraphs marked like this highlight possible Welding work should only be performed by specially
dangers for persons. instructed expert personnel.
Caution
! Danger
!
Paragraphs marked like this highlight possible Electric shock!
dangers for machines or parts of the machine.
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
i Note
eyes!
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine. Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
Environment grease or solvent residues, etc.!
Paragraphs marked like this point out practices ● Check welding equipment and cables for damage
for safe and environmental disposal of fuels and before use (also the validity of inspection stickers).
lubricants as well as replacement parts.
● Ensure good conductivity between earth cable and
Observe the regulations for the protection of the work piece.
environment.
● Start the extraction fan before starting work and
guide with the progressing work as required.
General
●
Always isolate the burner when laying it down (re-
●
Before starting repair work stand the machine on move possible electrode residues).
level and solid ground.
● Protect cables from being damaged, use cables
● Always secure the machine against unintended roll- with insulated couplings.
ing.
●
Ensure sufficient fire protection, keep a fire extin-
● Secure the engine reliably against unintentional guisher at hand.
starting.
008 910 92 BOMAG 9

● In case of welding work in fire or explosion endan- full face visor; a facility suitable for rinsing the eyes
gered environments, you should always ask for a should also be available.
welding permission. ● Avoid prolonged and repetitive contact with oil, es-
● Remove combustible parts from the vicinity or cover pecially with old oil. In case of open incisions and in-
such parts. juries seek medical advice immediately.
● Name a fire watch during and after welding work. ● Apply protective cream before starting work, so that
oil can be easier removed from the skin.
● Do not clamp the welding rod holder and the inert
gas welding gun under your arm and lay these parts ● Wash with soap and water to ensure that all oil has
only on an insulated top. been removed (a skin cleaning agent and a nail
brush will help). Lanolin containing agents will re-
● Place the inert gas bottles in a safe place and se-
place natural skin oils that were lost.
cure them against falling over.
● Do not use gasoline, kerosene, diesel, thinner or
● Use a protective screen or an arcing shield with
solvents to wash the skin.
welding glass, wear welding gloves and clothes,
this applies also for assisting persons. ● Do not put oil soaked cloths into your pockets.
● Switch the welding unit off before connecting weld- ● Avoid clothes, especially underpants, getting soiled
ing cables. by oil.
Behaviour in case of faults

● Overalls must be washed at regular intervals.
Clothes that cannot be washed, must be disposed
● Check electrode holders and electric cables at reg- of.
ular intervals.
●
If possible degrease components before handling.
●
In case of deficiencies switch off the welding unit
and inform supervising persons.
Environment
●
In case of an extractor fan failure or any other fault
inform the supervising persons. It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Entrust
Maintenance; waste disposal special companies with the waste disposal of old
●
Replace damaged insulating jaws and welding rod oil. If in doubt you should consult your local au-
holders immediately. thorities.
●
Replace the welding wire reels only in deenergized
Hydraulics
state.
● Hydraulic oil escaping under pressure can pene-
What to do in case of accidents; First Aid trate the skin and cause severe injury. You should
●
Keep calm. therefore relieve the pressure in the system before
disconnecting any lines.
●
Call first air helpers.
● Before applying pressure to the system make sure
●
Report the accident.
that all line connections and ports have been prop-
● In case of an electric accident: Interrupt the power erly tightened and are in perfect condition.
supply and remove the injured person from the ● Hydraulic oil leaking out of a small opening can
electric circuit. If breathing and heart have stopped
hardly be noticed, therefore please use a piece of
apply reactivation measures and call for an emer-
cardboard or wood when checking for leaks. When
gency doctor.
being injured by hydraulic oil consult a physician im-
mediately, as otherwise this may cause severe in-
Old oils fections.
Prolonged and repetitive contact with mineral oils will ● Do not step in front of or behind the drums/wheels/
remove the natural greases from the skin and causes crawler tracks when performing adjustment work in
dryness, irritation and dermatitis. Moreover, used en- the hydraulic system while the engine is running.
gine oils contain potentially hazardous contaminants, Block drums and/or wheels / crawler tracks with
which could cause skin cancer. Appropriate skin pro- wedges.
tection agents and washing facilities must therefore
be provided.
●
Wear protective clothes and safety gloves, if possi-
ble.
● If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
10 BOMAG 008 910 92

Reattach all guards and safety installations after plastic material, a so-called fluoroelastomer. Under
all work has been completed. normal 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 hydraulic oil
caustic hydrofluoric acid, which can cause severe
into the soil, the sewer system or into natural wa-
burns in contact with skin.
ters. Entrust special companies with the waste
disposal of old oil. If in doubt you should consult ● If the material is in such a state it must only be
your local authorities. touched with special protective gloves. These
gloves must be disposed of directly after use.
Fuels ● If the material has contacted the skin despite these
measures, take off the soiled clothes and seek
medical advice immediately. In the meantime wash
Danger
!
the affected parts of the skin for 15 to 60 minutes
Repair work on fuel systems must only be per- with cold water or lime water.
formed by appropriately trained personnel.
The following notes refer to general safety precau- Poisonous substances
tions for danger free handling of fuel. These notes are
Some of the fluids and substances used are toxic and
only general instructions; in case of uncertainties you
must under no circumstances be consumed.
should consult the person responsible for fire protec-
tion. Skin contact, especially with open wounds, should be
strictly avoided.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu- These fluids and substances are, amongst others,
tion with air creates an easily inflammable mixture. anti-freeze agents, hydraulic oils, washing additives,
The vapours are heavier than air and therefore sink lubricants and various bonding agents.
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por- Engine
tion of spilled fuel is therefore potentially dangerous.
● Fire extinguishers charged with FOAM, SCHAUM, Danger
!
CO2 GAS or POWDER must be available wherever
Do not work on the fuel system while the engine is
fuel is stored, filled in, drained off, or where work on
running - danger to life!
fuel systems is performed.
After the engine has stopped wait until the pres-
● The vehicle battery must always be disconnected,
sure has dropped (on Commonm Rail engines ap-
BEFORE work in the fuel system is started. While
prox. 5 minutes, other engines 1 minute), because
working on the fuel system you should not discon-
the system is under high pressure - danger to life!
nect the battery, because this could generate
sparks, which would ignite explosive fuel vapours. Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
●
Wherever fuel is stored, filled, drained off or where
leaks - danger to life!
work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed. When performing work on the fuel system make
Search lights must be fire proof and well protected sure that the motor cannot be started unitention-
against possible contact with running out fuel. ally - danger to life!
● Maintenance and cleaning work on the engine must
Hot fuels onyl be performed with the engine stopped and
cooled down. Make sure that the electric system
Before draining fuel off the tank for repair work, you
has been switched off (ignition key pulled out).
must strictly apply the following measures:
● Observe the accident prevention regulations for
● Allow the fuel to cool down, to prevent any contact
electric systems (e.g. -VDE-0100/-0101/-0104/-
with a hot fluid.
0105 Electric precautions against dangerous con-
● Vent the system, by removing the filler cap in a well tact voltages).
ventilated area. Screw the filler cap back on, until ● Cover all electric components properly before wet
the tank is finally emptied.
cleaning.
Synthetic rubber
Many O-rings, hoses and similar parts, which are ap-
parently made of natural rubber, are actually made of
008 910 92 BOMAG 11

Air conditioning system from April 1989). Paragraph 10 of the pressure ves-
sel directive demands that these pressure contain-
ers must be periodically inspected and tested by a
Caution
!
specialist, according to paragraph 32. In this case
Lines in the air conditioning system must only be periodically recurring inspections consist of external
loosened by trained and explicitly instructed ex- examinations, normally on containers in operation.
perts. The refrigerant container must be visually inspected
two times per year, within the frame work of major
● Wear safety goggles! Put on your safety goggles.
inspections. Special attention must thereby be paid
This will protect your eyes against coming into con-
to signs of corrosion and mechanical damage. If the
tact with refrigerant, which could cause severe
container is in no good condition, it should be re-
damage by freezing.
placed for safety reasons, in order to protect the op-
● Wear safety gloves and an apron! Refrigerant are erator or third parties against the dangers when
excellent solvents for greases and oils. In contact handling or operating pressure vessels.
with skin they will remove the protective grease film. ● Secure pressure vessels against tipping over or roll-
However, degreased skin is very sensitive against
ing away.
cold temperatures and germs.
● Do not throw pressure vessels. Pressure vessels
● Do not allow liquid refrigerants to come into contact
may thereby be deformed to such an extent, that
with skin! Refrigerant takes the heat required for
they will crack. The sudden evaporation and escape
evaporation from the environment. Very low tem-
of refrigerant releases excessive forces. This ap-
peratures may be reached. The results may be local
plies also when snapping off valves on bottles. Bot-
frost injuries (boiling point of R134a -26.5°C at am-
tles must therefore only be transported with the
bient pressure).
safety caps properly installed.
● Do not inhale higher concentrations of refrigerant ●
Refrigerant bottles must never be placed near heat-
vapours! Escaping refrigerant vapours will mix with
ing radiators. Higher temperatures will cause higher
the ambient air and displace the oxygen required for
pressures, whereby the permissible pressure of the
breathing.
vessel may be exceeded. The pressure vessel di-
● Smoking is strictly prohibited! Refrigerants may be rective therefore specifies that a pressure vessel
decomposed by a glowing cigarette. The resulting should not be warmed up to temperatures above 50
substances are highly toxic and must not be in- °C.
haled. ●
Do not heat up refrigerant bottles with an open
● Welding and soldering on refrigeration equipment! flame. Excessive temperatures can damage the
Before starting welding or soldering work on vehi- material and cause the decomposition of refriger-
cles, (in the vicinity ant.
of air conditioning components) all refrigerant must ●
Do not overfill refrigerant bottles, since any temper-
be drawn out and the rests removed by blowing out
ature increase will cause enormous pressures.
the system with nitrogen. The decomposition prod-
ucts created from the refrigerant under the influence
of heat not only are highly toxic, but also have a Environment
strong corrosive effect, so that pipes and system In operation, during maintenance and repair work
components may be attacked. The substance is and when taking refrigeration systems our of
mainly fluorohydrogen. service it is not permitted to let refrigerant escape
● Pungent smell! In case of a pungent smell the afore into the atmosphere, which would contradict the
mentioned decomposition products have already current status of technology.
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respi- Battery
ratory system, the lungs and other organs may be ● Wear goggles and face protection (acid).
harmed.
● Wear suitable clothes to protect face, hands and
● When blowing out components with compressed air body (acid).
and nitrogen the gas mixture escaping from the
components must be extracted via suitable exhaust
●
Work and store accumulators only well ventilated
facilities (workshop exhaust systems). rooms. (Development of oxyhydrogen gas).
● Do not lean over the battery while it is under load,
Handling pressure vessels being charged or tested. (Danger of explosion).
● Since the fluid container is pressurized, the manu- ● Burning cigarettes, flames or sparks can cause ex-
facture and testing of these pressure vessels is gov- plosion of the accumulator
erned by the pressure vessel directive. (New edition ● Keep ignition sources away from the battery.
12 BOMAG 008 910 92

● Always shield eyes and face towards the battery. ● There is a danger of scalding when draining off en-
● Do not use battery chargers or jump leads without gine or hydraulic oil at operating temperature.
following the operating instructions. ● on machines with rubber tires a tire may busr if in-
● Keep the cell plugs closed. correctly assembled. This can cause severe injury.
● After an accident with acid flush the skin with water ● Do not exceed the specified highest permissible tire
and seek medical advice. pressure.
● Do not allow children access to batteries.
● When mixing battery fluid always pour acid into wa-
ter, never vice-versa.
Special safety regulations

● Use only genuine BOMAG spare parts for repair
purposes. Original parts and accessories have
been specially designed for this machine.
● We wish to make explicitly clear that we have not
tested or approved any parts or accessories not
supplied by us. The installation and/or use of such
products may therefore have an adverse effect on
the specific characteristics of the machine and
thereby impair the active and/or passive driving
safety. The manufacturer explicitly excludes any li-
ability for damage caused by the use of non-original
parts or accessories.
●
Unauthorized changes to the machine are prohibit-
ed for safety reasons.
●
If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine, danger of injury!
●
Do not perform cleaning work while the engine is
running.
●
If tests must be performed with the engine running
do not touch rotating parts of the engine, danger of
injury.
● Exhaust gases are highly dangerous. Always en-
sure an adequate supply of fresh air when starting
the engine in closed rooms.
●
Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
● Keep used filters in a separate waste container and
dispose of environmentally.
●
Dispose of oils and fuel environmentally when per-
forming repair or maintenance work.
●
Do not refuel in closed rooms.
● Do not heat up oil higher than 160 °C because it
may ignite.
●
Wipe off spilled oil and fuel.
● Do not smoke when refuelling or when checking the
acid level in the battery.
● Do not check the acid level of the battery with a na-
ked flame, danger of explosion!
● Old batteries contain lead and must be properly dis-
posed of.
008 910 92 BOMAG 13

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

A structured approach in trouble shooting saves time
and helps to avoid mistakes and expenses, especially
in the fields of electrics and electronics. Understand-
ing electronic controls requires the knowledge of
some basic terms concerning their general perform-
ance. In many cases error logs are just simply read
out and control units are replaced without any further
trouble shooting. This is in most cases unnecessary
and, even more important, very expensive.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
●
In approx. 10 % of the examined cases the prob-
lems were caused by control units.
●
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:
●
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Electric signals must be checked at
the locations to which they are applied, i.e. on con-
trol unit or sensor technology. So, if the system had
been diagnosed without unplugging the control unit
and checking the wiring, one should be alerted.
● 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.
●
Perform trouble shooting in a systematic way. Do
not become confused by the high number and vari-
ety of electric cables, current can only flow in a
closed circuit. You should first become acquainted
with the function of the corresponding electric circuit
by following the correct wiring diagram. Detected
faults should be rectified immediately. If the system
still does not work correctly after this measure, trou-
ble shooting must be continued. Several faults very
rarely occur at the same time, but it is not impossi-
ble.
●
Do not disconnect or connect battery or generator
while the engine is running.
● Do not operate the main battery switch under load.
14 BOMAG 008 910 92

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

●
Surge voltages in the electric system must be strict-
ly avoided:
●
When performing welding work always fasten the
earth clamp of the welding unit in the immediate vi-
cinity of the welding location.
!Caution
Switch off the main battery switch, doisconnect
the generator and pull the plug out on the control
unit before starting welding work.
008 910 92 BOMAG 15

Hydraulic system ● After changing a component perform a high and

charge pressure test, if necessary check the speed
of the exciter shaft.
Caution
!
● The operating pressure of the exciter shaft to a
Do not open any hydraulic components if you
great extent depends on the base under the vibrat-
have not been properly trained and without exact
ing drum. If the soil is too hard place the drums on
knowledge.
old rubber tires. Do not activate the vibration on a
Please note hard, concreted base, danger of bearing damage.
Cleanliness is of utmost importance. Make sure that ●
After the completion of all tests perform a test run
no dirt or other contaminating substances can enter and then check all connections and fittings for leaks
into the system. with the engine still stopped and the hydraulic sys-
tem depressurized.
● Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt. Before commissioning
● Before disconnecting hoses, pipes or similar relieve ● After changing a component clean the hydraulic oil
the system pressure with the engine shut down. tank thoroughly.
● During repair work keep all openings closed with ● Fill the housings of hydraulic pumps and motors
clean plastic plugs and caps. with hydraulic oil.
● Do not run pumps and motors without oil. ● Use only hydraulic oils according to the specifica-
● When cleaning hydraulic components take care not tion in the maintenance instructions.
to damage any fine machine surfaces. ●
After changing a component clean the hydraulic
● Chemical and rubber soluble cleansing agents may system as described in the flushing instructions in
only be used to clean metal parts. Do not let such order to prevent all other components from being
substances come in contact with sealing material. damaged by abrasion and metal chips remaining in
the system.
● Rinse of cleaned parts thoroughly, dry them with
compressed air and apply anti-corrosion oil immedi-
●
Change the hydraulic oil filter.
ately. Do not install parts that show traces of corro- Commissioning
sion.
●
Bleed the hydraulic circuits.
● Avoid the formation of rust on fine machined caused
by hand sweat. ●
Start up the system without load.
● Grease must not used as a sliding agent for assem- ●
Check the hydraulic oil level in the tank, fill up oil if
bly work. Use hydraulic oil. necessary.
●
Do not start the engine after the hydraulic oil has After commissioning
been drained off. ●
Check system pressures and speeds.
● Use only the specified pressure gauges. Risk of ● Check fittings and flanges for leaks.
damaging the pressure gauges under too high pres-
sure. ● After each repair check all adjustment data, rota-
tional speeds and nominal values in the hydraulic
● Clean ports and fittings before removal so that no
system, adjust if necessary.
dirt can enter into the hydraulic system.
● Do not adjust pressure relief valves and control
●
Check the hydraulic oil level before and after the
valves to values above their specified values.
work.
● Use only clean oil according to specification.
● Check the hydraulic system for leaks, find and rec-
tify the cause.
● Fill new hydraulic units with hydraulic oil before
starting operation.
●
After changing a component thoroughly flush and
bleed the entire hydraulic system.
● Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).
16 BOMAG 008 910 92

Air conditioning system damp air is drawn into the component by the differ-
ence in temperatures.
CFC - halon prohibition ● Damaged or leaking parts of the air conditioning
The CFC - halon prohibition from May 06, 1991 regu- must not be repaired by welding or soldering, but
lates the withdrawal from the use of CFC and the han- must generally be replaced.
dling of these refrigerants.
● Do not fill up refrigerant, but extract existing refrig-
Contents: erant and refill the system.
Since 1995 CFC (R12) is no longer permitted for use ● Different types of refrigerant must not be mixed.
in new systems.
Only the refrigerant specified for the corresponding
In operation, during maintenance and repair work and air conditioning system must be used.
when taking refrigeration systems our of service it is ● Refrigerant circuits with refrigerant type R134a
not permitted to let refrigerant escape into the atmos-
must only be operated with the compressor oil / re-
phere, which would contradict the current status of
frigeration oil approved for the compressor.
technology.
● Used compressor oil / refrigeration oil must be dis-
Work on refrigeration systems must only be carried
out by persons with well founded knowledge about posed of as hazardous waste.
such systems and who have the necessary technical ● Due to its chemical properties compressor oil / re-
equipment available. frigeration oil must never be disposed of together
The use of refrigerant must be documented. with engine or transmission oil.
Old systems should be converted to refrigerants

● Compressor oil / refrigeration oil is highly hydro-
harmless to ozone (refrigerant substitutes). scopic. Oil cans must strictly be kept closed until
use. Oil rests should not be used, if the can had
For this reason the Federal Environmental Agency at been opened over a longer period of time.
the end of 1995 published suitable replacement refrig-
erants for R 12. As a consequence old systems must ●
All O-rings as well as pipe and hose fittings must be
no longer be filled with R12. As soon as such a system oiled with compressor/refrigeration oil be-
is opened for service, the system must be converted foreiassembly.
to a suitable replacement or service refrigerant. Old ●
When replacing a heat exchanger, e.g. evaporator
systems may still be used, as long as they are leak or condenser, any compressor oil / refrigeration oil
tight. R 134a was nominated as replacement for R 12. lost by exchanging the components, must be re-
Inside the European Union the "EU-Directive 2037/ placed with fresh oil.
2000 on substances causing decomposition of the ●
A too high compressor oil / refrigeration oil level ad-
ozone layer" regulates the production, use and avail- versely affects the cooling performance and a too
ability of CFC and H-CFC. low oil level has a negative effect on the lifetime of
● In case of a repair on the refrigeration system you the compressor.
should first evacuate the air conditioning system for ●
If a air conditioning unit needs to be opened, the
at least 45 minutes to remove any moisture from the dryer must be replaced in any case.
system, before you start to refill. Moisture bonded in
the compressor oil / refrigeration oil (PAG oil) can
● Always use new O-rings when reassembling the
only be removed from the system by changing the unit.
oil. ●
Always use two spanners when connecting pipes or
●
During repair work on refrigerant lines and compo- hoses, to prevent the pipe end from being damaged
nents, these must be kept closed as far as possible, .
in order to prevent the invasion of air, moisture and ● Tighten screw fittings with the specified torque.
dirt, because the operational reliability of the system
can only be assured if all components in the refrig-
●
Check the connections of pipes, fittings or compo-
nents thoroughly; do not use if damaged.
erant circuit are clean and dry from inside.
●
Do not leave the refrigerant circuit unnecessarily
● Make sure that no dirt or foreign parts can enter into
open to the atmosphere. Do not attempt to repair
the compressor or the air conditioning system. The
bent or burst pipes.
area around the refrigerant hoses should be
cleaned with a gasoline free solvent. ●
Compressor valves must only be opened after the
system has been properly sealed.
● All parts to be reused should be cleaned with a
gasoline free solvent and blow-dried with clean ● The use of leak detection colouring matter is not
compressed air or dried with a lint-free cloth. permitted, because its chemical composition is un-
known and its effect on compressor oil and rubber
● Before opening all components should have
elements is not predictable. The use of leak detec-
warmed up to ambient temperature, to avoid that
008 910 92 BOMAG 17

tion colouring matter makes any warranty claims Fuel hoses

null and void.
● Tools used on refrigeration circuits must be of ex-
cellent condition, thus to avoid the damage of any
connections.
● The dryer is to be installed last, after all connections
in the refrigerant circuit have been tightened.
● After completion of repair work screw locking caps
(with seals) on all connections with valves and on
the service connections. Start up of the air condi-
tioning system. Observe the filling capacity.
● Before start up of the air conditioning system after a Fig. 1
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com- ! Caution
pressor/control valve switched off. - Once the idle All fuel hoses have two layers of material, a rein-
speed of the engine has stabilized switch on the forced rubber coating outside and an internal Vi-
compressor and run it for at least 10 minutes at idle ton hose. If a fuel hose has come loose one must
speed and maximum cooling power. make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
●
Never operate the compressor over longer periods
layer. In case of a separation the hose needs to be
of time with high engine speeds without a sufficient
replaced.
amount of refrigerant in the system. This could
probably cause overheating and internal damage.
18 BOMAG 008 910 92

Gaskets and mating surfaces threads or splines. If no assembly sleeve is availa-
ble, you should use a plastic tube or adhesive tape to
Leaking or failing seals and gaskets can in most cases
prevent the sealing lip from being damaged.
be tracked down to careless assembly, causing dam-
age not only to the seal or gasket, but also to the mat-
ing surfaces. Careful assembly work is mandatory if
good results are to be achieved.
● Before assembling replacement seals make sure
that the running surface is free of pitting, flutes, cor-
rosion or other damage.
●
Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
● Sealing compound should only be used if specially
requested in the instructions. In all other cases
these joints should be assembled in dry condition.
● Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the Fig. 3
compound does not enter into oil galleries or blind ● Lubricate the outer rim 1 (Fig. 3) of the seal and
threaded bores.
press it flat on the housing seat.
●
Before assembly remove any residues of old seal-
ing compound. Do not use any tools that could dam-
age the sealing surfaces. i Note
If possible, use a "bell" 1 (Fig. 3), to make sure that
●
Examine the contact faces for scratches and burrs,
the seal will not skew. In some cases it may be ad-
remove these with a fine file or an oilstone; take
visable to assemble the seal into the housing first, be-
care that no grinding dust and dirt enters into
fore sliding it over the shaft. Under no circumstances
tapped bores or enclosed components.
should the full weight of the shaft rest on the seal.
●
Blow lines, ducts and gaps out with compressed air,
If you have no proper service tools at hand, use a suit-
replace any O-rings and seals that have been dis-
able drift punch with a diameter which is about 0.4mm
lodged by the compressed air.
smaller than the outer diameter of the seal. Use VERY
Assembly of radial seals LIGHT blows with the hammer if no press is available.
●
Press or knock the seal into the housing, until it is
flush with the housing surface.
Fig. 2
●
Lubricate sealing lips 1 (Fig. 2) with clean grease; in
case of double seals fill the space between the seal-
ing lips with a generous amount of grease.
●
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve 1 (Fig. 2), to pro-
tect the lip from being damaged by sharp edges,
008 910 92 BOMAG 19

Feather keys and keyways Ball and roller bearings
!Caution !Caution
Feather keys must only be reused if they show no Ball and roller bearings must only be reinstalled
differences to new feather keys, any notches must after it has been assured that they are in perfect
be considered as initial signs of wear. condition.
Fig. 4
● Clean and thoroughly examine the feather key.
● Debur and thoroughly clean the edges of the key-
way with a fine file before reassembling.
Fig. 5
● Remove any lubricant residues from the bearing to
be examined by washing it with gasoline or any oth-
er appropriate degreasing agent. Cleanliness is of
utmost importance for all related work.
●
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. If necessary replace the bearing with
a new one, since these symptoms are first signs of
wear.
●
Hold the bearing with you thumb and the index fin-
ger by the inner race, rotate the outer race and
make sure that it runs without friction. Hold the
bearing by the outer race and repeat this test with
the inner race.
●
Move the outer race gently to and fro while holding
it by the inner race; check for resistance while rotat-
ing and replace the bearing if it does not work cor-
rectly.
● Lubricate the bearing with an appropriate lubricant
before reinstalling.
20 BOMAG 008 910 92

● Check shaft and bearing housing for discolouration Screws and nuts
or other signs of movement between bearing and
seats. Tightening torque
● Make sure that shaft and housing are free of burrs
before assembling the bearing. !Caution
● If a bearing of a pair of bearings shows any defects, Always tighten nuts or screws to the specified
we highly recommend the replacement of both tightening torque. Tightening torques deviating
bearings. from the ones in the table are specially mentioned
in the repair instructions.
● On greased bearings (e.g. wheel bearings) fill the
space between bearing and outer seal with the rec- Damaged screws must under no circumstances
ommended type of grease before assembling the be used any longer. Recutting threads with thread
seal. cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
● Always mark the individual parts of separable bear-
roded thread pitches can cause incorrect torque
ings (e.g. taper roller bearings) to enable correct re-
value readings.
assembling. Never assemble the rollers to an outer
race that has already been used, replace the com- Self-locking nuts must be generally renewed.
plete bearing instead. The use of screws with too high strength can
cause damage!
● Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
● When checking or retightening screw joints to the
specified tightening torque you should first relieve
by a quarter turn and then tighten to the correct
torque.
● Before tightening you should lightly oil the thread, in
order to ensure low friction movement. The same
applies for self-locking nuts.
Fig. 6 ● Make sure that no oil or grease will enter into tapped
bores. The hydraulic power generated when turning
in the screw could cause breakage of the effected
Caution
!
part.
When assembling the bearing to the shaft load
must only be applied to the inner race 1 (Fig. 6).
When fitting the bearing into the housing load
must only be applied to the outer race (2).
008 910 92 BOMAG 21

Strength classes of metric screws Strength classes of metric nuts

The strength classes (from 3.6 to 12.9) are specified Nuts are differentiated by three load groups. Each
for all strength classes from a nominal diameter of load group has a special designation system for the
5mm. The corresponding identification can be found strength class assigned, so that the load group can be
where allowed for by the shape of the screw. clearly identified.
Nuts for screw joints with full load capability (4, 5,

6, 8, 10, 12)
Fig. 8 Identification of nuts

In a connection with a screw, these nuts 1 (Fig. 8)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
Strength class of Strength class of associated

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
Fig. 7 Identification of screws 6 6.8
8 8.8
Example: A screw is identified with 12.9.
9 9.8
The first number corresponds with 1/100 of the nomi- 10 10.8
nal tensile strength (minimum tensile strength) in N/ 12 12.8
mm2.
Nuts for screw joints with limited load factor (04,
●
The nominal tensile strength is 12 X 100N/mm2 = 05)
1200 N/mm2.
The preceding "0" indicates that, due to their low
The second number specifies 10-times the ration be- height, nuts 2 (Fig. 8) in this group are only able to
tween lower yield point and nominal tensile strength withstand the force of a screw to a limited extent.
(yield point ratio). Nut height below 0.8 d (d = nominal dimension).
Nuts for screw joints without specified load factor

i Note
(11H, 14H, 17H, 22H)
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas- This standard contains strength classes (hardness
tic deformation). classes) for nuts 3 (Fig. 8), for which no load values
can be specified, e.g. because of their shape and di-
When exceeding the upper yield point the material will mensions, but which can only be classified by their
not restore its original shape after being relieved. hardness.
● The lower tensile strength is 9/10 X 1200 N/mm2 = Nut height below 0,5 d (d = nominal dimension).
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
22 BOMAG 008 910 92

Identification in clock system
Fig. 9 Identification of nuts in clock system

For small nuts (Fig. 9) the clock system can be used
for identification.
● The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
●
The strength class is identified by a dash (b).
008 910 92 BOMAG 23

1.4 Tightening torques
The values specified in the table apply for screws:

● black oiled
● with surface protection A4C
● with surface protection DACROMET
i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with metric unified thread1
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
1 Coefficient of friction μ tot. = 0,14
Tightening torques for screws with metric unified fine thread1
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
24 BOMAG 008 910 92

Tightening torques 1.4
Tightening torques for screws treated with anti-seizure paste OKS 2401 (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
1 Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques for wheel nuts (fine thread) 1 2
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
2 These values result in a 90% utilization of the yield point
008 910 92 BOMAG 25

The values specified in the table apply for screws:

● black oiled
● with surface protection A4C
● with surface protection DACROMET
i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread
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, 1 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
26 BOMAG 008 910 92

Tightening torques 1.4
Tightening torques for screws with UNF thread, 1 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
008 910 92 BOMAG 27

28 BOMAG 008 910 92

2 Maintenance
008 910 92 BOMAG 29

2.1 General notes on maintenance
2.1 General notes on maintenance the engine's performance and temperature level as
well as the quality of the exhaust gas.
When servicing the machine pay careful attention to
If your machine has to work permanently in "thin air"
all applicable safety instructions.
(at high altitudes) and with full load you should consult
Thorough maintenance of the machine ensures max- or service department or the service department of the
imum reliability and prolongs the lifetime of important engine manufacturer.
components. The necessary effort can by no means
be compared with the faults which may occur when Notes on the hydraulic system
not observing these instructions.
When servicing the hydraulic system cleanliness if of
The terms left/right are always related to travel direc-
utmost importance. make sure that no dirt or other
tion forward.
contaminating systems can enter the system. Small
● Clean machine and engine thoroughly before start- particles can flute valves, cause pumps to seize and
ing maintenance work. block restrictors and pilot bores, thereby causing cost-
ly repairs.
● For maintenance work park the machine on level
ground. ● If during the daily oil level check the oil level is found
to have dropped, check all lines, hoses and compo-
● Maintenance work must generally be carried out
nents for leakages.
with the engine shut down.
● Seal leakages immediately. If necessary inform the
● Depressurize hydraulic lines before working on
responsible service department.
them.
●
Disconnect the battery and cover it with insulation
●
Always use the filling and filtering unit (BOMAG
material before starting to work on electrical compo- part-no. 007 610 01) to fill the hydraulic system.
This unit is equipped with a fine filter which cleans
nents.
the hydraulic oil and prolongs the lifetime of the fil-
●
Always attach the articulation lock (transport lock) ter.
before starting to work in the articulation area of the ●
Clean fittings, filler caps and their immediate sur-
machine.
rounding area before removing them, so that no dirt
can fall in.
Environment ●
Do not leave the tank opening unnecessarily open,
During maintenance work catch all oils and fuels cover it so that no dirt can fall in.
and do not let them seep into the ground or into
the sewage system. Dispose of oils and fuel envi-
ronmentally.
Store used filters in a special waste container and
dispose of environmentally.
Always catch biodegradable oil separately.
Notes on the fuel system

The lifetime of the diesel engine is decisively depend-
ing on the cleanliness of the fuel.
● Keep the engine free of dirt and water as this could
damage the injection elements of the engine.
● When choosing the storage location for fuel make
sure that spilled fuel will not harm the environment.
● Do not let the suction hose disturb the sludge on the
bottom of the drum.
●
Fuel left in the fuel drum is not suitable for the en-
gine and should only be used for cleaning purpos-
es.
Notes on the engine performance

Combustion air and fuel injection rates of the diesel
engine have been carefully adjusted and determine
30 BOMAG 008 910 92

Fuels and lubricants 2.2
2.2 Fuels and lubricants Regular lubrication oil changes
The longest permissible time a lubrication oil should
Engine oil remain in an engine is 1 year. If the following oil
change intervals are not reached over a period of 1
● Use winter grade engine oil for winter operation! year, the oil change should be performed at least once
per year, irrespective of the operating hours reached.
Oil quality
Preferably use oils of ACEA-classification E3-96/E5-
02. This enables utilization of the longest oil change
intervals. Oil of ACEA-classification E2-96 may also
when reducing the period between oil changes by 50
percent.
Oils of API-quality class CG-4/CH-4 enable utilization
of the longest oil change intervals. Oils of API-quality
classes CF/CF-4 may also be used when reducing the
period between oil changes by 50 percent.
Lubrication oil change intervals

Oil change intervals with oil quality
ACEA
E2-96 = 250 operating hours
API
API CF/CF-4 = 250 operating hours
Fig. 10
ACEA
In order to assure perfect cold starting it is import to
chose the viscosity (SAE-class) of the engine oil ac- E3-96/E5-02 = 500 operating hours
cording to the ambient temperature. API
For winter operation below -10 °C the oil change inter- CG-4/CH-4 = 500 operating hours
vals must be shortened.
Lubrication oil with a too high viscosity index causes
! Caution
starting difficulties. The temperature when starting the
engine is therefore of highest importance when These intervals apply only when using a diesel
choosing the viscosity of engine oil for winter opera- fuel with maximum 0.5 % sulphur by weight and
tion. for ambient temperatures higher than -10 °C.
When using fuels with a sulphur content of more
Oil viscosity than 0.5% to 1% or under ambient temperatures
below -10 °C the oil change intervals specified in
Since lubrication oil changes its viscosity with the tem-
the table must be halved. When using fuels with a
perature, the ambient temperature at the operating lo-
sulphur content higher than 1% to 1.5% the engine
cation of the engine is of utmost importance when
oil must have a TBN of approx. 12 x the S-content
choosing the viscosity class (SAE-class) (Fig. 10).
in % by weight when halving the oil change inter-
Occasional falling short of the temperature limit (e.g. vals.
use of SAE 15W/40 down to -15 °C) may effect the
cold starting ability of the engine, but will not cause
Lubrication oil quality classes
any engine damage.
The oil manufacturer is solely responsible for assign-
Temperature related lubrication oil changes can be
ing a product to a certain quality class.
avoided by using multi-purpose oils. The following oil
change intervals apply also when using multi-purpose
oils. i Note
When changing to a higher alloyed oil quality after a
longer period of operation, it is recommended to per-
form the first oil change of the higher quality oil already
008 910 92 BOMAG 31

2.2 Fuels and lubricants
after 20 operating hours. The lubrication oil filter car- Lubrication grease
tridge must be changed at the same time.
For lubrication purposes use an EP-high pressure
grease, calcium and/or lithium saponified (penetration
Fuels 2), acc. to DIN 51502 KP 2G.
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and en-
sure strict cleanliness when filling in. A higher sulphur
content has a negative effect on the oil change inter-
vals. Use only winter-grade diesel fuel under low am-
bient temperatures. The fuel level should always be
topped up in due time so that the fuel tank is never run
dry, as otherwise filter and injection lines need to be
bled.
The following fuel specifications are permitted: DIN
51601; Nato Codes: F-54, F-75; BS 2869: A1 and A2;
ASTM D 975-78: 1-D and 2-D; VV-F-800 a: DF-A, DF-
1 and DF-2.
Winter fuel
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.
In most cases a sufficient cold resistance can also be
achieved by adding flow enhancing fuel additives.
Consult the engine manufacturer.
Mineral oil based hydraulic oil

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

On request the hydraulic system can also be filled with
ester based biodegradable hydraulic oil, Panolin HLP
Synth. 46. This biologically quickly degradable hy-
draulic 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 manufactur-
er for details.
Check the filter more frequently after this change.
Drum drive gear oil

For the gearbox use only multi-purpose transmission
oil of API-class GL5 with viscosity class SAE 80W-90.
32 BOMAG 008 910 92

Fuels, lubricants and filling capacities 2.3
2.3 Fuels, lubricants and filling
capacities
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention

Observe the level marks
Engine Engine oil
ACEA: E3-96/E5-02 approx. 10 litres without

oil filter up to oil quantity
max.
API: CG-4/CH-4
SAE 10W/40 (-20 °C to +30 °C)
SAE 10W/40 (-10 °C to +40 °C)
SAE 30 SAE 10W
(+5 °C to +30 °C) (-5 °C to -30 °C)
SAE 40 SAE 20W/20
(+25 °C to +40 °C) (-10 °C to +10 °C)
Fuel
Diesel Winter diesel fuel (down 160 litres

to -12 °C)
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity 60 litres

46 mm2/s at 40 °C or
ester based biodegradable hydraulic oil
Sprinkler system Water Anti-freeze mixture and 800 litres

water 1
Emulsion approx. 40 litres
Drum SAE 15W/40 5,3 litres (BW 141 AD-4)
- Exciter shaft tube 6,3 litres (BW 151 AD-4)

6,3 liters (BW 151 AC-4)
Travel gear, drum SAE 80W-90, API GL5 approx. 1.5 litres
Steering chains High pressure grease (lithium saponified) as required
Oscillating articulated joint High pressure grease (lithium saponified) as required

1 Mix water and anti-freeze agent by following the instructions of the manufacturer
008 910 92 BOMAG 33

2.4 Running-in instructions
2.4 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

● Check the engine for leaks.
● Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts.
● Retighten the bolted connections on the machine.

● 1st oil change in drum drive gear.
● Change the engine oil.
● 1. Oil change in the exciter shaft tube.

● 2. Oil change in drum drive gear.
● 2. Oil change in the exciter shaft tube.
Special intervals
●
Switch the heating system1 on every month for
about 10 minutes.
●
Switch the air conditioning* on every month for
about 10 minutes.
1 Optional equipment
34 BOMAG 008 910 92

Maintenance chart 2.5
2.5 Maintenance chart
every 10 operating hours, daily
every 1000 operating hours


No. Maintenance work Remark
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection X
glass
5.10 Check the water level X
5.11 Checking the emulsion level X
5.12 Clean the cooling fins on engine X
and hydraulic oil cooler
5.13 Change the engine oil* see foot note X
5.14 Change the engine oil filter car- min. 1x per year X
tridge1
5.15 Service the air conditioning (sum- X
mer operation)
5.16 Service the battery Pole grease X
5.17 Change the fuel filter cartridge X
5.18 Change the fuel pre-filter cartridge X
5.19 Change the oil in the drum drive see foot note X
gear2
5.20 Check, tension, lubricate the steer- X
ing chain
5.21 Check the engine mounts X
5.22 Check, tension, replace the V-belt X
5.23 Checking, tensioning, replacing X
the refrigerant compressor V-belt
5.24 Change the oil in the vibrator shaft see foot note X
tube3
5.25 Check, adjust the valve clearance X
5.26 Change hydraulic oil and breather see foot note X
filter4
008 910 92 BOMAG 35

2.5 Maintenance chart
every 10 operating hours, daily


No. Maintenance work Remark
as required
5.27 Changing the hydraulic oil filter at least every 2 X
years
5.28 Grease the articulated joint at least every 2 X
years
5.29 Replace the injection valve X
5.30 Service the combustion air filter min. 1x per X
year,
safety cartridge
at least every 2
years
5.31 Clean the water tank X
5.32 Clean the water filter X
5.33 Water sprinkler system, mainte- X
nance in the event of frost
5.34 Cleaning the emulsion filter X
5.35 Fill the provision tank for the wind- X
screen washer system
5.36 Adjusting the scrapers X
5.37 Checking the tire pressure X
5.38 Tightening torques X
5.39 Engine conservation X
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Oil change after 250 h, after 500 h, then every 1000 h
3 Oil change after 250 h, after 500 h, then every 1000 h
4 Also after repairs in the hydraulic system.
36 BOMAG 008 910 92

3 Technical data
008 910 92 BOMAG 37

3.1 Technical data
3.1 Technical data
Fig. 11
Dimensions in A B C D H H2 K L O W
mm
BW 141 AD-4 3300 1660 710 1220 2320 3000 400 4520 80 1500
BW 151 AD-4 3300 1660 715 1220 2320 3000 400 4520 80 1680
1 BW 141 AD-4 BW 151 AD-4
Weights
Operating weight (CECE) kg 7500 7900
Operating weight (CECE) with kg 8000 8300
ROPS-cabin
Front axle load (CECE) kg 3700 3900
Rear axle load (CECE) kg 3800 4000
Static linear load front (CECE) kg/cm 24,7 23
Static linear load rear (CECE) kg/cm 25,3 24
Dimensions
Oscillation angle +/-° 6 6
Inner track radius mm 4490 4400
Travel characteristics
Travel speed (1) km/h 0-10,5 0-10,5
Max. gradability without/with vibra- % 40/35 40/35
tion (soil dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2011 BF4M 2011
Cooling Oil Oil
Number of cylinders 4 4
Rated power ISO 9249 kW (PS) 60 60
Rated speed rpm 2500 2500
Electrical equipment V 12 12
Battery V/AH 12/100 12/100
Drive system hydrost. hydrost.
Driven drum front + rear front + rear
38 BOMAG 008 910 92

Technical data 3.1
1
BW 141 AD-4 BW 151 AD-4
Brakes
Service brake hydrost. hydrost.
Parking brake mechanical mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost.
Steering angle +/- degree 30 30
Crabwalk, lateral offsetting of mm 170 170
drum (right/left)
Vibration system
Frequency 1/2 Hz 40/60 40/60
Amplitude 1/2 mm 0,64/0,28 0,64/0,28
Vibrating drum front + rear front + rear
Water sprinkler system

Type Pressure Pressure
Interval control (+) (+)
Filling capacities
Fuel (diesel) l 160 160
Water l 800 800
Hydraulic oil l 60 60
Engine oil l approx. 10 approx. 10
1 The right for technical modifications remains reserved
Fig. 12
Dimensions in A B C D H H2 K L O W
mm
BW 151 AC-4 3300 1660 715 1220 2320 3000 400 4520 80 1680
BW 161 ADCV 3300 1660 715 1220 2320 3000 400 4520 80 1680
008 910 92 BOMAG 39

3.1 Technical data
1
BW 151 AC-4 BW 161 ADCV
Weights
Operating weight (CECE) kg 8300 7900
Operating weight (CECE) with kg 8750 8300
ROPS-cabin
Front axle load (CECE), drum kg 4150 3900
Rear axle load, (CECE) wheels kg 4600 4000
Static linear load front (CECE) kg/cm 27,7 23
Static linear load rear (CECE) 24
Dimensions
Oscillation angle +/-° 6 6
Inner track radius mm 4400 4400
Travel characteristics
Travel speed (1) km/h 0-10,5 0-10,5
Max. gradability without/with vibra- % 40/35 40/35
tion (soil dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2011 BF4M 2011
Cooling Oil Oil
Number of cylinders 4 4
Rated power ISO 9249 kW (PS) 60 60
Rated speed rpm 2500 2500
Electrical equipment V 12 12
Battery V/AH 12/100 12/100
Driven drum front + rear front + rear
Drums and tires

Drum width mm 1680
Number of tires 4
Tire size 11,00-20 16 PR
Brakes
Service brake hydrost. hydrost.
Parking brake mechanical mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost.
Steering angle +/- degree 30 30
Crabwalk, lateral offsetting of mm 170 170
drum (right/left)
Vibration system
Frequency 1/2 Hz 40/60 40/60
40 BOMAG 008 910 92

Technical data 3.1
1
BW 151 AC-4 BW 161 ADCV
Amplitude 1/2 mm 0,60/0,31 0,64/0,28
Vibrating drum front front + rear
Water sprinkler system

Type Pressure Pressure
Interval control (+) (+)
Filling capacities
Fuel (diesel) l 160 160
Water l 800 800
Hydraulic oil l 60 60
Engine oil l approx. 10 approx. 10
1 The right for technical modifications remains reserved
008 910 92 BOMAG 41

3.1 Technical data
Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 850 ± 150
High idle speed rpm 2700 ± 50
Spec. fuel consumption g/kWh 245
Valve clearance intake mm 0,3
Valve clearance exhaust mm 0,5
Injection valves opening pressure bar 210 + 8
Travel pump
Manufacturer Bosch-Rexroth
Type A4VG 56 HW/32
System Axial piston/swash plate
Max. displacement cm3/rev. 56
Max. flow capacity l/min 136,1
High pressure limitation bar 440
Pressure override valve bar 400 ± 10
Charge pressure, high idle bar 25 +3/-1
Drum reduction gear

Type 705 C 2H
Transmission ratio 48
Travel motors
Type A2 FE 32
System Axial piston
Displacement (stage 1) cm3/rev. 32
Permissible leakage rate l/min 2
Flushing quantity l/min 5
Wheel drive BW 151 AC-4

Type MS 08
System Radial piston
Quantity 2
Displacement (stage 1) cm3/rev. 704
Permissible leakage rate l/min 1,5
Vibration pump
Manufacturer Bosch-Rexroth
Type A10VG 45 EZ
System Axial piston/swash plate
Max. displacement cm3/rev. 45
Start up pressure bar 360 ± 20
Operating pressure, soil dependent bar approx. 100
Vibration motor
Type A4FM 22
42 BOMAG 008 910 92

Technical data 3.1
System Axial piston – swash plate
Displacement cm3/rev. 22
Check steering/
Type HY/ZFFS11/16+8
System Tandem gear pump
Displacement cm3/rev. 11/ 8
Max. steering pressure bar 200 ± 5
Steering valve
Type OSPC 400 LS
System Rotary valve
008 910 92 BOMAG 43

3.1 Technical data
The following noise and vibration data acc. to
- EC Machine Regulation edition 98/37/EC and
- 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 operator’s stand:
BW 141 AD-4 LpA = 80 dB(A) BW 161 AD-4, determined acc. to ISO 11204 and EN 500
BW 151 AD-4 LpA = 82 dB(A) BW 161 AD-4, determined acc. to ISO 11204 and EN 500
BW 151 AC-4 LpA = 83 dB(A) determined acc. to ISO 11204 and EN 500
BW 161 ADCV LpA = 79,7 dB(A) determined acc. to ISO 11204 and EN 500
Guaranteed sound capacity level:

BW 141 AD-4 LWA = 105 dB(A) determined acc. to ISO 3744 and EN 500
BW 151 AD-4 LWA = 106 dB(A) determined acc. to ISO 3744 and EN 500
BW 151 AC-4 LWA = 105 dB(A) determined acc. to ISO 3744 and EN 500
BW 161 ADCV LWA = 106 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 boy (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is <= 0.5m/sec2.
Hand-arm vibration values

The weighted effective acceleration value determined according to EN 500/ISO 5349 is 2,5 m/sec2.
44 BOMAG 008 910 92

4 Connection overview
008 910 92 BOMAG 45

4.1 Connection overview
46 BOMAG 008 910 92

Connection overview 4.1
1 Port T1, leak oil to port T2 on vibration pump 23 Pressure test port R, travel pump case pressure
2 Pressure test port MB high pressure 24 Pressure test port X1, travel pump
3 Port T 25 not used
4 High pressure port B, to the travel motors 26 Pressure test port X4, control chamber pressure,
5 not used travel pump
6 High pressure port A, to the travel motors 27 Pressure override valve, vibration pump
7 Adjustment screw, high frequency 28 Pressure cut-off valve, travel pump
8 not used 29 Pressure test port MA high pressure
9 Port T1 to tank 30 Port T2, leak oil to tank
10 High pressure port B, to vibration shut-off valve 31 High pressure relief valve, travel drive
11 High pressure port A, to vibration shut-off valve 32 Adjustment screw for mechanical neutral position
of travel pump
12 Pressure test port MB high pressure
33 Pressure test port X3, control chamber pressure,
13 Magnetic coil Y57, low frequency travel pump
14 High pressure relief valve, vibration 34 Charge pressure relief valve, travel pump
15 Magnetic coil Y56, high frequency 35 Port G, charge pressure
16 Pressure test port X2, travel pump 36 Adjustment screw for low frequency
17 Pressure test port X1, travel pump 37 Port T2, leak oil from port T1 on travel pump
18 Pressure test port R, vibration pump case pres- 38 High pressure relief valve, vibration
sure
39 Charge pressure relief valve, blocked
19 High pressure relief valve, travel drive
40 Charge pressure test port, travel and vibration
20 not used pump
21 Pressure test port X2, travel pump 41 High pressure test port, low frequency
22 Adjustment screw, hydraulic neutral position 42 Distributor block, travel system
008 910 92 BOMAG 47

4.1 Connection overview
48 BOMAG 008 910 92

5 Tests and adjustments
008 910 92 BOMAG 49

5.1 Special tools, tests and adjustments

1. Vibration reed frequency meter
1000 - 4000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80
Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
Fig. 2
3. Anti-freeze tester, quick and accurate measuring,
sturdy plastic housing, automatic temperature
correction, no after-dripping, instructions for use
on unit, reading down to -40 °C. Material: Plastic,
Temperature range: down to -40 °C
Fig. 3
4. Digital rpm-meter for petrol engines
Fig. 4
50 BOMAG 008 910 92

Special tools, tests and adjustments 5.1
5. Digital rpm-meter for petrol engines
Fig. 5
6. Digital rpm-meter, optical/mechanical, universal
use
Fig. 6
7. Infrared manual thermometer, -18 to 275°C
Fig. 7
8. Hydraulic test case, large
i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 8
008 910 92 BOMAG 51

9. Hydraulic test case, small
i Note
1X 25 bar pressure gauge
1X 150 bar pressure gauge
2X 400 bar pressure gauges
4 pressure test hoses
Fig. 9
10. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03
Fig. 10
11. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04
Fig. 11
12. Adapter for pressure test hose
Fig. 12
52 BOMAG 008 910 92

Special tools, tests and adjustments 5.1
13. Gear pump testing device
Fig. 13
14. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 14
008 910 92 BOMAG 53

5.2 Adjusting the angle sensor on travel control lever
5.2 Adjusting the angle sensor on travel

control lever
i Note
The rotation angle sensor (Fig. 1) works contact
free and delivers an electric current of 4 to 20 mA.
Fig. 1
i Note
The setting applies for module 920 225 17 (Fig.
2).
Fig. 2
! Caution
The setting does not apply for module
920 225 24 (Fig. 3).
i Note
Neutral position of the travel control lever (mod-
ule 920 225 24) is automatically learned with the
brake applied.
Fig. 3
54 BOMAG 008 910 92

Adjusting the angle sensor on travel control lever 5.2
Adjusting the angle sensor
1. Switch on the ignition.
2. Apply the brake (Fig. 4).
Fig. 4
3. Slightly slacken both screws (Fig. 5) for the angle
sensor.
Fig. 5
4. Keep turning the sensor, until LED 3 (Fig. 6) lights
up.
i Note
LED 2 serves as adjustment aid. If the flashing
frequency rises while turning, you are turning to
the wrong direction.
If LED 2 flashes in intervals of a second and LED
3 lights permanently, the correct setting is
achieved.
If the adjustment range for the sensor is not big
enough, you may extend or shorten the connect-
Fig. 6 ing linkage 2 (Fig. 5).
! Caution
In order to check the setting the travel lever
must be shifted back and forth in the brake
gate, whereby the LED on Pin 3 (travel lever
out of "Neutral") should not light up. Other-
wise repeat the adjustment procedure.
5. Retighten the angle sensor fastening screws.
008 910 92 BOMAG 55

5.3 Checking the rotation speeds
5.3 Checking the rotation speeds

Special tools
Vibration reed frequency meter, RPM-meter for
diesel engines
! Caution
Perform measurements at operating tempera-
ture (40 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
Fig. 1
Check the engine speed
i Note
If necessary, the engine speed may also be
checked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.
2).
2. Run the engine with maximum speed.
3. Apply the brake.
4. Measure the rotation speeds.
Nominal value high idle speed

see technical data
5. Switch on vibration of both drums.
Nominal value nominal speed

see technical data
Fig. 2
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting for the engine.
56 BOMAG 008 910 92

Checking the rotation speeds 5.3
Checking the exciter shaft speed
1. Switch the vibration on at max. engine speed.
2. Apply the brake.
3. Measure the speed of the vibrator shaft by letting
the tester rest on your thumb (Fig. 3).
Nominal value
see technical data.
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting in the vibration circuit.
Fig. 3
008 910 92 BOMAG 57

5.4 Pressure tests in the travel circuit
5.4 Pressure tests in the travel circuit

Special tools
Hydraulic test case
! Caution
ture of the hydraulic oil (40 °C).
1. Block the drums with suitable chocks (Fig. 1).
Fig. 1
2. Pull the plug (Fig. 2) off the brake solenoid valve
to close the brake.
Fig. 2
3. Connect a 600 bar pressure gauge (Fig. 3) each
to test ports MA and MB.
Fig. 3
58 BOMAG 008 910 92

Pressure tests in the travel circuit 5.4
4. Connect a 60 bar pressure gauge (Fig. 4) to the
charge pressure test port.
5. Start the engine and run it with maximum speed.
6. Read high pressure and charge pressure gaug-
es.
Nominal value
Charge pressure = see technical data "travel
pump, charge pressure high idle".
High pressure = see technical data "travel pump,
charge pressure high idle".
Evaluation of test
Fig. 4
If the nominal value is not reached, check the
steering/charge pump.
7. Move the travel lever quickly to forward and back-
ward, read the pressure gauges.
Nominal value
High pressure = see technical data "travel pump,
pressure override".
Evaluation of test
If the specified high pressure is not reached,
check the travel pump.
If the charge pressure drops considerably during
the high pressure test, check the components in-
dividually.
008 910 92 BOMAG 59

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

tions of the travel pump
Special tools
Hydraulic test case
! Caution
Fig. 1
1. Unhook the travel cable (Fig. 2) from the travel
pump.
Fig. 2
to close the brake.
Fig. 3
60 BOMAG 008 910 92

Checking / adjusting the neutral positions of the travel pump 5.5
Fig. 4
Mechanical neutral position

1. As a measure to avoid signal residues from the
hydraulic neutral position connect both control
chambers X1 and X2 with a hose (Fig. 5).
Fig. 5
3. Read the pressure gauges (Fig. 6).
i Note
For a more exact adjustment repeat the test with
60 bar pressure gauges
Nominal value
Both pressure gauges must show identical pres-
sure, if necessary correct the mechanical neutral
position.
Fig. 6
4. Adjust the neutral position (Fig. 7) so that both
pressure gauges show identical pressure (charge
pressure).
i Note
Equalize the dead range of the neutral position.
Fig. 7
008 910 92 BOMAG 61

5.5 Checking / adjusting the neutral positions of the travel pump
Hydraulic neutral position

1. Remove the hose connection between the control
chambers and screw the plugs back in (Fig. 8).
Fig. 8
3. Read the pressure gauges (Fig. 9).
i Note
For a more exact adjustment repeat the test with
60 bar pressure gauges
Do not actuate the travel lever, since this may de-
stroy the pressure gauges.
Nominal value
Both pressure gauges must show identical pres-
sure (charge pressure), if necessary correct the
hydraulic neutral position ....
Fig. 9
4. ..... for this purpose loosen the clamping (Fig. 10).
! Caution
Do not adjust the eccentric beyond the ± 90°
position.
5. Adjust the neutral position on the eccentric (2), so
that both pressure gauges show identical pres-
sure (charge pressure).
6. Retighten the clamping.
Fig. 10
62 BOMAG 008 910 92

Check the setting of the high pressure relief valves in the travel 5.6
5.6 Check the setting of the high pressure
relief valves in the travel circuit
Special tools
Hydraulic test case
! Caution
Fig. 1
to close the brake.
Fig. 2
Fig. 3
008 910 92 BOMAG 63

5.6 Check the setting of the high pressure relief valves in the travel
4. Turn the setscrew (Fig. 4) of the pressure over-

ride completely in to block the valve.
! Caution
Perform the following pressure test for max. 3
seconds, otherwise pump damage caused by
overheating.
6. Move the travel lever quickly to both travel direc-
tions and read the pressure gauges.
Fig. 4
Nominal value
see technical data, "travel pump high pressure

limitation".
Evaluation of test:
If the nominal value is only reached to one direc-
tion, clean or replace the valve (Fig. 5) if neces-
sary.
If the nominal value is not reached to both direc-
tions check the travel pump, replace if necessary.
Fig. 5
Adjusting the pressure override
! Caution
To assure a reliable function of the pressure
override, the pressure override valve must be
adjusted 10% lower than the high pressure re-
lief valve.
1. Turn the setscrew (Fig. 6) back out again, until
the high pressure is limited to its setpoint, when
the drums are blocked.
Nominal value
see technical data, "travel pump pressure over-
ride".
Fig. 6
64 BOMAG 008 910 92

Pressure tests in the vibration circuit 5.7
5.7 Pressure tests in the vibration circuit
Special tools
Hydraulic test case
! Caution
Fig. 1
4. Connect a 60 bar pressure gauge to the charge
pressure test port.
6. Apply the brake.
7. Switch on vibration at high or low frequency and
read the pressure gauge.
Nominal value
Fig. 2
Start-up pressure = see technical data " vibration
pump, start-up pressure".
Operating pressure = see technical data "vibra-
tion pump, operating pressure soil dependent".
Evaluation of test
If the charge pressure drops, check the compo-
nents individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one fre-
quency, check the high pressure relief valves.
008 910 92 BOMAG 65

5.8 Check the setting of the high pressure relief valves in the vibra-
5.8 Check the setting of the high pressure

relief valves in the vibration circuit
Special tools
Hydraulic test case
! Caution
Fig. 1
Fig. 2
10. Turn the setscrew (Fig. 3) of the pressure over-
ride completely in to block the valve.
12. Apply the brake.
! Caution
Perform the following pressure test for max. 3
seconds, otherwise pump damage caused by
overheating.
13. Switch on vibration at high or low frequency and
read the start-up pressure on the pressure
Fig. 3
gauge.
Nominal value for start-up pressure

see technical data, "vibration pump, start-up
pressure".
66 BOMAG 008 910 92

Check the setting of the high pressure relief valves in the vibra- 5.8
Evaluation of test:
If the nominal value is only reached for one fre-

quency, clean or replace the valve (Fig. 4) if nec-
essary.
If the nominal value is not reached for both fre-

quencies check the travel pump, replace if neces-
sary.
Fig. 4
Adjusting the pressure override
! Caution
To assure a reliable function of the pressure
override, the pressure override valve must be
adjusted 10% lower than the high pressure re-
lief valves.
1. Turn the setscrew (Fig. 5) back out again, so that
the start-up pressure for the vibrator shafts is lim-
ited to the nominal value.
Nominal value for start-up pressure

see technical data, "vibration pump, start-up
pressure".
Fig. 5
008 910 92 BOMAG 67

5.9 Checking / adjusting the vibrator shaft speeds
5.9 Checking / adjusting the vibrator shaft

speeds
Special tools
Vibration reed frequency meter
! Caution
3. Start the diesel engine and shift the throttle lever
to max. speed position.
4. Apply the brake.
5. Select the frequency and switch the vibration on.
Fig. 1
6. Measure the speed of the vibrator shaft (Fig. 2) by
letting the tester rest on your thumb.
Nominal value
high amplitude/
low frequency = see technical data
low amplitude/
high frequency = see technical data
Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit.
Fig. 2
7. Adjust the speed on the corresponding adjust-
ment screw (Fig. 3).
i Note
Turning the adjustment screw in reduces the
speed, turning the screw out increases the
speed.
Fig. 3
68 BOMAG 008 910 92

Check the leakage rate of the vibration motor 5.10
5.10 Check the leakage rate of the vibration
motor
Special tools
Hydraulic test case
! Caution
2. Apply the brake.
Fig. 1
3. Disconnect leak and flushing oil lines (Fig. 2) and
join them together.
4. Connect a leak oil hose to the leak oil port of the
motor and hold it into a measuring vessel
5. Start the diesel engine and shift the throttle lever
to max. speed position.
6. Select the frequency and switch the vibration on.
7. Measure the leak oil over a period of one minute.
! Caution
This measurement detects only the external
Fig. 2 leak oil quantity.
Internal leaks, directly from the high to the
low pressure side, are not detected.
Nominal value
max. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
008 910 92 BOMAG 69

5.11 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 with high idle speed.
3. Apply the brake.
! Danger
Danger of squashing!
Do not stand in the articulation area of the ma-
chine.
4. Turn the steering against an end stop.
5. Read the pressure gauge.
Fig. 1
Nominal value
approx. 196 bar
Evaluation of test
If the nominal value is reached, check the steer-
ing cylinder.
6. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) and (Fig. 3) the steering cylinders and
close them with plugs.
7. Start the engine and run it at idle speed.
8. Turn the steering wheel.
9. Read the pressure gauge.
Nominal value
approx. 170 bar
Evaluation of test
If the nominal value is reached, replace the steer-
Fig. 2 ing cylinder.
If the nominal value is not reached, check the
10. Reconnect the hydraulic hoses to the steering
cylinders.
70 BOMAG 008 910 92

Pressure test in steering circuit 5.11
Fig. 3
11. Close the pump outlet (Fig. 4) with a 200 bar
pressure relief valve
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. 4
008 910 92 BOMAG 71

72 BOMAG 008 910 92

6 Flushing and bleeding
008 910 92 BOMAG 73

6.1 Special tools for flushing

1. Filling and filtering unit with oil bag

2. Filter element
Fig. 1
3. Flushing filter (S connection)

4. Filter element 1μ

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

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

8. Filter element

9. Flushing hose 15L (2 pieces)

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

12. O-ring
BOMAG part-no. 062 203 30
Fig. 4
74 BOMAG 008 910 92

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

14. O-ring
Fig. 5
15. Reducing fitting 18L - 15L
Fig. 6
16. Reducing fitting 25S - 20S
Fig. 7
17. Reducing fitting 20S - 16S
Fig. 8
008 910 92 BOMAG 75

18. Connecting socket 15L
Fig. 9
19. Connecting socket 18L
Fig. 10
20. Connecting socket 16S
Fig. 11
21. Connecting fitting 20S
Fig. 12
76 BOMAG 008 910 92

Special tools for flushing 6.1
22. Connecting fitting 25S
Fig. 13
23. Angular fitting 18L
Fig. 14
24. Elbow fitting 16L
Fig. 15
25. Elbow 20S
Fig. 16
008 910 92 BOMAG 77

26. Elbow 25S
Fig. 17
27. Pipe connection 16S - 16S
Fig. 18
28. Connecting hose 15L
Fig. 19
78 BOMAG 008 910 92

Flushing - general 6.2
6.2 Flushing - general
Caution
!
Solid particles in the circuit will very quickly cause damage to machine components.
Environment
Environmental damage
Catch running out hydraulic oil and dispose of environmentally.
Changing a component
Caution
!
Always flush the complete oil circuit after you have replaced a component.
Chips (abrasion) in the oil

● Open and clean all components in the oil circuit, replace if necessary.
● Clean all high pressure hoses in the oil circuit, replace if necessary.
● If abrasion is found in the travel circuit you should also flush the vibration circuit.
● If abrasion is found in the vibration circuit you should also flush the travel circuit.
Before flushing
Change the filter element
Fig. 1
● Change the hydraulic oil filter element (1).
008 910 92 BOMAG 79

6.2 Flushing - general
Clean the hydraulic tank
Fig. 2
Caution
!
Change the oil in case of excessive contamination, oil discoloration or if the oil change interval is
almost due.
● Filter the tank content with the filling and filtering unit and pump it into the oil bag.
● Mark all hoses and disconnect them from the hydraulic oil tank.
● Clean the oil tank thoroughly from inside, if necessary remove the complete tank cover.
● Reconnect all hoses.
● Fill the hydraulic oil tank again with the filling and filtering unit.
Bleeding
Fig. 3
● Always bleed closed hydraulic circuits if lines had been removed or connected.
80 BOMAG 008 910 92

Flushing - general 6.2
Servicing the flushing filter kit
Fig. 4
● Replace the filter element of the flushing filter when the red control pin of the contamination indicator
is pressed out during the filtering process.
● Clean hoses and connections and store the flushing kit in a clean and protected environment.
008 910 92 BOMAG 81

6.3 Flushing schematic for front drum drive
1 Travel pump 7 Flushing filter with filter element 1μ (tool)

2 Bulkhead fitting (tool) 8 Hose connection, travel pump A - drum drive mo-
tor B, front
3 Elbow union (tool)
4 Screw socket 1" - 25S (tool) 9 not used
10 Bulkhead bushing, front left
5 Flushing hose 25S - 20S (tool)
11 Drum motor, front left
82 BOMAG 008 910 92

Flushing the front drum drive 6.4
6.4 Flushing the front drum drive
Replacing the hydraulic oil filter element
Cleaning the hydraulic oil tank
i Note
Observe the chapter "Flushing - General"
Installing the flushing filter
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump.
With the connection shown in the illustration
the travel pump must therefore be actuated to
reverse direction.
1. Disconnect the high pressure hose 8 (Fig. 1) from
the travel pump 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") to the high pressure port A on the travel
pump.
Fig. 1
Disconnecting the front drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the hoses together.
Fig. 2
008 910 92 BOMAG 83

Bleeding the travel circuit
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 3
Flushing the front hoses
4. Block the drums with suitable chocks.
i Note
On AC-machines block drum and rubber wheels.
Fig. 4
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 5
! Caution
Move the travel lever only to travel direction
reverse, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction reverse.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the high pressure hoses to the drum
drive motor.
Fig. 6
84 BOMAG 008 910 92

Flushing the front drum drive 6.4
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. 7
i Note
flushing process.
Fig. 8
! Caution
11. Start the engine, run it with maximum speed and
shift the travel lever to travel direction reverse.
12. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve reverse travel.
Fig. 9 14. Remove the flushing filter and reconnect the high
pressure lines.
i Note
Keep circulating the tank content.

15. After completing the bleeding process circulate
the tank content with the filtering unit for another
15 minutes.
008 910 92 BOMAG 85

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).
Fig. 10
86 BOMAG 008 910 92

Flushing schematic for rear drum drive system 6.5
1 Travel pump 7 Flushing filter with filter element 1μ (tool)

2 Bulkhead fitting (tool) 8 Hose connection, travel pump A - drum drive mo-
tor B, rear
3 Elbow union (tool)
9 Drum motor, rear right
4 Screw socket 1" - 25S (tool)
10 Bulkhead bushing, front frame rear
6 Flushing hose 25S - 20S (tool) 11 Bulkhead bushing, rear left
008 910 92 BOMAG 87

6.6 Flushing the rear drum drive
i Note
! Caution
pump.
reverse direction.
1. Disconnect the high pressure hose (8) from the
travel pump and connect it with the flushing hose
(6) flushing filter inlet "IN" (see chapter "Flushing
schematic for rear drum drive").
2. Connect the flushing hose (5) flushing filter outlet
"OUT" to the high pressure port "A" on the travel
pump.
Disconnecting the rear drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the hoses together.
Fig. 11
88 BOMAG 008 910 92

Flushing the rear drum drive 6.6
i Note
Fig. 12
Flushing the rear hoses
Fig. 13
i Note
flushing process.
Fig. 14
! Caution
direction reverse.
8. Reconnect the high pressure hoses to the drum
drive motor.
Fig. 15
008 910 92 BOMAG 89

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. 16
i Note
flushing process.
Fig. 17
! Caution
pressure lines.
i Note

15 minutes.
90 BOMAG 008 910 92

Flushing the rear drum drive 6.6
Function test
necessary.
on a gradient.
Fig. 19
008 910 92 BOMAG 91

6.7 Flushing schematic for wheel drive motors, AC-machines
1 Travel pump 9 Wheel motor rear right

2 Bulkhead fitting (tool) 10 Bulkhead bushing, rear
3 Elbow union (tool) 11 Wheel motor rear left
4 Screw socket 1" - 25S (tool) 12 Plug (tool)
5 Flushing hose 25S - 20S (tool) 13 Socket (tool)
6 Flushing hose 25S - 20S (tool) 14 Hose connection, travel pump A - wheel motor
rear right
7 Flushing filter with filter element 1μ (tool)
8 Hose connection, travel pump A - wheel motor rear
left
92 BOMAG 008 910 92

Flushing the rear wheel drive on AC machines 6.8
6.8 Flushing the rear wheel drive on AC
machines
i Note
! Caution
pump.
reverse direction.
1. Disconnect the high pressure hoses (8 and 14)
from the travel pump and connect them with the
flushing hose (6) flushing filter inlet "IN" (see
chapter "Flushing schematic for wheel motors)".
2. Connect the flushing hose (5) flushing filter outlet
"OUT" to the high pressure port A on the travel
pump.
3. Close the rear high pressure port A on the travel
pump with a plug.
Disconnecting the wheel motors
4. Take the drum drive motors (9 and 11) out of the
hydraulic circuit and join the hoses together.
i Note
If necessary remove the rubber wheels.
Fig. 1
008 910 92 BOMAG 93

6.8 Flushing the rear wheel drive on AC machines
i Note
Fig. 2
Flushing the rear hoses
5. Block drums and wheels with suitable chocks .
Fig. 3
i Note
flushing process.
Fig. 4
! Caution
direction reverse.
9. Reconnect the high pressure hoses to the wheel
drive motors.
Fig. 5
94 BOMAG 008 910 92

Flushing the rear wheel drive on AC machines 6.8
Flushing the wheel motors
! Danger
Danger of accident!
The rubber wheels must be able to rotate free-
ly.
10. 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 11. Secure the front drum with chocks .
i Note
flushing process.
Fig. 7
! Caution
pressure lines.
i Note

15 minutes.
008 910 92 BOMAG 95

6.8 Flushing the rear wheel drive on AC machines
Function test
necessary.
on a gradient.
Fig. 9
96 BOMAG 008 910 92

Flushing schematic for vibration drive on AD-machines 6.9
1 Vibration shut-off valve 9 Rear vibration motor

2 Elbow union (tool) 10 Bulkhead bushing, front left
3 Bulkhead fitting (tool) 11 Bulkhead bushing, front frame rear
4 Vibration pump 12 Flushing hose 25S - 20S (tool)
5 Flushing hose 25S - 20S (tool) 13 High pressure hose, vibration pump to vibration
shut-off valve
6 Screw socket R1 - 25S (tool)
14 High pressure port B, low frequency
7 Flushing filter with filter element 1μ (tool)
8 Front vibration motor 15 Bulkhead bushing rear right
008 910 92 BOMAG 97

6.10 Flushing schematic for vibration circuit on AC-machines
1 not used 8 Front vibration motor

2 Elbow union (tool) 9 not used
3 Bulkhead fitting (tool) 10 Bulkhead bushing, front left
4 Vibration pump 11 not used
5 Flushing hose 25S - 20S (tool) 12 Flushing hose 25S - 20S (tool)
6 Screw socket R1 - 25S (tool) 13 High pressure hose
7 Flushing filter with filter element 1μ (tool) 14 High pressure port B, low frequency
98 BOMAG 008 910 92

Flushing the vibration circuit 6.11
6.11 Flushing the vibration circuit
i Note
! Caution
so that only cleaned oil will enter the vibration
pump.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
1. Disconnect the high pressure hose (13) from the
vibration pump and connect it with the flushing
hose (12) (flushing filter inlet "IN"), see chapter
"Flushing circuit vibration circuit".
2. Connect the flushing hose (5, flushing filter outlet
"OUT") to the high pressure port (14) on the vibra-
tion pump.
Disconnecting the vibration motors
3. Take the vibration motors (8 and 9) out of the hy-
draulic circuit, for this purpose join the hoses on
the vibration motors together.
i Note
AC-machines are fitted with a front vibration mo-
tor only.
Fig. 10
008 910 92 BOMAG 99

Bleeding the vibration circuit
i Note
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".
Fig. 11
Flushing the hoses
i Note
On AC-machines block drum and rubber wheels.
Fig. 12
i Note
flushing process.
Fig. 13
5. Switch on vibration of front and rear drums.
i Note
Not available on AC-machines.
Fig. 14
100 BOMAG 008 910 92

Flushing the vibration circuit 6.11
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
6. Switch on vibration with high frequency .
8. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
10. Reconnect the high pressure hoses to the vibra-
Fig. 15 tion motors.
Flushing the vibration motors
11. Unscrew the fastening screws for the vibration
motors and pull both motors (8 and 9) out of the
coupling.
i Note
AC-machines are fitted with a front vibration mo-
tor only.
Fig. 16
i Note
flushing process.
Fig. 17
i Note
Fig. 18
008 910 92 BOMAG 101

! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
14. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
16. Remove the flushing filter and reinstall the vibra-
tion motors.
Fig. 19
Bleeding the vibration circuit
17. Bleed the vibration circuit (see corresponding
chapter).

15 minutes.
Function test
necessary.
20. Test drive.
Fig. 20
102 BOMAG 008 910 92

Bleeding the travel circuit 6.12
6.12 Bleeding the travel circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.
! Danger
The engine should not start.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Operate the starter motor for approx. 30 seconds.
Wait one minute and repeat this procedure, until
oil starts to run out from the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
008 910 92 BOMAG 103

6.12 Bleeding the travel circuit

pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.
Fig. 4
! Caution
With the flushing filter installed shift the travel
lever only to travel direction reverse, as other-
wise the flushing filter will be subjected to oil
flow from the wrong direction.
!Danger
Run the engine with idle speed.
10. Start the engine.
11. Shift the travel lever (Fig. 5) approx. 1/3 to re-
verse direction.
Fig. 5 12. After approx. 1 to 2 minutes shut down the engine
for a minute.
i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
104 BOMAG 008 910 92

Bleeding the vibration circuit 6.13
6.13 Bleeding the vibration circuit
Environment
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Crank the engine approx. 10 seconds with the
starter motor. Wait one minute and keep repeat-
ing this procedure, until oil starts to run out from
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
008 910 92 BOMAG 105

6.13 Bleeding the vibration circuit

pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-
cedure, until the pressure gauge shows a con-
stant charge pressure.
Fig. 4
i Note
Fig. 5
! Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
11. For bleeding switch on vibration with high fre-
quency (Fig. 6).
12. Start the engine.
13. After running the engine 1 to 2 minutes pause for
approx. one minute.
Fig. 6 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.
106 BOMAG 008 910 92

7 Fundamental electrics
008 910 92 BOMAG 107

7.1 Understanding circuit diagrams

Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do
not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry
logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
● Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, ...
● The sequence in which current flows through the individual elements in the electric circuit.
● Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.
● Pin assignment of plug-and-socket connections.
Structure
● Table of contents
● Function groups
● List of components
Table of contents
The table of contents lists all function groups.
Fig. 7 Table of contents
Example:
Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.
108 BOMAG 008 910 92

Understanding circuit diagrams 7.1
Function groups
On the individual pages the electric circuits are combined to function groups.
Arrangement of current paths

The individual current paths must be read as follows:
● From top (plus potential) to bottom (minus potential).
● From left to right.
● From function group to function group.
● Via cross references for potentials and relays.
Fig. 8 Function groups
Potential cross references

Potential cross references serve the purpose of tracking signals, which are transmitted from one function group
to another.
Example:
Potential "15" on page no. 6 is continued to the left on page no. 4 in current path "10" and to the right on page
no. 8 in current path "1“.
Relay cross reference

Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts.
A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is
additionally attached to the bottom of each contactor coil.
Example:
The coil of relay (K99) is located on page no. 8 in current path "6".
The mimic diagram under the relay informs that a change-over switch with contact types 30, 87 and 87a is trig-
gered.
The changeover contact can be found on page no. 8 in current path "3".
008 910 92 BOMAG 109

Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 1) (0 ..... 20).
Fig. 1 Current paths
110 BOMAG 008 910 92

Understanding circuit diagrams 7.1
List of components
Here you find all components used in alphabetical order, related to the name of the component (A01, A02....).
Fig. 1 List of components
Component cross references

Example:
The warning horn "B 11" is located on page no. 8 in current path 3.
008 910 92 BOMAG 111

Graphic symbol
Graphic symbols are standardized representations for electrical appliances. They serve the purpose of a simpli-
fied representation of complete systems, from which, however, the function can be clearly identified. This stand-
ardization is in compliance with the globally valid regulations of the IEC (International Electrical Commission).
For Germany these symbols were included in the DIN-Standard. The standardization serves the purpose of glo-
bal understanding and fault free connection of appliances, especially in automobile repairs.
Since the wiring diagram is intended to show only the most essential aspects, the graphic symbol only shows
as much of the function, as is needed for easy recognition and for the avoidance of mistakes.
Fig. 2 Graphic symbol

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

1 Diode
2 Transistor
3 NPN-Transistor
4 changeable resistance
5 Condenser
6 Working current relay
112 BOMAG 008 910 92

Terminal designations 7.2
7.2 Terminal designations
For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a ter-
minal designation. In Germany the designation of the individual connection terminals is determined by the stand-
ard DIN 72552. The following table represents a section with the most important terminals from this standard.
Terminal designa- Meaning

tion
1 Ignition coil, ignition distributor low voltage
1a Ignition distributor with 2 separate electric circuits, to ignition timer 1
1b Ignition distributor with 2 separate electric circuits, to ignition timer 2
2 Short circuit terminal (magneto ignition)
4 Ignition coil, ignition distributor high voltage

4a Ignition distributor with 2 separate electric circuits, from ignition coil 1, terminal 4
4b Ignition distributor with 2 separate electric circuits, from ignition coil 2, terminal 4
15 Switch plus (after battery) : Output of ignition-travel switch

15a Output from dropping resistor to ignition coil and starter
17 Preheating starter switch, preheating
19 Preheating starter switch, starting
30 Battery plus direct

30a Battery changeover relay 12V / 24V, input from battery 2 plus
31 Battery minus direct or ground

31a Battery changeover relay 12V / 24V return line to battery 2 minus
31b Return line to battery minus or ground via switch or relay (switched minus)
31c Battery changeover relay 12V / 24V return line to battery 1 minus
32 Electric motors, return line
33 Electric motors, main connection

33a Electric motors, limit shut down
33b Electric motors, shunt field
33f Electric motors, for 2nd lower speed range
33g Electric motors, for 3rd lower speed range
33h Electric motors, for 4th lower speed range
33L Electric motors, counter-clockwise rotation
33R Electric motors, clockwise rotation
45 Starter, separate starter relay output; starter: Input (main current)

45a 2-starter parallel operation, start relay for engagement current, output starter 1
45b 2-starter parallel operation, start relay for engagement current, output starter 2
48 Terminal on starter and on start repeat relay, monitoring of starting process
49 Input flasher relay

49a Output flasher relay
49b Flasher relay output 2nd flasher circuit
49c Flasher relay output 3rd flasher circuit
50 Starter, starter control

50a Battery changeover relay, output for starter control
50b Starter control, parallel operation of 2 starters with sequence control
008 910 92 BOMAG 113


tion
50c Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 1
Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 2
50d Start locking relay, input
50f Start locking relay, output
50g Start repetition relay, input
50h Start repetition relay, output
51 A.C.-generator, direct voltage on rectifier

51a A.C.-generator, direct voltage on rectifier with reactance coil for day travel
52 Trailer signals: further signals from trailer to towing vehicle
53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding
53c Electric windscreen washer pump
53e Wiper, braking effect
53i Wiper motor with permanent magnet and 3rd brush for higher speed
54 Trailer signals, trailer plug device and lamp combination, brake light
54g Trailer signals, compressed air valve for permanent brake in trailer, electromag-
netically operated
55 Fog light
56 Head light
56a Head light, travel light and travel light control
56b Head lights, dimmed head light
56d Head lights, flash light
57 Parking light for motor cycles (abroad also for cars and trucks)
57a Parking light
57L Parking light left
57R Parking light right
58 Side lights, tail light, number plate light, dashboard light

58b Tail light changeover for single axle trailers
58c Trailer plug for single core wired and trailer fused tail light
58d Adjustable dashboard light, tail light and side light
58L Side light, left
58R Side light, right
59 A.C.-generator (magneto generator), alternating voltage output or rectifier input

59a A.C.-generator, charging armature output
59b A.C.-generator, tail light armature output
59c A.C.-generator, brake light armature output
61 Generator control
71 Intermittent tone control unit, input

71a Intermittent tone control unit, output to horn 1 + 2 (low)
71b Intermittent tone control unit, output to horn 3 + 4 (high)
72 Alarm switch (flashing beacon)
114 BOMAG 008 910 92

Terminal designations 7.2
tion
75 Radio, cigarette lighter
76 Loudspeaker
77 Door valve control
81 Switch (breaker and two-way contact), input

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

82a Switch (maker), output 1
82b Switch (maker), output 2
82z Switch (maker), input 1
82y Switch (maker), input 2
83 Switch (multi-position switch), input

83a Switch (multi-position switch), output position 1
83b Switch (multi-position switch), output position 2
83L Switch (multi-position switch), output position left
83R Switch (multi-position switch), output position right
84 Current relay, input drive and relay contact

84a Current relay, output drive
84b Current relay, output relay contact
85 Switching relay, output drive winding end (minus or ground)
86 Switching relay, input drive winding start

86a Switching relay, input drive winding start 1st winding
86b Switching relay, input drive winding start 2nd winding
87 Relay contact on breaker and two-way contact, input

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

88a Relay contact on maker and two-way contact, (maker side) output 1
88b Relay contact on maker and two-way contact, (maker side) output 2
88c Relay contact on maker and two-way contact, (maker side) output 3
88z Relay contact on maker, input 1
88y Relay contact on maker, input 2
88x Relay contact on maker, input 3
B+ Battery Plus
B- Battery Minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
008 910 92 BOMAG 115


tion
DF2 Dynamo field 2 (generator excitation current)
U Three-phase generator, three-phase terminal

V Three-phase generator, three-phase terminal
W Three-phase generator, three-phase terminal
C Travel direction indicator (flasher relay) control light 1

C0 Main connection for control light separated from flasher relay
C2 Travel direction indicator (flasher relay) control light 2
C3 Travel direction indicator (flasher relay) control light 3 (e.g. for 2 trailer operation)
L Indicator left
R Indicator right
116 BOMAG 008 910 92

Current and voltage 7.3
7.3 Current and voltage The following statements concerning electric volt-
age can be made
● electric voltage is the pressure or force applied to
General
free electrons.
If one wants to describe electric current, this can most ● the electric voltage is the cause of electric current
simply be accomplished by means of a comparison:
● electric voltage is a result of the equalization at-
One simply compares electric current with water. tempt of electric charges.
Voltage is measured with a Voltmeter.
Voltage
Unit, Volt
The electric voltage (U) is measured in Volt (V).
Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.
Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons
008 910 92 BOMAG 117

7.3 Current and voltage
Current Types of current

Electric current generally describes the directed Direct current (D.C.)
movement of charge carriers.
● The charge carriers may either be electrons or ions.
● Electric current can only flow if there is a sufficient
amount of free moving charge carriers.
● The higher the number of electrons flowing through
a conductor per second, the higher the amperage.
Current is measured with an ammeter.
Unit, Ampere Fig. 1 Direct current (D.C.)
The electric amperage (I) is measured in Ampere Direct current flows with steady voltage and amper-
(A). age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
The technical flow direction is specified from
tors or batteries.
PLUS to MINUS.
The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
i Note the consumers switched on, the voltage is not con-
Current actually flows from minus to plus, because the stant, but drops gradually according to the battery
current flow is made up of negatively charged elec- charge condition.
trons.
The internal resistance of the battery also causes per-
But since this was only discovered after the poles of a manent changes in the vehicle voltage, as soon as
current source had already been designated, the as- consumers are switched on or off.
sumption that current flows from plus to minus was
maintained for historic reasons. Alternating current (A.C.)
Circuit
Fig. 2 Alternating current (A.C.)
Fig. 3 Circuit Alternating current not only changes its direction, but
also its amperage.
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring. Pulsating direct current
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).
Fig. 3 Pulsating direct current

Converting alternating current into a direct current sig-
nal by means of a rectifier results in an pulsating direct
current.
118 BOMAG 008 910 92

Current and voltage 7.3
Pulse width modulation (PWM)
Fig. 4 PWM
The PWM signal is in most cases generated by a con-
trol and can be used to trigger proportional valves.
The signal (square wave signal) is changed in its
pulse control factor, the period, however, remains un-
changed.
The following applies:
●
The signal voltage cannot be measured.
●
The current can be measured.
Caution
!
Solenoid valves must not be interference sup-

pressed with suppressor diodes.
008 910 92 BOMAG 119

7.4 CAN-Bus
7.4 CAN-Bus
Controller Area Network

created by Bosch at the end of the eighties for automobile applications.
Development objectives:
Real-time critical, robust and low price communication of control units, such as transmission and engine control,
but also less time critical applications in the field of convenience electronics, such as air conditioning.
Fig. 1 CAN
Why CAN?
● Networking of control units for the realization of complex functions.
● Reduction of the extend of wiring and plug connections.
● Better diagnostic possibilities (central diagnostics socket).
Characteristics of CAN
It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are
required.
CAN lines are twisted together 30 to 40 times per metre. Electromagnetic interferences therefore always occur
simultaneously in both lines, the software is thus able to filter out interfering signals more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow
120 BOMAG 008 910 92

Resistance 7.5
7.5 Resistance ● The cleaner the contacts, the better the current.
● The quality of the ground cable is of the same im-
portance as the supply line.
Resistance and voltage drop
While current flows through a conductor the current
Unnecessary resistances
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance. Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.
Bad
Fig. 1 Various size resistors

Fig. 1 Screw-type terminals
Each conductor has its specific resistance, which is
characteristic for the corresponding material. A good Copper wires are squashed and thus become faulty.
conductor has a low resistance, a poor conductor has
Better
a high resistance.
Fig. 2 Spring clamps

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

Rule of thumb:
●
The thicker the cable cross-section, the lower the
voltage loss.
●
The shorter the cable, the better the current.
008 910 92 BOMAG 121

7.5 Resistance
Sometimes the flanks of flat plugs bend open. If these

are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.
Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
keeps water away.
Fig. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.
Fig. 4 Balistol oil
122 BOMAG 008 910 92

Series / parallel connection 7.6
7.6 Series / parallel connection ● In series connection the plus pole of the first battery
must be connected with the minus pole of the sec-
Series connection ond battery.
In a series circuit the resistors (consumers) are lined ● The sum of all individual voltages is applied to the
up one after the other and the same current (I) passes free poles.
through each of the consumers However, series con- ● The total capacity (Ah) is identical with the capacity
nection of consumers is not suitable in practice, as of the individual battery.
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).
Fig. 1 Series connection
Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3
Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3
Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3
Series connection of batteries
Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.
008 910 92 BOMAG 123

7.6 Series / parallel connection
Parallel connection ● In parallel connection the plus pole of the first bat-
In parallel connection all resistances (consumers) are tery is connected with the plus pole of the second
connected between feed and return line. battery and the minus pole of the first battery with
the minus pole of the second battery.
● All resistances (consumers) are supplied with the
same voltage.
● Plus and minus poles have the voltage of the single
battery applied.
● Each of the resistances (consumers) draws as
much current as required.
● The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.
Fig. 3 Parallel connection
Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3
Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3
Resistance
The total resistance is less than the lowest individual
resistance.
Parallel connection of batteries
Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.
124 BOMAG 008 910 92

Ohm's law 7.7
7.7 Ohm's law 7.8 Electrical energy
In a closed electric circuit voltage, current and resist-
ance must always be considered in close relation.
This relation is represented by Ohm's Law.
Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
Fig. 1 If a current of 1 Ampere flows at a voltage of 1 Volt,
According to this law a voltage of 1V is required to let energy of 1 Watt is produced.
1A (ampere) flow through a conductor with a resist-
Advice
ance of 1 (Ohm Ω).
By means of this triangle the formula can be easily re-
Advice arranged, the value you are looking form must just be
By means of this triangle the formula can be easily re- blanked off with a finger.
arranged, the value you are looking form must just be
Energy P = I multiplied with U
blanked off with a finger.
Amperage I = P divided by U
Voltage U = I multiplied with R
Voltage U = P divided by I
Resistance R = U divided by I
U = Voltage in Volt
Amperage I = U divided by R
I = Current in Ampere
U = Voltage in Volt
P = Power in Watt
I = Current in Ampere
R = Resistance in OHM Ω
008 910 92 BOMAG 125

7.9 Formula diagram
7.9 Formula diagram

Description:
● Select the desired value from the inner circle.
● Determine the formula variables in the quarter circle
● Calculate
Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere
Fig. 1 Formula diagram
Resistance, R Ohm Ω
Voltage, U Volt
Current, I Ampere
Power, P Watt
126 BOMAG 008 910 92

Metrology 7.10
7.10 Metrology Multimeter
This tester is a multimeter and can be used to meas-
Test lamps ure e.g. current, voltage and resistance. Depending
on the design it may also be suitable for transistor and
Test lamp frequency.
Fig. 1 Multimeter
In order to avoid damage:
Fig. 1 Test lamp
●
the range selector switch must be correctly set for
the corresponding measurement.
! Caution ●
the test cable must be plugged into the correct
This type of tester must not be used for testing on socket.
electronic components. The high power con- ●
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic ●
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp ●
the measuring range should be chosen higher at
This instrument is used for simple voltage measure- the beginning of the test.
ments. The test lamp consists of two test points. The ● In order to avoid any influence on the circuitry to be
negative measuring cable is connected to ground and measured, the internal resistance of the voltage
the positive measuring cable to the corresponding tester should be as high as possible.
measuring location.
Resistance and continuity measurement with mul-
timeter
The continuity tester of the multimeter can be used to
measure whether there is a connection between 2
measuring points. The following information should be
observed when measuring resistance and continuity:
● The component to be measured must not be con-
nected to the power supply during the measure-
ment.
● At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
● Polarity is of no significance.
Fig. 2 Diode test lamp

If voltage is present, the corresponding light emitting
diode will light up.
008 910 92 BOMAG 127

7.10 Metrology
Voltage and voltage drop measurement with mul- Clip-on measuring instrument
timeter
The clip-on measuring instrument can be used to
measure current, voltage and resistance.
Fig. 2 Voltage measurement

● The meter is always connected parallel to consum-
er, component or power source.
● Measurement at the voltage source measures the
currently available Voltage.
● A measurement at the consumer measures the volt-
age drop at this component.
Current measurement with the multimeter
Fig. 1 Clip-on measuring instrument

●
For measuring current the individual conductor
must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
Fig. 3 Current measurement

●
During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened. The meter is connected in series
with the consumer.
Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.
128 BOMAG 008 910 92

Diodes, relays, fuses 7.11
Magnet tester 7.11 Diodes, relays, fuses
Diodes
Fig. 1
Fig. 1 Magnet tester
A diode consists of two different semi-conductors,
The magnet tester is used to test solenoid valves and which are connected by a separating layer. The max.
magnetic coils. conducting state current must not be exceeded.
The test lamp responds to the magnetic fields of A.C- Plus-voltage on diode:
voltage, D.C.-voltage and permanent magnets. ● At 0.6 – 0.7 Volt (silicium diode) the diode becomes
●
The component to be tested does not need to be re- conductive.
moved.
Negative voltage on diode:
● The magnetic coil can also be tested under a pro-
tective cap.
● The diode does not allow current to pass through.
Fig. 2 Marking of the cathode

Diodes are used:
●
For rectifying A.C. voltage.
●
For absorbing voltage peaks (free-wheeling diode).
●
For construction of logical circuits.
008 910 92 BOMAG 129

7.11 Diodes, relays, fuses
Diode logics and free-wheeling diode Light emitting diodes
Fig. 4 LED
The light emitting diode, also referred to as LED, is a
semi-conductor diode, which generates (emits) light
during operation in forward direction. A semi-conduc-
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the
head. Light emitting diodes are available in various
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.
Fig. 3 Diode circuitry

● The solenoid valve Y48 (Fig. 3) is supplied with
electric current when switch S34 is switched to po-
sition "1" or "2".
● Solenoid valve Y20 is supplied, if the switch is in po-
sition "1".
● Solenoid valve Y21 is supplied, if the switch is in po-
sition "2".
The three diodes V02 serve as free-wheeling diodes
with the function of of eliminating voltage peaks.
130 BOMAG 008 910 92

Diodes, relays, fuses 7.11
Relays 85 = Ground supply for coil
30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact
Fuses
Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
A free-wheeling diode prevents induction voltage from
flowing back from the coil into the vehicle wiring sys-
tem, which would cause interference with electronic
components (control units).
With the possibility of using breaker - maker contacts
the effect of an information can be reversed.
Fig. 1
Fuses are used to protect lines and equipment against
overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.
Caution
!
Fuses must not be repaired or bridged.

The melting time at 23 °C is:
● approx. 1 hour with 1.5 times the rated current
● approx. 1 minute with 2.5 times the rated current.
A 5 Amp fuse loaded with 1.5 times the rated current
(7.5 Amp) will finally melt after approx. 1.5 hours.
Yellow = 5 A
Brown = 7.5 A
White = 8 A
Red = 16 A
Blue = 25 A
Fig. 2 Relay circuitry

The windscreen wiper and washer motors can only be
operated via switches S20 and S21, when relay K32
is supplied with electric current (Fig. 2).
86 = Positive supply for coil
008 910 92 BOMAG 131

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

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

Checking the acid density:
● The cells are filled with diluted sulphuric acid as
electrolyte (approx. 25 Vol% sulphuric acid in dis-
tilled water), also referred to as accumulator acid,
Fig. 2 which has a density of 1.285 kg/dm3 at a tempera-
All cells are filled with a conductive fluid, the electro- ture of +27° Celsius. This means that one litre of
lyte. For a 12 Volt battery 6 cells are connected in se- electrolyte has a weight of 1.285 kg. As the cell is
ries. being discharged lead sulphate (PbSO4) will form
on both electrodes and the electrolyte will increas-
Capacity ingly change to water. Since water has a lower spe-
is a synonym for the amount of current taken up and cific weight than diluted sulphuric acid the density of
discharged by a battery over a specified period of the electrolyte will also drop during the discharge
time. and with a fully discharged cell and a temperature
of 27°C it will only be 1.18 kg/dm3.
● With a lead cell the acid density is therefore a meas-
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead
132 BOMAG 008 910 92

Batteries 7.12
battery. The so-called acid tester (hydrometer) is
used for this purpose. In a battery of good condition
the acid density should be the same in all cells.
Acid density at 27 °C in kg/dm3

● 1.25 -1.28, open-circuit voltage approx. 12.7 Volt.
Battery is charged.
● 1.20 -1.24, open circuit voltage approx.12.4 to 12.5
Volt, is 50% discharged. Charging is necessary.
● 1.19 and less, open circuit voltage less than 12.3
Volt. Battery is insufficiently charged. Battery needs
to be recharged immediately.
Fig. 4 Battery and generator tester

i Note
The battery and generator tester comes with an 8-line
If the current consumption during charging is not 1/20 LC display with background illumination and is able to
of the nominal capacity (example 100 Ah battery: print out test results via an (optional) integrated ther-
100Ah x 1/20 = 5 A) or full charging of the battery re- mal printer.
sults in a final acid density of only 1.24 kg/dm3 or less,
the battery shows normal wear by aging. The battery
was insufficient charging or exhaustive discharge. i Note
Before testing clean the poles and ensure good con-
nection between clamps and poles.
The test program calculates the text messages "good"
or "replace" on the basis of the charge condition (de-
rived from the battery voltage) and the currently avail-
able starting power of the battery. A battery with 45%
starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
The starting power represents the ratio of detected
cold testing current to the entered cold testing current
of the battery.
The starting power can exceed 100%.
Fig. 3 Reading the acid level

●
Maximum permissible tolerance between highest
and lowest measuring value of the 6 cells: 0.03 kg/
dm3.
Testing batteries without screw plugs

On closed batteries the acid density cannot be meas-
ured, we therefore recommend testing with the follow-
ing mobile tester:
008 910 92 BOMAG 133

7.12 Batteries
Charge condition with hydrometer
Fig. 5 Charge condition

Green = Charge condition >65%
Dark = Charge condition <65%
Light = Electrolyte level too low
! Danger
Danger of explosion!!! If the electrolyte level is too

low, the battery must no longer be charged.
134 BOMAG 008 910 92

Three-phase generator 7.13
7.13 Three-phase generator Design and function
In the generator the armature windings are located in-
General side the stationary stator, whereas the exciter winding
is arranged on the internally revolving rotor (Fig. 6).
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.
! Caution
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
disconnect the generator while the engine is run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be Fig. 6 Rotor with claw poles
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
ly limited.
Plus and minus cables must be disconnected dur-
ing rapid charging of the battery or electric weld-
ing on the vehicle.
When cleaning the generator with a steam or wa-
ter jet make sure not to direct the steam or water
jet directly on or into the generator openings or
ball bearings. After cleaning the generator should
be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
Fig. 7 Stator with 3 windings
The three stator windings (Fig. 7) are electrically offset
to each other by 120°. The excitation of the magnetic
field requires direct current, which is fed to the rotor
via two carbon brushes and slip rings.
008 910 92 BOMAG 135

7.13 Three-phase generator
This includes :
● Electric motors
● Relays
Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
es work with alternating or three-phase current.
This includes :
● Accumulators
● Control units
● All electronics
● Communication equipment.
Charge control light

It has by no means the function to show whether the
ignition is switched on or off. It has the function of in-
dicating that the generator works correctly. Under nor-
mal operating conditions the generator should work
and the charge control light should be off. The charge
control lamp receives (+) from the battery at one pole.
The other pole is connected to (D+), i.e. the (+) carbon
Fig. 8 3-phase current of the generator. If the generator is working correctly,
The generator first of all produces three-phase volt- (+) is attached to both connections on the charge con-
age / three-phase current. trol lamp. Since there is no difference in voltage, no
current can flow, the lamp does not light up. If the gen-
The wiring diagram (Fig. 8) shows the 3 windings in Y- erator does not work, current flows via the (+) carbon
connection and the 6 associated rectifier diodes. through the armature winding, via the (-) carbon to
The diodes D1, D2, D3 are also referred to as minus ground and from there back to the battery. The electric
diodes, because they have B- as common connection circuit is closed, battery voltage is applied to the
(minus plate). charge control lamp and the lamp lights up. Since the
The other diodes are the plus diodes. generator does not work when the engine is not run-
ning, the charge control lamp is not connected directly
The rectifier diodes have the effect that the negative to the battery, but via the ignition switch. When the ig-
half-wave is suppressed and only the positive section
nition is off, the charge control lamp is dead.
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage. Voltage regulator
Reverse current protection A generator without regulator would just work light a
bicycle dynamo. The power output would increase
The rectifier diodes also prevent discharging of the with rising speed. The voltage output would fluctuate
battery via the stator windings. The current can only with the load. (In case of a bicycle dynamo the tail light
flow from the generator to the battery. bulb is overloaded when the head light does not con-
Why does three-phase current need to be rectified sume any power). The function of the regulator is the
and how does this work? provision of a uniform vehicle voltage, almost com-
pletely independent from speed and load of the gen-
There are a few components for which can either be
erator.
operated with alternating current or direct current, be-
cause they work independently from the current flow
direction.
This includes :
●
Incandescent lamps
●
Fluorescent lamps
●
Glow lamps
●
Electric heating elements.
There are also a few components that could be oper-
ated either with alternating current, direct current or
three-phase current, if the components were designed
accordingly.
136 BOMAG 008 910 92

Checking the generator
First one must check whether the generator is actually
defective.
● This can be easily found out by checking whether
the charge control light in the dashboard lights up. If
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula-
tor, the wiring or the V-belt.
● When the engine is at rest, the charge control light
must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the volt-
age supply within certain limits.
● Cable connections on the generator OK?
● V-belt OK?
● Generator ground (engine ground) OK?
● Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
Fig. 9 Regulator with diode plate and rectifier diodes
replaced or the following trouble shooting procedure
In most cases voltage regulators (Fig. 9) with carbon must be performed.
brushes form a compact component. The voltage reg-
ulator is maintenance free and the wear of carbon
brushes is only so little, that they hardly ever need to
be replaced during the lifetime of a machine.
The regulator has the following function:
●
To maintain the vehicle voltage under any operating
conditions below 14.4 V.
●
To match the regulator voltage to the temperature.
●
Smooth rising of generator current when switching
loads (convenience function to avoid jerking of the
engine).
008 910 92 BOMAG 137

Checking the pre-excitation circuit Measuring the charge current

The most common reason for a 3-phase alternator not ● All plug-and-socket connectors must be free of cor-
charging is a too low pre-excitation current. The pre- rosion and intermittent contact.
excitation current through connection D+ depends on ● The generator ground connection must be OK.
the connected consumer (resistance), e.g. charge ● During the measurement switch on as many con-
control light or relay of a MD+ engine control.
sumers as possible.
The pre-excitation current should be approx. 250 mA 1 Attach the clip-on ammeter around the B+ line.
at 12 Volt. This corresponds with a 3 Watt light bulb or
an equivalent combination of light bulb + resistance or 2 Gradually increase the engine speed.
an LED + resistance. 3 The generator current must be at least as high as
the total current of all consumers.
The total resistance of the disconnected dead supply
line D+ max. should not exceed 48 Ohm.
In case of faults like
● charge control light stays on
● no voltage increase, e.g. from 12 V to 14 V
one should check that the correct resistance is as-
sured.
Fig. 10 Connections on the three-phase alternator (exemplary de-

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
● Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 10). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.
138 BOMAG 008 910 92

Checking the rotor Checking the stator
i Note
The rotor coils can only be measured in disassembled
state.
Fig. 11 Rotor
●
Remove the regulator with carbon brush.
Fig. 12 Stator
●
Contact the rotor slip ring with the tester points.
●
The resistance should be between 3 and 6 OHM Ω.
i Note
●
The rotor coils should not have continuity to ground. The stator coils can only be measured in disassem-
bled state.
● Measure the resistance of all three coils.
● The coils should not have contact among each oth-
er.
008 910 92 BOMAG 139

Checking the regulator voltage with the generator Checking the regulator voltage with the multime-
tester ter
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.
Fig. 14
● All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
Fig. 13 ● The generator ground connection must be OK.
The generator test assesses the regulator voltage and ●
The battery should be in good condition – the idle
the ripple factor of the generator voltage. speed voltage of the battery should be at least 12.6
●
All plug-and-socket connectors must be free of cor- Volt.
rosion and intermittent contact. ●
If possible switch off all consumers.
●
The generator ground connection must be OK. ●
Perform the measurement at raised engine speed.
●
The battery should be in good condition – the idle ●
The voltage (B+) should adjust itself at 13 to 14 Volt.
speed voltage of the battery should be at least 12.6
Volt.
●
If possible switch off all consumers.
●
Perform the measurement at raised engine speed.
140 BOMAG 008 910 92

Checking the regulator in disassembled state
On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator. Fig. 16
E.g minus controlled regulator
i Note One connects the regulator (Fig. 16) with D+ and D- to
When testing the regulator one should be aware that the power source, as shown in the illustration, and the
there are 2 different types of regulators: lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
● If the carbon brush is not connected to ground the will first become brighter, because the regulator al-
regulator is a so-called minus controlled regulator. lows all lamp current (= exciter current) to flow at volt-
The exciter winding is positioned between D+ and age values up to 14.4V. Once the regulator voltage is
DF, the regulator therefore regulates the exciter reached, the regulator switches the lamp current off.
winding on the ground side. The other carbon brush When returning the voltage back below the control
is connected with the cathodes of the exciter di- voltage, the regulator will switch the lamp back on.
odes, terminal D+. This leaves one further terminal,
With this test the major difficulty is the problem to re-
this is DF.
move the regulator an identify terminals D+, DF and
D+ (vehicle wiring system) D-.
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)
Fig. 17
Fig. 18
Fig. 15
The illustrations (Fig. 17) and (Fig. 18) show two dif-
● If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).
008 910 92 BOMAG 141

Replacing carbon brushes

● On a Bosch generator unscrew two fastening
screws for the regulator and lift the regulator off.
Pull out the carbon brushes from underneath. Their
minimum length is 5 mm, shorter carbon brushes
need to be replaced, unsolder both connection litz
wires. Solder the litz wires of the new carbon brush-
es, insert these and fasten the regulator again. For
this work the generator does not need to be re-
moved.
●
For replacing the carbon brushes in the Delco-
Remy generator the generator needs to be disas-
sembled and partly dismantled. The carbon brush
holder is located inside the collector ring bearing.
142 BOMAG 008 910 92

Electric starter 7.14
7.14 Electric starter ● establish the gear connection between starter and
combustion engine.
The starter converts the electric energy stored in the ● to maintain this connection.
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
● to switch on the starter current.
capacity is available. After starting the engine:
Duties of the starter: ● to return the starter pinion to initial position.
● to accelerate the combustion engine to start speed ● to switch off the starter current.
with lowest possible current consumption.
Fig. 1 Electric starter For purposes like e.g. purging the fuel systems,
1 Pinion starters may be operated for maximum 1 minute
2 Roller free-wheeling without interruption. Then you should wait for at
least 30 minutes (cooling down) until trying again.
3 Steep thread During the 1 minute starting period this process
4 Guide ring should not be interrupted.
5 Spring winding Starter motors must not be cleaned with high
6 Armature pressure steam cleaning equipment.
7 Pole shoe The contacts on starter terminals 30, 45, 50 must
8 Carbon brushes be protected against unintended shorting (jump
protection).
9 Armature brake
10 Collector When replacing the starter the ring gear on the en-
gine flywheel must be checked for damage and its
11 Magnetic switch number of teeth - if necessary replace the ring
12 Engagement lever gear.
Always disconnect the battery before starting as-
!Caution sembly work in the starter area of the engine or on
So-called jump starting (using an additional exter- the starter itself.
nal battery) without the battery connected is dan-
gerous. When disconnecting the cables from the
poles high inductivities (arcs, voltage peaks) may
occur and destroy the electrical installation.
008 910 92 BOMAG 143

7.14 Electric starter
Function of pre-engaged-drive starting motor

This type of starter uses a solenoid to engage the pin-
ion with the ring gear. The engaging solenoid contains
switching contacts for the starting current. When clos-
ing the starter switch, the relay holding winding is ac-
tive and current flows also through the series
connection of pick-up winding and electric motor. The
engaging solenoid picks up and moves the free-
wheeling with the pinion forward via the engaging le-
ver and the engaging spring. In case of a favourable
position of the pinion to the ring gear a tooth of the pin-
ion will directly engage in a tooth gap. In this case the
pinion will engage over the entire length of the screw
path, until the contact bridge in the engaging relay
touches the relay contacts. The starter motor is no
switched on. However, if the pinion does not directly Fig. 2 Switching position during engagement
find a tooth gap, the ring gear will block any further en-
gaging movement. The engaging lever in this case
compresses the engaging spring and the main contact
closes, even though the pinion and the ring gear are
not engaged. The electric motor keeps rotating the
pinion in front of the ring gear face, until a pinion tooth
gap matches a tooth on the ring gear and the preload-
ed engaging spring moves pinion and free-wheeling
forward. When switching the relay winding off, the re-
turn spring forces the relay armature and the pinion
with free-wheeling back to rest position. This disen-
gagement is supported by the steep thread.
Magnetic switch
The magnetic switch is normally arranged directly
above the starter. Fig. 3 Switching position during starting
With the starter switch switched on, both the pickup 1 Ground
winding and the holding winding are energized and 2 Battery
shift the iron core in axial direction. With a lever this
iron core pulls the starter pinion towards the engine 3 Starter switch
flywheel. 4 Pull-in winding
Once the gears are engaged the starter current is ap- 5 Holding winding
plied to the back through a large cross-section. At the 6 Exciter winding
same time the pickup winding is shorted via the starter 7 Restoring spring
current and thus switched off as a measure to reduce
8 Driver
the load on the energy household.
9 Pinion
10 Flywheel
144 BOMAG 008 910 92

Electric starter 7.14
Trouble shooting "Starter" Testing and measuring the electric starter
The most frequent fault is definitely a fully discharged
battery. i Note
If the starter rotates too slowly, either the brushes The highest current flows when the starter is blocked!
are partly worn off, or parts of the exciter or armature (Short circuit current in starter). This is the case when
winding is shorted. In some cases oxidized electric the pinion is engaged and the starter has the duty to
contacts or a soiled ground connection causing ex- accelerate the flywheel to starting speed.
tremely high voltage losses in the overall starter sys-
tem are the cause of problems. Function test with starter installed
If the starter only emits a clicking sound,- either
● Initiate the starting process and measure the volt-
the magnetic switch is defect / soiled (dismantle and age on the pickup solenoid switch (50a). At least
clean))- the main contacts on the magnetic switch are 10.8 Volt should be applied.
worn off / soiled (scrape off carefully with a file and ● When operating the starter switch the magnetic
clean)- the starter motor is defective / soiled (remove switch must engage in the flywheel ring gear (no-
armature and clean), cover cleaned, moveable parts ticeable clicking sound) and release the starting
with grease. current to the starter. On most magnetic switches
the voltage can be measured with the multimeter. If
Frequently a jammed return mechanism is the reason
this does not happen even though voltage is ap-
for a starter failure.
plied, replace the magnetic switch.
Occasionally worn contacts are found on the magnetic
return switch Function tests with disassembled starter
Defects on the actual starter motor including pinion
and carbon brushes are very rare. !Caution
With a trouble shooting chart the faults in the starter Before removing the starter you must disconnect
system can be narrowed down. The starter system the ground cable from the minus pole of the bat-
can only work when many conditions are fulfilled at tery while the ignition is switched off.
the same time. ● Check the wear on the carbon brushes and their
●
Immobilizer deactivated? contact pressure.
●
Ignition switch OK? ● Check the collector, it must not have electrical con-
●
Travel lever in correct position? tact with the rotor shaft.
●
Emergency stop not actuated? ● Check the drive pinion for excessive wear.
●
Battery sufficiently charged? ● The return mechanism should not be tight, if neces-
●
Battery poles OK? sary grease amply with silicon grease (Bosch PZ 2
V3) or a comparable grease.
●
Main battery fuse OK?
● Measure the resistance of the magnetic switch main
●
Main battery switch closed?
contact in disengaged condition. Maximum value
●
Main starter cable (terminal 30) OK? 0.2 OHM Ω.
●
Starter control cable (terminal 50) OK, voltage
drop?
●
Ground cable OK?
● Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
●
the experience of the specialist
●
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.
008 910 92 BOMAG 145

7.15 Telemecanique switch

Example of terminal designations
Fig. 1 Terminal designations

●
Normally open contact 23 located on block 2
●
●
Normally closed contact 12 located on block 1
●
Normally closed contact 11 located on block 1
●
●
●
●
●
●
i Note
If e.g. block 5 is not needed to design a switch, the
numbering for blocks 1,2,3,4 and 6 remains un-
changed.
146 BOMAG 008 910 92

Telemecanique switch 7.15
Disassembly
Fig. 2 Disassembly
● Lift up the interlock (5).
Fig. 4 Pulling out the front element

● Lift up the interlock (2) and pull out the front element
(3).
Fig. 3 Folding down the switch block
● Fold down the switch block (4).
● Loosen screw (1).
008 910 92 BOMAG 147

Assembly
Fig. 5 Assembly
● Insert the front element (3) into the bore in the con-
trol panel.
Fig. 7 Assemble the switch block

● Clip on the switch block (4).
Fig. 6 Observe the marks.

i Note
Hook in the switch block at the bottom first (Fig. 7).
● Clip the fastening adapter (6) onto the front element
(3).
i Note
Watch the marls on front element (Fig. 6) and fasten-
ing flange.
●
Tighten the screw (1) with a tightening torque of 0.6
Nm.
148 BOMAG 008 910 92

Inductive proximity switches 7.16
7.16 Inductive proximity switches NPN circuitry
General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 10 NPN circuitry
proximity switches are today indispensable. Com-
pared with mechanical switches, they offer almost ide- On sensors with NPN-circuitry the output stage con-
al prerequisites: non-contact, wear free operation, tains a NPN-transistor, which switches the load
high switching frequencies and switching accuracies, against the negative operating voltage. The load is
as well as high protection against vibration, dust and connected between the output and the positive oper-
moisture. Inductive sensors detect all metals without ating voltage.
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.
Working principle
Fig. 8
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field. Fig. 11
This stray field leaks out from the active area of the Proximity switches are used as breaking or making
proximity switch. If metal or non-ferrous metal enters contacts. Depending on the design the switching dis-
into the response range energy is absorbed. The os- tances are 2 or 4 mm. The maximum amperage is 300
cillator is thus dampened and the resulting change in mA.
current consumption is evaluated. The LED (Fig. 11) lights up, when the initiator has de-
tected metal in its stray field.
PNP circuitry
Fig. 9 PNP circuitry

On sensors with PNP-circuitry the output stage con-
tains a PNP-transistor, which switches the load
against the positive operating voltage. The load is
connected between the output and the negative oper-
ating voltage. The switch is designed with a normally
open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.
008 910 92 BOMAG 149

7.17 Angle sensor with current output
7.17 Angle sensor with current out-

put
Fig. 1 Sensor
The the function of the angle sensor (Fig. 1) is based
on the so-called "Hall-Effect". Named after the Ameri-
can physicist E.H. Hall. Due to the fact that moving
electrons are deflected in a magnetic field, a voltage
transverse to the flow direction of the primary current
can be expected on a current conducting conductor in
the magnetic field. Since the electrons are deflected in
Fig. 12 Circuit diagram, making contact
transverse direction by the magnetic field, they must
The circuit diagram (Fig. 12) shows a proximity switch enrich on the one side and reduce on the opposite
with normally open contact. side. If a very thin circuit board is now subjected to a
Brown = voltage supply current that is uniformly distributed across its cross
section, no voltage will be measured between two
Blue = ground supply
points A and B, which have an identical distance to the
Black = switching output current supply lines and are connected by a highly
The initiator switches the relay (K05) sensitive galvanometer. When generating a magnetic
field vertical to the circuit board, voltage will be
present between A and B and a current will flow
through the galvanometer connected to these points.
This is referred to as "Hall-Effect". The cause for this
effect is the warping of the originally parallel electron
orbits in the board by the magnetic field.
150 BOMAG 008 910 92

Plug connectors 7.18
7.18 Plug connectors
Duties and requirements
Electric plug connectors must provide a reliable con-
nection between different system components and
thus ensure the safe function of the systems under
any operating condition. There design ensures that
they will withstand the applied loads throughout the
lifetime of the machine.
Examples for these loads are:
● Vibration acceleration
●
Temperature fluctuations, high and low tempera-
tures
● Dampness
Fig. 2 Connection diagram ● Micro movements of the contact with resulting fric-
The angle sensor has 3 electric connections (Fig. 2). tion corrosion.
Ub, supply voltage (+ 8.5 Volt) These loads may increase the transition resistances
Gnd, ground of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
Out, output current 4-20 mA. cuits in neighbouring lines. Electric plug connectors
● at -35° = 4 mA output current must therefore have the following properties:
●
at 0° = 12 mA output current ●
Low transition resistances of the conductive parts.
● at +35° = 20 mA output current. ●
High insulation strength between conductive parts
with different voltage potentials.
●
Excellent leak tightness against water and mois-
ture.
008 910 92 BOMAG 151

7.19 Deutsch plug, series DT and DTM
7.19 Deutsch plug, series DT and DT Series

DTM
General
Plug connectors DT and DTM have a wedge to hold
the pins and sockets in their position. This wedge can
be removed and replaced, without having to cut any
leads.
Fig. 1 DT plug connection
Fig. 3 Crimp connections
Fig. 2 DT Series
Caution
!
Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Fig. 3 Sectional drawing
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
●
Perform a pull test on each lead, each of the termi-
nals and connections must withstand a pulling force
of 45 N without any difficulties.
152 BOMAG 008 910 92

Deutsch plug, series DT and DTM 7.19
Installing DT contacts
Fig. 4
● Insert the contacts through the rubber grommet until
they click into place.
● Insert the orange wedge in direction of arrow.
Caution
!

nals and connections must withstand a pulling
force of 45 N without any difficulties.
i Note
Use the same method when assembling the socket.
008 910 92 BOMAG 153

Disassembling DT contacts
Fig. 5
● Pull the orange wedge out with long nose pliers.
●
Slightly pull the lead and unlock the interlocking
hook with a screw driver.
● Pull the contact out of the socket.
i Note
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
154 BOMAG 008 910 92

DTM Series
Fig. 1 DTM plug connection
Fig. 2 DTM Series
Fig. 3 Sectional drawing
008 910 92 BOMAG 155

Installing DTM contacts
Fig. 4
●
Insert the contacts through the rubber grommet until
they click into place.
●
Insert the orange wedge, until it clicks into place.
Caution
!

nals and connections must withstand a pulling
force of 45 N without any difficulties.
i Note
156 BOMAG 008 910 92

Disassembling DTM contacts
Fig. 5
● Pull the orange wedge (interlock) out with long nose
pliers.
● Slightly pull the lead and unlock the interlocking
hook with a screw driver.
● Pull the contact out of the socket.
i Note
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
008 910 92 BOMAG 157

7.20 Plugs and terminals in spring clamping technology
7.20 Plugs and terminals in spring ventional copper conductors (single, multiple or fine
stranded) with or without wire and ferrule.
clamping technology
! Caution
General
The spring clamp technology is not suitable for
extra fine conductors. Extra fine conductors can
be easily pulled out of the spring clamp!
Fig. 1
Spring clamp technology (Fig. 1) for quick, vibration
resistant and maintenance-free connection of all con-
Connecting terminal for quick repairs
Fig. 2 That's how it works

The connecting clamp clamps up to 3 or 5 stripped
fine conductors of 0.08 mm² to 4 mm², single or multi-
ple strand up to 2.5 mm². And this even without tools
(Fig. 3).
That's how it works

● Strip 9-10 mm of the lead. Fig. 3 Connecting clamp
● Open the actuating lever and insert the strand.

● Return the actuating lever to initial position.
!Caution
nals must withstand a pulling force of 45 N with-
out any difficulties.
158 BOMAG 008 910 92

Plugs and terminals in spring clamping technology 7.20
Series clamp
Fig. 4 That's how it works
That's how it works

● Insert a screw driver into the actuating opening until
it bottoms.
● Strip 9-10 mm of the lead and insert it into the
clamp.
● Pull out the screw driver.
!Caution
Measuring signals
On these terminal blocks the bridge slot is most suita-
ble for tapping off and measuring signals. Here you
may directly insert a 4 mm test adapter (see special
tools for electrics) for connecting a measuring lead.
This test adapter is standard in the central electrics of
heavy equipment machines.
Fig. 5 Test adapter
008 910 92 BOMAG 159

7.20 Plugs and terminals in spring clamping technology
X-COM System for universal system wiring, ever since it was intro-
The X-COM-SYSTEM, a synthesis of plug connector duced in 1997. All the familiar series clamping func-
and series clamp, has grown up to a construction kit tions have thus become pluggable.
X-COM plug clamp
Fig. 6 That's how it works Measuring signals

That's how it works
●
Insert a screw driver into the actuating opening until
it bottoms.
●
Strip 9-10 mm of the lead and insert it into the plug.
●
Pull out the screw driver.
!Caution
Fig. 8 X-COM plug plugged onto the series clamp
Fig. 7 X-COM plug with measuring cable

● The most reliable measurements on the plug can be
made when using the measuring and connecting
cable with 2mm plug (see special tools for
electrics).
160 BOMAG 008 910 92

8 Special tools, electrics
008 910 92 BOMAG 161

8.1 Special tools, electrics

Measuring equipment
15. Electric test case
Fig. 9
16. Multimeter
Fig. 10
17. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.

18. Test prod red, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.
Fig. 11
19. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.

20. Test prod red, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.
Fig. 12
162 BOMAG 008 910 92

Special tools, electrics 8.1
21. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 0.5 m.

high flexible design, black, length 1 m.

high flexible design, black, length 2 m.

Fig. 13 high flexible design, red, length 0.5 m.

high flexible design, red, length 1 m.

high flexible design, red, length 2 m.

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

sign, black, length 600 mm.

sign, red, length 300 mm.
Fig. 14
sign, red, length 600 mm.

31. Transition plug connector, with 4 mm plug on one
side and 2 mm socket on the other, insulated de-
sign
Fig. 15
008 910 92 BOMAG 163

32. Magnetic coil tester
Fig. 16
33. Clip-on measuring instrument
Fig. 17
34. Battery - generator tester
Fig. 18
Spring clamps (Wago or Weidmüller)
35. Cranked screwdriver (Fig. 19) to open spring
clamps (Fig. 20).
Fig. 19
164 BOMAG 008 910 92

36. Testing adapter to measure the signals from the
series spring clamps (Wago).
Fig. 20
Deutsch contacts
37. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).
Fig. 21
38. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm2 cable cross-section
AWG 16 = 1,5 mm2 cable cross-section
Fig. 22
39. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
Fig. 23
008 910 92 BOMAG 165

40. Disassembly tool for Deutsch contacts of series

HDP.
AWG 20, BOMAG part-no.: 079 900 78
Fig. 24
ITT contacts
41. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 25
42. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 26
43. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.
Fig. 27
166 BOMAG 008 910 92

Schaltbau contacts
44. Disassembly tool for Schaltbau contacts of series
M1, M2.
Fig. 28
45. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm2.
Fig. 29
FCI Burndy contacts
46. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO
Fig. 30
AMP contacts
47. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).
Fig. 31
008 910 92 BOMAG 167

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

PER-SEAL with connecting cross-section 0.75 -
1.25 mm2.
Fig. 32
49. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).
Fig. 33
TON with connecting cross-section AWG 14 - 10.
Fig. 34
TON with connecting cross-section AWG 16 - 14
and AWG 18.
Fig. 35
168 BOMAG 008 910 92

52. Crimping tool for Powertimer contacts with indi-
vidual strand sealing (example: ESX control)
Fig. 36
53. Crimping jaws for Crimping tool 079 900 25
Fig. 37
54. Disassembly tool for AMP-contacts of series CIR-
CULAR-CONNECTOR.
1.5 mm2, BOMAG part-no.: 079 900 74
2,5 mm2, BOMAG part-no.: 079 900 75
Spare sleeve 1.5 mm2, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm2, BOMAG part-no.: 079
900 77
Fig. 38
Universal tools
55. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 - 1.0 mm2.
Fig. 39
008 910 92 BOMAG 169

56. Precision pressing pliers for non-insulated flat

male and female connectors0.5 - 6,0 mm2.
Fig. 40
Measuring adapter
57. Current measurement adapter for Hirschmann
plugs.
Fig. 41
58. Voltage measurement adapter for Deutsch plugs,
8-piece (2 to 12 pole).
Fig. 42
59. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.
Fig. 43
170 BOMAG 008 910 92

9 Electronic modules
008 910 92 BOMAG 171

172 BOMAG 008 910 92
9.1 BEM, BOMAG Evib-meter
008 910 92 BOMAG 173

Bild 44
i Hinweis
The documentation "Service Training Electrics BAM (BOMAG Asphalt Manager)" contains also the documenta-
tion BEM (BOMAG Evib-meter).
The BOP (BOMAG Operation Panel) is only installed in connection with BAM machines, BEM-machines are
equipped with display module. The display module is used for the output of fault codes and display values, as
well as for the input of code numbers.
174 BOMAG 008 910 92

BEM, BOMAG Evib-meter 9.1
Service Training
Electrics
BAM
P/N 008 097 11 Version 3.04
Status: 30.05.2006 Page 1 of 55

Author: T.Löw / TE
Dateiname: p:\schulung\elektrik\tandem\bam\englisch\00809711_schulung elektrik bam_v3.04_gb.doc
008 910 92 BOMAG 175

Table of contents
1 Document alteration list.....................................................................................................................3
2 Proof of software change MESX .......................................................................................................4
3 Proof of software change BOP..........................................................................................................5
4 Known faults......................................................................................................................................6
5 How to proceed when replacing components?.................................................................................7
5.1 How to proceed when replacing an ESX control? .....................................................................7
5.2 Which components can be replaced without a subsequent adjustment procedure? ................7
5.3 List of machine types .................................................................................................................8
6 Possible adjustments on machines without BOP .............................................................................9
6.1 Description of the Display Module .............................................................................................9
6.2 Input of code numbers ...............................................................................................................9
6.3 Changing the machine type (only via display module) ............................................................10
6.4 Changing the bit rate (only with display module).....................................................................11
7 Adjustment/display possibilities on machines with BOP.................................................................12
7.1 Adjusting the machine type (BOP)...........................................................................................12
7.2 Changing the units system (metric/imperial) ...........................................................................14
7.3 Accessing the diagnostics menu .............................................................................................16
7.3.1 Extended diagnose for articulated machines ......................................................................... 18
7.3.2 Extended diagnose pivot steered machines........................................................................... 19
7.4 Changing the printout language...............................................................................................20
7.5 Setting the machine serial number ..........................................................................................22
7.6 Teaching distance pulses ........................................................................................................24
7.7 Changing the display mode (metric/imperial) ..........................................................................26
7.8 Simulation mode ......................................................................................................................28
8 Block diagram BOMAG Evib meter (BEM) .....................................................................................33
9 Block Diagram BOMAG Asphalt Manager ......................................................................................34
10 Description of the Signals on the ESX-Control............................................................................35
11 Fault codes of the ESX control ....................................................................................................41
11.1 Overview...............................................................................................................................41
11.2 Description of fault reactions ................................................................................................42
11.3 Detailed description of fault codes and their possible causes ............................................43
12 Input codes for ESX control (only via BEM display module) .......................................................48
12.1 Travel system .......................................................................................................................48
12.2 Vibration ...............................................................................................................................49
12.3 Light......................................................................................................................................49
12.4 Acceleration transducer........................................................................................................50
12.5 Diesel engine........................................................................................................................50
12.6 Setting the machine type......................................................................................................51
13 Terminology in connection with ESX...........................................................................................52
Status: 30.05.2006 Functions of the ESX control Page 2 of 55

Author: T.Löw / TE
176 BOMAG 008 910 92

1 Document alteration list
Version Date Description of changes resp.

2.00 09.09.2004 x Creation of first version (derived from single drum rollers) Löw
3.00 17.09.2004 x Paragraph "Simulation mode" added Löw
3.01 18.02.2005 x Fault codes for temperature sensor added Löw

x Fault description for acceleration transducer corrected
x Serial numbers in machine type description added
x Description "Changeover Metric/Imperial" added
3.02 30.03.2005 x Proof of software change separated for MESX and BOP Löw
3.03 21.07.2005 x Machine type codes extended Löw
x Fault description from code 9000 and up extended
x Description Pin 39 inserted
x Software extension MESX and BOP extended
x Description fault code 4531 and 4532 extended
x Item "6 Adjustment possibilities on machines without BOP"
included.
x Item "8 Block diagram BOMAG Evib Meter (BEM)"
included.
3.04 10.04.2006 x Machine codes extended Löw
x Software description MESX extended
x Note "...limitation +-20%..." under item “7.6 teaching
distance pulses” removed.

Author: T.Löw / TE
008 910 92 BOMAG 177

2 Proof of software change MESX

1.04 09.06.2004 Creation of first version, derived from single drum rollers Löw
2.00 09.09.2004 x problems with sporadic crashing eliminated Löw
x Number of machine variants extended to 25
x BW203 AD AM and BW174-2 AD AM released
x Changeover metric/imperial implemented
x BOP software required as a minimum changed to 1.3
3.00 17.09.2004 x Changeover metric/imperial for Evib value, effective Löw
amplitude and frequency extended
x Printouts for a.m. representation of measuring values
adapted
x So-called "Simulation mode" for swivelling the exciter
without vibration and at standstill realized
3.01 18.02.2005 x Power stage setpoints transmitted to BCM Löw
x Calculation of measuring path for BCM modified, to make
it more accurate for 10m even with a lower number of
pulses.
x Evaluation of a CAN message with ID100 realized (drum
steering angle)
x Transmission of a.m. steering angle data to the BCM
x Control of bmfsa deactivated, because bmfsa of travel
control already connected to CAN1 (BW174 GPS
machine)
x Displayed amplitude for angles > 90° limited to max.
amplitude
3.02 18.02.2005 x Initialization of variables in MMI structure at start-up only Löw

with 0, not with reinit!
3.03 18.02.2005 x BW141AD-4AM and BW151AD-4AM freely switched Löw
x Axle loads BW154AD-4AM corrected acc. to SAP
x Pulse frequencies for BW144 and BW154 corrected
x max. adjustment angle limited from 82.5 to 80 (analog
single drum rollers)
3.04 30.03.2005 x Machine types BW170AD AM and BW184AD AM Löw
released
x Function "Check MMI Software Version" corrected
3.05 21.07.2005 x BW161AD and BW151AC added Löw
x bmfsa display activated (for BEM)
x Evaluation ampl. for high and low amplitude extended (for
BEM)
x Suppression of speed display when travel lever is in
neutral
x Start delay Evib calculation reduced from 4s to 2s
x Movement of exciter also to be released after 2s
x Starting of minimum amplitude in automatic mode must
ALWAYS be assured
x Pulse changed to 10m for BW170 from 130 to 123
x Printout not to be stopped when pressing CLEAR
3.06 11.04.2006 x BW141AD,BW151AD and BW151AC-AM added Löw
x BW141AD AM with 20g input and changed control
behaviour in automatic
x Error code 4531 (voltage input asphalt temperature)
corrected to 4631
x Limitation in teaching distance pulses (+-20%) removed.

Author: T.Löw / TE
178 BOMAG 008 910 92

3 Proof of software change BOP

1.02 11.05.2004 x first version to achieve compliance with single drum rollers Löw
x Screen with mph and °F for BW190
x Switching between languages and machine types locked
1.03 09.09.2004 x Start page index extended (articulated joints and pivot Löw
steered machines)
x Changeover metric to imperial realized for km/h and °C
2.00 17.09.2004 x Imperial display extended by psi and in Löw
x Simulation mode implemented on OPUS
3.00 30.03.2005 x Software version changed, because MESX version is also Löw
3.x (analog single drum rollers)
x imperial display for pivot steered machines corrected
x Designation "ESX" replaced by "MESX" and "OPUS" by
"BOP"
x Flags for all EU-languages, Japan and China stored in
BOP
3.01 21:07:2005 x Designation ESX replaced by MESX and OPUS by BOP Löw
x Show "Changing settings" when changing the display
mode (metric/imperial)
x Show warning message on machines with circular exciter

Author: T.Löw / TE
008 910 92 BOMAG 179

4 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Behaviour of machine Possible cause
During initial commissioning the display shows the Bit rate on bmfsa not set to 125 kBit
reading "ct0" => see "Setting the bit rate"

Author: T.Löw / TE
180 BOMAG 008 910 92

5 How to proceed when replacing components?

Each machine is adjusted individually during initial commissioning. This is mainly accomplished by
setting the correct machine type (see "6.3 Changing the machine type (only via display module)", or
"7.1 Setting the machine type (BOP)7.1 Adjusting the machine type (BOP)").
The following chapter describes the necessary adjustments to the control when replacing individual
components in the measuring system.
5.1 How to proceed when replacing an ESX control?
Attention: A machine must not be operated with a wrong type setting,

because in such a case the correct function of the control cannot
be assured!
You should therefore set the machine type first! see "7.1 Setting
the machine type (BOP) Adjusting the machine type (BOP)").
After setting the machine type check the following items:
x Set the machine serial number (only on machines with BOP), see: 7.5
x Set the printer language (only machines with printer), see: 7.4
5.2 Which components can be replaced without a subsequent

adjustment procedure?
x BOP
x Acceleration transducer
x Valve block for exciter adjustment
x Printer
x Bmfsa display module
x All switches in the dashboard
x Axle sensor or drum sensor speed
Note: A final function test of the complete machine is highly recommended.

Author: T.Löw / TE
008 910 92 BOMAG 181

5.3 List of machine types

Since the same control is used for all tandem rollers with the new measuring technology, it is
necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This
type adjustment is necessary, because the machines have e.g. different axle loads or different drum
widths, which requires the calculation of measuring values to be adapted.
The following machine types can be adjusted:
Machine type First serial number Last serial number Code Available from
version
141 AD-4 101 920 00 1001 XXX XXX XX XXXX 7700 3.06
141 AD-4 AM 101 920 20 1001 XXX XXX XX XXXX 7703 3.03
144 AD-4 XXX XXX XX XXXX XXX XXX XX XXXX 7710 not available at present
144 AD-4 AM XXX XXX XX XXXX XXX XXX XX XXXX 7713 not available at present
151 AD-4 101 920 01 1001 XXX XXX XX XXXX 7720 3.06
151 AC-4 101 920 10 1001 XXX XXX XX XXXX 7722 3.05
151 AC-4 AM 101 920 41 1001 XXX XXX XX XXXX 7724 3.06
161 AD-4 101 920 02 1001 XXX XXX XX XXXX 7740 3.05
161 AC-4 XXX XXX XX XXXX XXX XXX XX XXXX 7741 not available at present
161 ADH-4 XXX XXX XX XXXX XXX XXX XX XXXX 7745 not available at present
174 AC-2 AM XXX XXX XX XXXX XXX XXX XX XXXX 7764 not available at present

Author: T.Löw / TE
182 BOMAG 008 910 92

6 Possible adjustments on machines without BOP
6.1 Description of the Display Module
Note: The display module described next is only used in machines without the Bomag
Operation Panel (BOP). On machines with BOP the settings are made via the BOP!
(see item "7 Adjustment/display possibilities on machines with BOP")
The display module consists of a 4-digit display and two keys, F1 and F2.
It is used for the output of fault codes and display values as well as for the input of code numbers.
Faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes
will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible. Higher
values lead to the display "- - - - ", negative values are indicated by the "minus dot" lighting up (see
illustration).
Vorzeichen
057 667 72
15/54
The following description describes the input of code numbers.
6.2 Input of code numbers

For the diagnostics of control inputs and outputs various code numbers can be entered via the display
module of the control. The input of a code number is performed as follows:
1. Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
)The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
2. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure
9 is displayed and the left hand key (F1) is pressed again, the display will return to the value 0 .
3. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the
ignition off.

Author: T.Löw / TE
008 910 92 BOMAG 183

6.3 Changing the machine type (only via display module)

For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module of the central electrics when switching the ignition on. It can also be checked at any
time by entering code 7000.
Adjusting the machine type requires the following sequence:
Note: Parameter adjustments can only be performed when the engine is not running!
x Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type".
The display module now permanently shows the code 7 0 1 0 .
x Select and enter the machine from the table above.
The display module now permanently shows the entered code. (e.g. 7 5 3 3 )
x Enter code number 7 0 1 1 . This code number confirms the entered machine type.
After confirming the machine type the control initiates a restart, the display module shows the new
machine type for approx. 3 seconds.
x Switch the ignition off and on again.
After this the newly adjusted machine type will be displayed for approx. 3 seconds.
Attention: A machine must not be operated with a wrong type setting, because in such a
case the correct function of the control cannot be assured!
New controls are delivered with the default machine type setting 7 5 0 0 .

Author: T.Löw / TE
184 BOMAG 008 910 92

6.4 Changing the bit rate (only with display module)

The multi-function display can be operated with different CAN transmission speeds. For operation in
our machines the bit rate must be set to 125 kBit/s. The bit rate is changed as follows:
x Hold both keys (F1 and F2) of the multi-function display depressed and switch on the ignition.
) The currently set bit rate is displayed, e.g. 0 1 0 0 .
x The bit rate can now be changed in fixed steps by pressing the right hand key (F2). Hold the key
depressed until the display reads 0 1 2 5 .
x By pressing the left hand key (F1) the bit rate is accepted and the display changes back to the
normal display mode.

Author: T.Löw / TE
008 910 92 BOMAG 185

7 Adjustment/display possibilities on machines with BOP
7.1 Adjusting the machine type (BOP)

Adjusting the machine type requires the following sequence:
Note: Parameter adjustments can only be performed when the engine is not running!
x Press key "?" to open the screen page "MENU". The following screen is displayed1:
x Press key "F2" to open the screen page "Adjust machine type". The following screen is displayed:
1
Note: This document shows the menu screen for articulated machines as an example. Operation of pivot steered machines is
identical, only the roller symbols are different.

Author: T.Löw / TE
186 BOMAG 008 910 92

x The desired machine type can be selected by pressing the keys "F11" and "F12". (see "List of
machine types" under item "7.1 Adjusting the machine type (BOP)").
x After selecting the desired machine type press key "F14", until the symbol (F14) lights green for
confirmation (approx. 4s).
When releasing the key the start screen will automatically be displayed and the control will initiate a
restart.
BOP and BAM are now adjusted to the new machine type.

Author: T.Löw / TE
008 910 92 BOMAG 187

7.2 Changing the units system (metric/imperial)

The BOP offers the possibility to change display and printout from metric units (km/h and °C) to
imperial units (mph and °F).
x Press key "?" to open the screen page "MENU". The following screen is displayed:
x Press key "F4" to open the screen page "Change units". The following screen is displayed:

Author: T.Löw / TE
188 BOMAG 008 910 92

x You can now switch between imperial and metric units system by pressing key "F5" ("Imperial = 1"
or "Imperial = 0").
x After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
When releasing the key "F14" the start screen will automatically be displayed and the control will
initiate a restart.
BOP and printer have been changed over to the new units system.

Author: T.Löw / TE
008 910 92 BOMAG 189

7.3 Accessing the diagnostics menu

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

Author: T.Löw / TE
190 BOMAG 008 910 92

If an actual error is present the corresponding error code will be displayed in the field "Actual Errors".
x Press "ESC" to leave the page.
x By pressing key "A" you can change into a machine specific, more detailed diagnostics menu (see
below).

Author: T.Löw / TE
008 910 92 BOMAG 191

7.3.1 Extended diagnose for articulated machines
4.25 V Uexciter: actual voltage of exciter position potentiometer
4,24 V Ub1: actual voltage front left acceleration transducer
4,25 V Ub2: actual voltage right acceleration transducer
0,86 V Utemp: actual voltage input asphalt temperature
Backward: Status BAM input "travel lever reverse" (LED on = 12V)
Ligths: Status BAM input light detection (LED on = 12V)
MD+ Status BAM input MD+ (detection engine running) (LED on = 12V)
Vibration: Status of vibration detection in the BAM (LED on = Vibration ON)
NOT Neutral: Status BAM input "travel lever NOT in neutral" (LED on = 12V)
+01234 Distance pulses detected by the control (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.

Author: T.Löw / TE
192 BOMAG 008 910 92

7.3.2 Extended diagnose pivot steered machines
4.25 V Uexciter: actual voltage of exciter position potentiometer
4,24 V Ub1: actual voltage front left acceleration transducer
4,25 V Ub2: actual voltage right acceleration transducer
0,86 V Utemp: actual voltage input asphalt temperature
0% Forward: Triggering of solenoid valve for travel pump forward in percent
0% Backward: Triggering of solenoid valve for travel pump reverse in percent
Backward: Direction signal detected by the BAM on basis of the travel pump control
Ligths: Status BAM input light detection (LED on = 12V)
MD+ Status BAM input MD+ (detection engine running) (LED on = 12V)
Vibration: Status of vibration detection in the control (LED on = Vibration ON)
Forward: Direction signal detected by the BAM on basis of the travel pump control
+01234 Distance pulses detected by the control (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.

Author: T.Löw / TE
008 910 92 BOMAG 193

7.4 Changing the printout language

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

Author: T.Löw / TE
194 BOMAG 008 910 92

x The desired printout language can be selected by pressing the keys "F11" and "F12".
x After selecting the desired language press key "F14" to save the setting. The symbol (F14) lights
green for a moment as a sign of confirmation.

Author: T.Löw / TE
008 910 92 BOMAG 195

7.5 Setting the machine serial number

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

Author: T.Löw / TE
196 BOMAG 008 910 92

x The desired printout language can be selected by pressing the keys "F11" and "F12".
x After the adjustment press key"F14" to save the setting. The symbol (F14) lights green for a

Author: T.Löw / TE
008 910 92 BOMAG 197

7.6 Teaching distance pulses

The distance pulses for the different machine types are already set by default after adjusting the
correct machine type. However, due to slippage on the drums the recorded distance measurement
may deviate from the actually travelled distance. In this case the distances pulses can be adjusted
accordingly.
Note: An adaptation of the distance pulses is only possible within a range of +/- 10% of the
preset value.
x Press key "F8" to open the screen page "Distance pulses". The following screen is displayed:

Author: T.Löw / TE
198 BOMAG 008 910 92

x Pressing the key "F5" starts the teach mode. The following symbol appears:
x Drive a distance of 10 m length in forward and press the key "F6" at the end. The following symbol
appears:
x After the end of the measuring travel press key "F14" to save the adjustment. The following
symbol appears:
Note: If the following symbol is displayed after the end of the travel distance the measured
distance pulses are not in the range of +/- 10% of the preset value. Saving is in this
case not possible! The measurement must be repeated!

Author: T.Löw / TE
008 910 92 BOMAG 199

7.7 Changing the display mode (metric/imperial)

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

Author: T.Löw / TE
200 BOMAG 008 910 92

x The imperial display (mph, °F, etc.) can now be activated or deactivated by pressing key "F5"
("Imperial = 1" or "Imperial = 0").
x After the desired change press key "F14" to save the adjustment. The symbol lights green for a

Author: T.Löw / TE
008 910 92 BOMAG 201

7.8 Simulation mode

From software version 3.00 it is possible to run the control in a so-called simulation mode. This mode
allows to swivel the Vario exciter at standstill and without vibration.
ATTENTION: In simulation mode the exciter swivels even with the machine at standstill!
Before switching on vibration the machine must therefore be placed on a
suitable base (rubber mat, car tires, etc.), as otherwise the base may be
damaged!
x Press key "F5" to open the screen page "Diagnose1". The following screen is displayed:

Author: T.Löw / TE
202 BOMAG 008 910 92

x Press key "A" to open the screen page "extended diagnose". The following screen is displayed:

Author: T.Löw / TE
008 910 92 BOMAG 203

x Press key "A" again to open the screen page "simulation m ode". The following screen is
displayed:

Author: T.Löw / TE
204 BOMAG 008 910 92

The control is in simulation mode.
x The simulated travel direction can be selected with keys "F5", "F6", "F7". The detected travel
direction is displayed in the roller symbol underneath.
x The assignment of keys "F9" to "F14" is identical with their assignment in standard operation.
The voltage of the "exciter position" potentiometer is displayed in addition to the detected Evib value
and the vibration frequency. This view does not show the asphalt temperature.
Exiting this page via "ESC" aborts the simulation mode. The adjusted manual and automatic stages as
well as the operating mode remain active.

Author: T.Löw / TE
008 910 92 BOMAG 205

206 BOMAG 008 910 92

Service Training BAM Block diagram
008 910 92
8 Block diagram BOMAG Evib meter (BEM)
BEM, BOMAG Evib-meter
BOMAG
Status: 30.05.2006 Block diagram Page 33 of 55
Author: T. Löw / TE
9.1
207
208
9.1
Service Training BAM Block diagram
9 Block Diagram BOMAG Asphalt Manager

CAN Bus I
CAN Bus I
Drucker
BOP RS 232
BOMAG
!
Beschleunigung
VV / VL 15g
Drehzahlsensor MESX Befehle

hinten
Signale
Lageregelung Lageregelung
Ventil 2 vorn Ventil 1 vorn
Hebel
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g
Erreger
Position vorn Vibrations-
Schalter
Status: 30.05.2006 Block diagram Page 34 of 55

008 910 92
Service Training BAM Description of signals
008 910 92
10 Description of the Signals on the ESX-Control
Notes:
1. Wherever the value of 12 V is mentioned in the following text it refers to the current battery
voltage under due consideration of voltage drops in the lines.
ESX terminal Signal description Nominal values (voltage / current)

X0:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
joystick, speed range switch etc.)
X0:2
X0:3 Output Evib display (only BEM) PWM signal (100Hz): ) approx. 0..6 V
PWM (max. 2.5 A)
X0:4 Interface RS 232 RxD, used for printer control. Measurement not possible!
X0:5 Interface RS 232 TxD, used for printer control. Measurement not possible!
X0:6
BOMAG
X0:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)
Open circuit voltage (vibration off): ) 4,2..4,3 V

Analogue input / voltage input 0..8.5 V
X0:8
X0:9 Input exciter position front Position of front exciter (measured against AGND)
Analogue input / voltage input 0..8.5 V Bottom stop ) approx. 2,2 V
Neutral position ) approx. 4,25 V
Top stop ) approx. 6,6 V
Status: 30.05.2006 Description of signals Page 35 of 55

9.1
209
210
9.1

X0:10
X0:11
X0:12
X0:13
X0:14 Pivot steered rollers: Pivot steered rollers:
Input travel pump reverse PWM signal 0..100% duty cycle
Digital input active high
Articulated rollers: Articulated rollers:

Input travel lever reverse Travel lever reverse: ) 12 V
Digital input active high Travel lever neutral or forward: )approx.2 V
X0:15 Input vibration 1 On Vibration on: )approx.0 V
Digital input active low only for articulated rollers Vibration off: )approx. 5 V
X0:16 Input button START (option) Button depressed: ) 12 V
Digital input active high Button not depressed ) 2V
X0:17 Input button STOP (option) Button depressed: ) 12 V
BOMAG
X0:18 Input button PRINT (option) Button depressed: ) 12 V
X0:19 Input button CLEAR (option) Button depressed: ) 12 V
X0:20
X0:21
X0:22
X0:23 Output voltage supply for sensors Nominal voltage = 8,5 V
This output supplies steering joystick, travel speed range switch, etc. Permissible range: approx. 7,65..9,35 V
Without this voltage the control cannot work correctly and will switch This voltage must be measured against AGND.
to override condition (emergency operation).
X0:24

008 910 92
008 910 92
X0:25
X0:26 Interface CAN-Bus Wire -, is used to communicate with the BOP Measurement not possible!
operating unit.
X0:27 Interface CAN-Bus Wire +, is used to communicate with the BOP Measurement not possible!
operating unit.
X0:28 Input potential terminal 15 Control switched on ) 12 V

Digital input active high Control switched off )approx.2 V
This signal must be present, so that the control can work.
X0:29 Input acceleration transducer VV/VL15g Acceleration signal (measured against AGND)

X0:30 Input acceleration transducer VH/VR15g Acceleration signal (measured against AGND)
BOMAG
X0:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)

X0:32
X0:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X0:34
X0:35 Input distance transducer Transducer delivers square-wave pulses Frequency depends on
machine type.

9.1
211
212
9.1

X0:36 Pivot steered rollers: Pivot steered rollers:
Input travel pump forward PWM signal 0..100% duty cycle
Articulated rollers: Articulated rollers:

Input travel lever NOT in neutral Travel lever NOT in neutral: ) 12 V
Digital input active high Travel lever in neutral: )approx.2 V
X0:37 Input D+ generator Engine running / engine is started ) 12 V
Digital input active high Engine stopped ) 0V
X0:38 Input vibration 2 On Vibration on: ) >6V
Digital input active high only for pivot steered rollers Vibration off: )approx.0 V
X0:39 Input vibration high amplitude High ampl. active: ) >6V
Digital input active high Low ampl. active: )approx.0 V
This input is set in addition to input 15 or 38, in order to recognized
high amplitude on machines with circular exciter.
BOMAG
X0:40
X0:41
X0:42
X0:43
X0:44
X0:45
X0:46 Output valve 1 front permissible current range: approx. 0..1,5 A

PWM digital output (max. 4 A)
X0:47 Output valve 2 front permissible current range: approx. 0..1,5 A
PWM digital output (max. 4 A)
X0:48

008 910 92
008 910 92
X0:49
X0:50
X0:51
X0:52
BOMAG
9.1
213
214
9.1

X0:53 Interface CAN-Bus2 Wire +, is used to communicate with the BCM05. Measurement not possible!
X0:54 Voltage supply for electronics Emergency stop not actuated ) 12 V
Emergency stop actuated ) 0V
X0:55 Ground connection electronics 0 V measured against ground
X0:56 Voltage supply for outputs approx. 12 V measured against ground
X0:61
BOMAG
X0:62
X0:63
X0:64
X0:65 Mouse port Baby Boards approx. 0 V

008 910 92
Service Training Fault codes of the ESX control
11 Fault codes of the ESX control
11.1 Overview
Fault code Fault description

4501 - Position controller (exciter potentiometer, valves)
4540
4601 - Acceleration transducer
4620
4630 - Asphalt temperature sensor
4631
8000 - Internal software errors
8250
Status: 30.05.2006 Fault codes of the ESX control Page 41 of 55

Author: T.Löw / TE
008 910 92 BOMAG 215

216
9.1
Service Training BAM Description of fault codes of the ESX control
11.2 Description of fault reactions
Fault reaction Description of fault reaction

1 Warning.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
2 Function affected, the faulty function is replaced by an emergency function.
3 Partial function faulty, the partial function cannot be overridden by an emergency function.
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
4 Partial function faulty, the partial function cannot be overridden by an emergency function.
BOMAG
The machine is no longer able to drive, e.g. because parts of the travel system are defective
) the diesel engine is shut down.
5 Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
Status: 30.05.2006 Description of fault codes of the ESX control Page 42 of 55

008 910 92
008 910 92
11.3 Detailed description of fault codes and their possible causes
Fault Fault description Possible cause Termina Input Fault

code l on code for reaction
ESX diagnose
450 Input exciter potentiometer front ) Wire breakage in current path X0:09 2
1 The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) Fuse has tripped or wire breakage in voltage supply current path
) Potentiometer defective
450 Input exciter potentiometer front ) Current path connected to +12 V / +8,5 V X0:09 2
2 The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective
BOMAG
9.1
217
218
9.1

ESX diagnose
452 Output proportional solenoid front ) Current path has short circuit to voltage supply X0:46 2
1 Valve for exciter up ) Current path has impermissible connection to another current
Output current too low. path
) Current path is interrupted
452 Output proportional solenoid front ) Current path has short circuit to ground X0:46 2
Output current too high. path
452 Output proportional solenoid front ) Current path is interrupted X0:46 2

Fault when calibrating the valve path / ground
452 Output proportional solenoid front ) Current path has short circuit to voltage supply X0:47 2
BOMAG
6 Valve for exciter down ) Current path has impermissible connection to another current
Output current too low. path
) Current path is interrupted
452 Output proportional solenoid front ) Current path has short circuit to ground X0:47 2
Output current too high. path
452 Output proportional solenoid front ) Current path is interrupted X0:47 2

Fault when calibrating the valve path / ground

008 910 92
008 910 92
ESX diagnose
453 Position controller positive limit reached ) Supply and ground terminal on exciter potentiometer mixed up X0:09 2
1 The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X0:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low
453 Position controller negative limit reached ) Supply and ground terminal on exciter potentiometer mixed up X0:09 2
2 The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X0:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low
460 Input acceleration transducer 1 ) Current path has no connection to +12 V / +8,5 V X0:29, 2
1 The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X0:31
BOMAG
460 Input acceleration transducer 1 ) Current path connected to +12 V / +8,5 V X0:29, 2
2 The voltage applied to the input is above the ) Current path not connected to ground or
460 Input acceleration transducer 2 ) Current path has no connection to +12 V / +8,5 V X0:30, 2
6 The voltage applied to the input is below the ) Current path connected to ground or
460 Input acceleration transducer 2 ) Current path connected to +12 V / +8,5 V X0:30, 2
7 The voltage applied to the input is above the ) Current path not connected to ground or

9.1
219
220
9.1

ESX diagnose
463 Input asphalt temperature sensor ) Current path has no connection to +12 V / +8,5 V X0:06 2
0 The voltage applied to the input is below the ) Current path connected to ground
specified range (see signal description). ) Transducer defective
463 Input asphalt temperature sensor ) Current path connected to +12 V / +8,5 V X0:06 2
1 The voltage applied to the input is above the ) Current path not connected to ground
specified range (see signal description). ) Transducer defective
BOMAG
008 910 92
008 910 92
ESX diagnose
800 Error message "Incorrect BOP Software version" - - 2
0 The software version of the BOP is too old, i.e.
various functions cannot be displayed.
This fault cannot be repaired on the machine.
The BOP needs to be replaced.

800 Fault message "severe software fault in control" - - - 5
1 - This fault cannot be repaired on the machine.
899 The control must be immediately replaced.
9
900 Error message "Communication via CAN bus ) Wire breakage in CAN bus lines X0:26 - 2
0 - disturbed" ) Short circuit between CAN bus lines X0:27-
919 The modules controlled via the CAN bus cannot ) One or both CAN bus line(s) has (have) connection to 12V or
9 be addressed by the main control (ESX). The ground
respective machine functions are not available
920
BOMAG
Fault message "Severe internal fault in control" - - - 5
0 - The control has automatically switched off. This
999 fault cannot be rectified on the machine. The
9 control must be immediately replaced.
Ct0 Display module has no connection to ESX- ) Wire breakage in CAN bus lines X0:26 - -
control. ) Short circuit between CAN bus lines X0:27
) One or both CAN bus line(s) has (have) connection to 12V or
ground
) Incorrect bit rate in display module (nominal value: 125 kBit)

9.1
221
222
9.1
12 Input codes for ESX control (only via BEM display module)
12.1 Travel system
Input code Description of display function Display values

1000 Transducer for travel direction 0000 ) 0V
Show status of transducer. 0001 ) 12 V
1001 Travel direction 1000 ) Forward travel detected

Displays the travel direction derived by the control from the 0000 ) Neutral position
"transducer for travel direction". 000I ) Reverse travel detected
1002 Transducer for distance pulses Display value = travel distance in 10 cm

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

008 910 92
008 910 92
12.2 Vibration

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

3002 Vibrations status high amplitude 0000 ) Vibration OFF
The vibration status for high amplitude is displayed. 0001 ) Vibration ON
12.3 Light

3010 Input light switch 0000 ) Light OFF
The status of the lighting is displayed. 0001 ) Light ON
BOMAG
9.1
223
224
9.1
12.4 Acceleration transducer

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

5000 Input MD+ 0000 ) Engine OFF
Show status of diesel engine. 0001 ) Engine ON
BOMAG
008 910 92
008 910 92
12.6 Setting the machine type

7000 Shows the adjusted machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert. )!
7010 Switches on function „Set machine type“ see adjustment instructions (page Fehler! Textmarke nicht
definiert. )!
7011 Confirms entered machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert. )!
7500..75 Preselect machine type see adjustment instructions (page Fehler! Textmarke nicht
99 definiert. )!
BOMAG
9.1
225
Service Training BAM
13 Terminology in connection with ESX

Short circuit
A direct, undesired connection between two different cables or between machine and
cables.
Examples:
Two lines rub against each other until the insulation has worn off.
A conductive line rubs off the insulation at the vehicle ground.
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
x torn (not necessarily visible from outside)
x chafed
x chafed mostly in connection with a short circuit to ground
Terminal, cable lug

x loosened, slipped off
x broken off,
x corroded,
x socket / plug faulty
Status: 30.05.2006 Terminology Page 52 of 55

Author: T.Löw / TE
226 BOMAG 008 910 92

Short circuit to ground

Line, terminal has direct connection to vehicle ground, often in connection with wire
breakage
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital, many states are permitted within a certain range. E.g. room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 : to 300
:; valve 0% to 100% opened (proportional valve)

Author: T.Löw / TE
008 910 92 BOMAG 227

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

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

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

Author: T.Löw / TE
228 BOMAG 008 910 92

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

In the event of a major fault the control will switch off and the override function will take over.
This has the effect that the machine can still be moved and steered with reduced speed.
Steering and dozer blade movements are only possible with a constant speed.
(see also: page 34, "")
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
PWM – digital output

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

Author: T.Löw / TE
008 910 92 BOMAG 229

230 BOMAG 008 910 92

9.2 Electrics module A03
008 910 92 BOMAG 231

232 BOMAG 008 910 92

Electrics module A03 9.2
008 910 92 BOMAG 233

234 BOMAG 008 910 92

008 910 92 BOMAG 235

236 BOMAG 008 910 92

008 910 92 BOMAG 237

238 BOMAG 008 910 92

008 910 92 BOMAG 239

240 BOMAG 008 910 92

008 910 92 BOMAG 241

242 BOMAG 008 910 92

008 910 92 BOMAG 243

244 BOMAG 008 910 92

008 910 92 BOMAG 245

246 BOMAG 008 910 92

008 910 92 BOMAG 247

248 BOMAG 008 910 92

008 910 92 BOMAG 249

250 BOMAG 008 910 92

008 910 92 BOMAG 251

252 BOMAG 008 910 92

008 910 92 BOMAG 253

254 BOMAG 008 910 92

008 910 92 BOMAG 255

256 BOMAG 008 910 92

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258 BOMAG 008 910 92

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260 BOMAG 008 910 92

Description UPM03
Module Seat Contact Monitoring / A 68
920 225 03
Version 1.04 dated 07.01.08
1 Version history....................................................................................................3
Januar 2008
008 910 92 BOMAG 261

Version history
2 Description of hardware .....................................................................................4

2.1 Input pin assignment .................................................................................................................4
2.2 Output pin assignment ..............................................................................................................4
2.3 Emergency operation.................................................................................................................6
3 Description of function.......................................................................................7
3.1 Switch on process......................................................................................................................7
3.2 Engine start .................................................................................................................................9
3.3 Driving the machine ................................................................................................................ 10
3.4 Engine protection .................................................................................................................... 12
4 Software version history ..................................................................................13
Alexander Hehner Module Seat Contact Monitoring Page 2 of 14

Department TE Version 1.04 dated 07.01.08
262 BOMAG 008 910 92

Version history
0 Version history
No. Version Date Description of version edited

1 1.0 22.08.02 1st version created Kochhan
2 1.01 05.12.02 Software change (enable starting only via brake Kochhan
switch)
3 1.1 05.06.03 Software change in the field of seat contact Fondel
control, engine shut-down introduced
4 1.03 13.04.04 Description changed. Hehner
5 1.04 25.05.05

008 910 92 BOMAG 263

Description of hardware
1 Description of hardware
The seat contact monitoring module consists of a modified UPM2 module.

The inputs were designed in such a way, that the following table applies:
Input Behaviour Comment
Input PIN11 HIGH-active LED lights when applying operating voltage (+UB)!
Input PIN12 HIGH- active LED lights when applying operating voltage (+UB)!
Input PIN13 LOW- active LED lights when applying ground potential (0V)!
1.1 Input pin assignment
Signal name Module pin Signal on input

Seat contact switch 11 +UB = Driver sits, LED on
0V = Driver stands, LED off
Travel lever operated 12 +UB = Operated, roller drives LED on
0V = 0-position, roller is stationary LED off
Oil pressure switch 13 0V = Oil pressure not OK LED on
+UB = Oil pressure OK LED off
D+ signal 14 +UB = Engine running LED on
generator 0V = Engine stopped LED off
Brake detent 15 +UB = Brake applied, LED on
(contact in travel lever) 0V = Brake released, LED off
1.2 Output pin assignment
Signal name Module pin Signal on output

Pick-up winding 4 +UB = energized LED on
diesel engine * 0V = dead LED off
Hydr. brake 5 +UB = Brake released, LED on
brake valve 0V = Brake applied, LED off
Control light 6 +UB = Brake control light On LED on
brake 0V = Brake control light Off LED off
Warning buzzer 7 +UB = Driver stand, travel lever operated LED on
seat contact switch 0V = Driver sits LED off
Holding winding 8 +UB = dead, engine able to run LED off
0V = energized, engine off LED on
* The pick-up winding is currently not used (but function is implemented), because
it is not required for the installed engine!
However; the function is also part of this description.

264 BOMAG 008 910 92

The hardware is available under BOMAG part-number 057 667 68.
Figure 1: Module
The complete module (including the specific software) is available under

BOMAG part-number 920 225 03.
The following applies when measuring the signal levels:
PIN Potential with LED on Potential with LED off

Inputs general Operating voltage UB Voltage < 1V
Input PIN 13 (oil pressure) Ground 0V Input open
Output PIN8 Ground 0V Output open
Outputs general ≈ Operating voltage (UB- 0,7V) Ground 0V (<< 1V)

008 910 92 BOMAG 265

1.3 Emergency operation

If a bridge is inserted between PIN2 and PIN3, the outputs PIN4, "Pick-up winding engine"
(currently not used) and PIN5 "Brake valve hydraulic brake" are on HIGH potential, and the
corresponding LED plus the red LED on PIN3 light up.
For the machine this means that the brake is permanently open and cannot be closed,
as long as the bridge remains in place!
This function can be used in emergency situations (defect) to open the hydraulic brake.

266 BOMAG 008 910 92

Description of function
2 Description of function
2.1 Switch on process

When operating voltage is applied to the module, the Stay-Alive LED will first flash to indicate
the version number and the revision number (currently 1.03). Then the Stay-Alive-LED will
continue to flash with one second intervals.
Figure 1: Start of the module
The output signals of the module are now switched in dependence on the inputs.
Output PIN 7 Indication driver standing always has 12 Volt applied (LED lights) when the
LED on PIN 11 Input seat contact sensor is off or no 12 Volt is applied.
Output PIN 5 Brake valve and PIN 6 Signal brake applied also work inverse to one another
(the brake is applied when the brake valve is not energized).
Attention:
Input PIN 12 (travel lever) and input PIN 15 (brake detent) must always have opposed
signals. If this is not true, the brake control light (output PIN 5) in the round instrument
will flash.
If no 12 V voltage is applied to PIN 14 (D+) when the module is switched on (LED on PIN 14
does not light), but ground is applied to PIN 13 (oil pressure) (LED on PIN 13 lights), it is
assumed that the engine is stopped and the brake will be applied, irrespective of PIN 15
(brake switch), to make sure that the machine is reliably stopped on an incline.
Figure 2 illustrates the sequence of a switch-on process. PIN 11 (Input seat contact switch)
in this case has no influence, because the engine is stopped.
When PIN15 (Brake switch) is opened (PIN 15 has ground contact, the LED on PIN 15 does
not light), the holding winding of the shut-down solenoid is switched off (0V on output PIN 8
Holding winding, LED on PIN 8 lights). This has the effect of preventing an engine start when

008 910 92 BOMAG 267

the brake is open (however, the starter motor would be able to turn, if this was not prevented
by an external circuitry).
Figure 2: Signals after starting the engine
All this happens, irrespective of the fact whether the driver is sitting or not!
If the travel lever is in neutral position (LED on PIN 12 is off), the engine can be started.

268 BOMAG 008 910 92

2.2 Engine start

If an engine start is detected on the D+ signal (LED on PIN 14 lights), the pick-up winding of
the shut-down solenoid is additionally switched on again for 2 seconds (the LED on PIN 4 will
light over this period).
The brake valve is now switched in dependence on input PIN 15 (Brake switch). If the brake
switch is closed (LED on PIN 15 lights), the brake valve will be closed (LED on PIN 5 is off),
the brake is applied and the signal lamp Brake lights up (LED on PIN 6 lights). If the switch is
open (LED off), the brake valve will be opened (LED on PIN 5 lights) and the signal lamp is
off (LED on PIN 6 off).
If no D+ is detected, the brake will be applied, irrespective of input PIN 15!
Figure 3: Behaviour of brake in dependence on D+

008 910 92 BOMAG 269

If the travel lever is actuated while the engine is running (D+ on PIN 14, LED lights), while
the driver is not sitting down (LED on PIN 11 is off), PIN 8 Holding winding will be
energized (LED on) and the engine will be shut down immediately.
Figure 4: Influence of the travel lever when the engine is running (driver standing)
If the driver is sitting while the travel lever is actuated, no shut-down will occur and the
machine will travel.
2.3 Driving the machine

If the driver is sitting (LED on input PIN 11 lights), the oil pressure is correct (LED on input
PIN 13 is off) and D+ is applied (LED on PIN 14 lights), the machine can be driven without
limitations.
In this case the LED on PIN 12 will also light when the travel lever is operated.
If the driver stands up in this operating condition (LED on input PIN 11 goes out, LED on PIN
7 lights up), the holding winding of the shut-down solenoid will be switched off after approx. 3
seconds by energizing output PIN 8 (LED on PIN 8 lights up).
The engine rotates slowly down to standstill. If the driver sits down again before the engine
has stopped (engine off is detected by removing D+ from PIN 14, LED off), the shut-down
solenoid will be switched on again (Holding winding, LED on PIN 8 goes out) and the pick-up
winding will be additionally switched on for approx. 2 seconds (LED on PIN 4 lights over this
period of time), so that the engine will rev up again.

270 BOMAG 008 910 92

Figure 5: Standing up while driving
If the engine stops before the driver has sat down (D+ switches off, LED on PIN 14 goes
out), the brake will be closed (LED on PIN 5 is off, LED on PIN 6 lights). This condition
remains, even if the driver sits down.

008 910 92 BOMAG 271

2.4 Engine protection

If a too low engine oil level is detected (ground signal on PIN 13, the LED on PIN 13 lights)
while D+ is applied (LED on PIN 14 lights), the engine will be shut down after approx.
12 seconds.
Figure 6: Behaviour in case of a too low oil level

272 BOMAG 008 910 92

Software version history
3 Software version history
_________________________________________________________________________
Version management: BOMAG Seat Contact Monitoring for BW 161/202-4

Module: BMUPM 3
Controller: PIC16F84A
__________________________________________________________________________
Version 1.01 dated 10.05.2002:

----------------------------
Checksum: 671C
1st version created.

----------------------------
Checksum: 76D2
2nd version created without oil pressure monitoring.
Checksum: D089
1st version with oil pressure monitoring created.
Changeover via Define before Compiling!
Version 1.02a dated 20.06.2002:

----------------------------
Checksum: 816A
Problems with Stay-Alive-LED rectified (stayed on continuously because of new processor)
by using another control routine.
Version 1.02b dated 20.08.2002:

----------------------------
Checksum: 94C5
Polarity of signal "Brake applied" reversed (BW161-3)
Version 1.02c vom 04.12.2002:

----------------------------
Checksum: F42E
Polarity of shut-down solenoid holding winding reversed

----------------------------
Checksum: A88A
Signal for seat occupied must no longer be denied and output because of the new IVEKA
instrument.
Instead a separate warning buzzer is now triggered when the seat is not occupied, the
engine runs and the travel lever is actuated.

008 910 92 BOMAG 273

_________________________________________________________________________
Version management: BOMAG Seat Contact Monitoring for BW 161/202-4

Module: BMUPM 3
Controller: PIC16F84A
__________________________________________________________________________

----------------------------
Checksum: 57A2
Output 6 (brake control light) was flickering. Problem rectified.
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!ATTENTION!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
!!!!!! !!!!!!
!!!!!! Compiled with Compiler Version 3.0.0.13 (saved under PICC2). !!!!!!
!!!!!! !!!!!!
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

274 BOMAG 008 910 92

008 910 92 BOMAG 275

276 BOMAG 008 910 92

Description UPM03
Vibration Interlock Module / A71
920 225 02
Version 3.0 dated 07.01.08
Januar 2008
008 910 92 BOMAG 277

Table of Contents
1 Version history....................................................................................................3
2 Description of hardware .....................................................................................4
2.1 Input pin assignment .............................................................................................................4
2.2 Output pin assignment ..........................................................................................................4
2.3 Emergency operation.............................................................................................................5
3 Description of function.......................................................................................7
3.1 Switch-on process .................................................................................................................7
3.2 Switching the vibration on ....................................................................................................7
3.3 Switching on the chip spreader ............................................................................................9
4 Software version history ..................................................................................11
Alexander Hehner Vibration Interlock Module Page 2 of 11

Department TES Version 3.0 dated 07.01.08
278 BOMAG 008 910 92

Version history
1 Version history
No. Version Date Version description edited

1 1.0 30.08.02 1st version created Kochhan
2 1.02 08.10.03 Fault in vibration signal output "Vibration front" for Fondel
Variomatic rectified. Logic adapted. Comments
added.
3 1.02 01.04.04 Changes in functional description added Hehner
4 3.0 18.05.05 Switch-on delay vibration rear / front (output 4 Hehner
and 7) added

008 910 92 BOMAG 279

The vibration interlock module consists of the modified UPM2 module.

The inputs were designed in such a way, that the following table applies:
Input Behaviour Comment
Input PIN11 HIGH-active LED lights when applying positive voltage!

Input PIN12 HIGH- active LED lights when applying positive voltage!
Input PIN13 LOW- active LED lights when applying ground potential!
2.1 Input pin assignment
Signal name Module pin Description

Switch vibration rear 11 HIGH = Vibration should be on LED on
LOW = Vibration should be off LED off
Vibration on switch 12 HIGH = Vibration on, LED on
LOW = Vibration off LED off
Chip spreader push 13 LOW = Button function LED on
button on HIGH = Normal state LED off
Switch vibration front 14 HIGH = Vibration should be on LED on
LOW = Vibration should be off LED off
Chip spreader 15 HIGH = Chip spreader should be on LED on
on switch LOW = Chip spreader should be off LED off
2.2 Output pin assignment
Signal name Module pin Description

Vibration valve front 4 HIGH = energized (vib. off), LED on
LOW = dead (vib. on) LED off
Chip spreader on 5 HIGH = Spreader on, LED on
(also vib. high LOW = Spreader off LED off
amplitude)
Chip spreader 6 HIGH = Valve on, LED on
valve on LOW = Off LED off
Vibration valve rear 7 HIGH = energized (vib. off), LED on
LOW = not energized (vib. an) LED off
Signal vibration 8 HIGH = Vibration front off, LED off
front switched on LOW = Vibration front on LED on

280 BOMAG 008 910 92

The hardware is available under BOMAG part-number 057 667 68.
Figure 1: Module
The complete module (including the specific software) is available under
BOMAG part-number 920 225 02.
The following applies when measuring the signal levels:

Inputs general Operating voltage UB Voltage < 1V
Input PIN 13 Ground 0V Input open
(vibration push button)
Outputs general ≈ Operating voltage (UB- 0,7V) Ground 0V (<< 1V)
2.3 Emergency operation

If a bridge is inserted between PIN2 and PIN3, the outputs PIN4, "High Amplitude" and
PIN5 "Vibration front off" are on HIGH-Potential and the corresponding LED, as well as the
red LED on PIN3 will light.
With this application this function does not realize a relevant emergency function and
should thus not be used!

008 910 92 BOMAG 281


282 BOMAG 008 910 92

3.1 Switch-on process

When operating voltage is applied to the module, flashing of the Stay-Alive-LED will first
indicate the version number and the revision number (currently 3.0). After this the Stay-Alive-
LED will continue to flash with 1 second intervals.
Figure 3: Start of module

The output signals of the module are now switched in dependence on the inputs.
3.2 Switching the vibration on

The vibration can only be switched on when the chip spreader is switched off (input on PIN
15 "Chip spreader switch" open, LED on PIN 15 off).
If this is true, the vibration can be switched on (LED on, voltage applied to input PIN 12) or
off (LED off, no voltage applied to input PIN 12), in dependence on input PIN 12 "Vibration
switch".
The vibration switch is connected to PIN 11 and PIN 14.
The type of vibration (front, rear) to be switched ion therefore depends on the states of the
inputs PIN 11 and PIN 14.
Dependence of the vibration on the switching position of the vibration selector switch:
Potential PIN 11 Potential PIN 14 Vibration rear PIN 7 Vibration front PIN 4
12V / LED on open / LED off ON LED OFF LED
OFF ON
open / LED off 12V / LED on OFF LED ON LED
ON OFF
open / LED off open / LED off ON LED ON LED
OFF OFF

008 910 92 BOMAG 283

Switching these inputs over will only cause changes to the outputs, if input PIN 12 "Vibration
switch" has been switched off (LED on PIN 12 off)!
When switching from "Vibration both drums" to "one drum" the outputs PIN 4 and PIN 7 will
be switched with an 0.7 second delay.
Figure 4: Vibration selection

The signal "Vibration front on" at PIN 8 is required to inform other machine components, that
"Vibration front" is switched on. Tapping the direct valve signal (PIN 4) is unfortunately not
possible, because this signal is also switched accordingly when using the chip spreader.

284 BOMAG 008 910 92

3.3 Switching on the chip spreader

The chip spreader can only be switched on when the vibration is switched off (input on PIN
12 "Vibration switch" open, LED on PIN 12 is off).
In this state the chip spreader can be switched on (LED on, voltage applied to input PIN 15)
or off (LED off, no voltage applied to input PIN 15), in dependence on the input PIN 15.
When voltage is applied to PIN 15 (LED lights), PIN 7 will immediately drop dead, PIN 6
("Chip spreader valve") and PIN 4 are switched on. PIN 5 "Chip spreader on" (LED on) can
be switched on via push button PIN 13 "Push button chip spreader", only 2 seconds after
these outputs have been switched.
If the push button is actuated before these 2 seconds have expired, PIN 5 will automatically
be switched after the full 2 seconds have elapsed.
If the push button is pressed again, PIN 5 will be switched off (LED off). With the next
actuation it will be switched on again, etc.
However, if the "Chip spreader switch" on PIN 15 is switched off (LED off), PIN 5 will
immediately drop dead (if the chip spreader was switched on via push button PIN 6). PIN 7
"Vibration valve rear" will be switched on after 2 seconds (LED on) and PIN 6 "Chip spreader
valve" will be switched off (LED off). Both outputs 4 + 7 will switch off after another 2 seconds
(LED off).
Einschalten Splittstreuer
Betriebsphase
1 2 3 4 5 6 7 8 9 10 11 12
PIN: 15 Auswahl ein LED an
Splittstreuer ein
Einschalter
Auswahl aus LED aus
PIN: 13 Streuer ein LED an

Taster Splittstreuer
ein
Streuer aus LED aus
PIN: 5 Splitt. ein LED an

Splittstreuer ein
(auch gr. Ampl.)
Splitt. aus LED aus
PIN: 7 bestromt (Vib.aus) LED an

Vibrationsventil
Hinten
nicht bestromt (Vib. an) LED aus
PIN: 6 bestromt (Vent.ein) LED an

Splittstreuerventil
nicht bestromt (Ventil aus) LED aus
PIN: 4 bestromt (Vib.aus) LED an

Vibrationsventil
Vorne
nicht bestromt (Vib. an) LED aus
Figure 5: Chip spreader

008 910 92 BOMAG 285

When the chip spreader is switched off, the system will wait for another 2 seconds, before
the vibration can be switched on again. This means that, after switching off the chip
spreader, a period of 4 seconds will pass before the vibration will start again.

286 BOMAG 008 910 92

4 Software version history
_________________________________________________________________________
Version management: BOMAG Vibration interlock for BW 161/202
Module: BM UPM 3
Controller: PIC16F84
__________________________________________________________________________

--------------------------------------------
Checksum: 4E60
1st Version created.
Version 1.01 from 13.08.2002:

--------------------------------------------
Checksum: 420B
Push button for chip spreader added
Version 1.01b dated 19.08.2002:

--------------------------------------------
Checksum: 9F34
Error "Vibration both" rectified (with LOW on both vibration selection pins "Vib.both" shall apply).
Triggering threshold for push button turned (switching now takes place at the transition from
HIGH to LOW).
Version 1.01c dated 23.09.2002:

--------------------------------------------
Checksum: 9F57
Error "With vibration switched off both Vib.rear and Vib.front high" changed in such a way, that
the signals on the vibration switch are switched through irrespective of the vibration switch.
However, changes to the selector switch will still only be accepted with the vibration switched off.
This means:
Vibration signal front on PIN8 is Low, when vibration front is off and open, when it is on.

--------------------------------------------
Checksum: f7f7
Error in vibration signal output " Vibration front" for Variomatic rectified. Logic adapted.
Comments added.

----------------------------------------
Checksum: f09d
Error: When switching from "Vibration both drums" to "one drum" the vibration of the
switched off drum will overshoot (caused by bypass) after switching the vibration off.
--> Switch-on delay for rear / front vibration (output 4 and 7) installed.

008 910 92 BOMAG 287

288 BOMAG 008 910 92

008 910 92 BOMAG 289
Description UPM1
Sprinkling System Module

BW141AC-4 / A04
538 380 01
56
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Version 1.1 vom 25.03.2004
March 2004
290 BOMAG 008 910 92

9HUVLRQKLVWRU\
1 Version history ................................................................................................... 3

2 Description of hardware .................................................................................... 4
2.1 Pin assignment digital inputs............................................................................................... 4
2.2 Pin assignment analog inputs.............................................................................................. 4
2.3 Pin assignment outputs ........................................................................................................ 4
3 Description of function ...................................................................................... 6
3.1 Sprinkling cycles, total overview ......................................................................................... 6
4 Version history for software.............................................................................. 7
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008 910 92 BOMAG 291

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Input Performance Remark

,QSXWPIN1 LOWDFWLYH LED lights whenDSSO\LQJground potential!
,QSXWPIN2 LOWDFWLYH LED lights whenDSSO\LQJground potential!
,QSXWPIN3 HIGHDFWLYH LED lights whenDSSO\LQJpositive voltage!
,QSXWPIN4 HIGHDFWLYH LED lights whenDSSO\LQJpositive voltage!
1.1 Pin assignment digital inputs

Signal Name Module Description
Pin
(PXOVLRQVZLWFK Active-LOW HPXOVLRQF\FOHQRPLQDO21 /('on
HIGH (PXOVLRQF\FOHQRPLQDO2)) /('off
0DVVEULGJHRSWLRQDO Active-LOW VSULQNOLQJF\FOH /('on
HIGH 6SULQNOLQJF\FOH /('off
1RWXVHG Active-HIGH /('on
LOW /('off
1RWXVHG Active-HIGH /('on
LOW /('off
1.2 Pin assignment analog inputs

Pin
1RWXVHG
1.3 Pin assignment outputs

Pin
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F\FOH /('on
LOW 6ZLWFKRIIHPXOVLRQVSULQNOLQJ
F\FOH /('off
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008 910 92 BOMAG 293

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PIN Signal Description

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The following applies when measuring the signal level:

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294 BOMAG 008 910 92

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2.1 Sprinkling cycles, total overview
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008 910 92 BOMAG 295

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296 BOMAG 008 910 92

008 910 92 BOMAG 297

9.6 Heating/air conditioning control
298 BOMAG 008 910 92

008 910 92 BOMAG 299
300 BOMAG 008 910 92

Heating/air conditioning control 9.6
008 910 92 BOMAG 301

302 BOMAG 008 910 92

Heating/air conditioning control 9.6
008 910 92 BOMAG 303

304 BOMAG 008 910 92

10 Speedometer Module
008 910 92 BOMAG 305

10.1 Speedometer module
Fig. 1 Speedometer module
With the programmable module BM UPM the software
realizes a speedometer function. To ensure that the
tachometer function is not only realized for one spe-
cial roller, there is a possibility to adapt the module to
any machine with the help of a self-teaching mode.
● Whenever the module is switched on the system
runs a self-test by passing through the entire dis-
play range in both directions. The display self-test
takes approx. 15 seconds.
● After this the module changes to measuring mode.
The frequency of the travel pulses of the roller is de-
tected and converted to a proportional output volt-
age that triggers the display.
● The output signal for the display is a PWM-signal.
Manual testing of the speedometer

When the module is in learning mode a manual dis-
play test can be performed via the input "Test". For
this purpose the input "IN" must be energized with 12
Volt, whereupon the speedometer is constantly trig-
gered with 3 Volt.
306 BOMAG 008 910 92

Speedometer module 10.1
Pin-no. module Pin name Description
Test E_ANZEIGENTEST Input HIGH active: Activate manual display test

IN E_WEGIMPULSE Input: Path pulses
Learn E_LERNMODUS Input: HIGH active: Activate teach mode
OUT - Display - Output: Ground connection for speedometer

OUT + Display + Output: Output voltage for speedometer
GND (2X) Ground Input: Module ground connection

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

In self-teach mode the number of arriving path pulses
is detected at the input (IN). The number of recorded
pulses is referred to as pulse number per 10 or 18 m
(machine dependent) travel distance of the roller.
● Connect the ground cable (-).
● Connect the sensor signal (speed sensor) to fre-
quency input (IN).
● Install a cable bridge from terminal "15/54" to the
connection "Teach".
● Connect potential "Ignition / 15" to connection "15/
54".
● Switch on the ignition, start the engine and travel a
distance of exactly 10 m.
Caution
!
BW24RH, BW27RH, C550H and C560H = travel 18

meters.
All other machines = travel 15 meters.
i Note
If the module is in teach mode the LED on output
"OUT +" will flash with the frequency of the path puls-
es arriving at input (IN).
●
Disconnect the cable bridge from "Teach" to "15/
54“.
●
Switch the ignition off and on again (Reset).
The module has now learned the pulses of the

speed sensor.
●
Connect the speedometer (0 to 6 Volt) to "OUT +"
and "OUT –“.
008 910 92 BOMAG 307

308 BOMAG 008 910 92

11 Service Training
008 910 92 BOMAG 309

310 BOMAG 008 910 92
11.1 Service Training
008 910 92 BOMAG 311

312 BOMAG 008 910 92

Service Training 11.1
Service Training
Tandem Rollers
BW 141 - 151 AD/AC-4
BW 154 AD/AC-4
Part-No. 008 097 16 06/2005
008 910 92 BOMAG 313

Service Training
Table of contents
Foreword A1
Documentation A2
General A3
Travel drive 141/151-4 E1

Travel pump E3
Charge pressure relief valve E9
High pressure relief valve E 10
Pressure override E 12
Travel motors E 15
Drum reduction gear E 18
Test and adjustment points, travel system E 19
Trouble shooting in travel system E 24
Travel drive 154-4 F1

Travel motors F7
Drum reduction gear F8
Flow divider F 11
Test and adjustment points F 19
BW 141 - 154 AD/AC-4
314 BOMAG 008 910 92

Service Training
Vibration G1
Vibration pump G3
High pressure relief valves G6
Control G7
Vibration motor G8
Vibration shut-off valve G9
Drum BW 141 AD-4 G 11
Drum BW 154 AD-4 G 12
Test and adjustment points, vibration system G 14
Trouble shooting in vibration system G 18
Steering system H1
Steering pump H3
Priority valve H4
Steering valve H5
Articulated joint H8
Test and adjustment points H 11
Trouble shooting steering system H 14
Working hydraulics - crab walk J1

Crab walk valve J2
Test and adjustment points J3
Blower drive K1
Water sprinkler system L1
AC-variant M1
Electrics with module description O1
Wiring diagram
Hydraulic diagram
BW 141 - 154 AD/AC-4
008 910 92 BOMAG 315

Service Training
Foreword
Reliable construction equipment is of greatest advantage for all parties involved:
• for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
• in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
• for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
• the location of components in the machine eases maintenance work,
• the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
• the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.
BW 141 - 154 AD/AC-4 -A1-
316 BOMAG 008 910 92

Service Training
Documentation
For the BOMAG machines described in this training manual the following documentation is additionally
available:
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.
1. Operating and maintenance instructions

2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.
BW 141 - 154 AD/AC-4 -A2-
008 910 92 BOMAG 317

Service Training
General
The tandem rollers of series BW 141 - 154 AD/AC-4 are high performance machines for the extremely
difficult use in asphalt compaction and earth work.
The machines of this series are powered by engine oil cooled Deutz diesel engines of series BF4M
2011.
Engine driven pumps transfer the engine output power via hydrostatic circuits for travel and vibration
systems to the drums. These hydrostatic drives ensure lowest possible power losses and a high
efficiency. The steering and crab-walk functions as well as the additional edge cutter option are supplied
by gear pumps driven by the auxiliary engine output.
The machines are equipped with a 2 cylinder operated articulated steering and a crab-walk function with
a separate hydraulic cylinder to offset the front frame laterally relative to the rear frame.
For the first time a machine of this product range is equipped with axial piston drum drive motors with
reduction gears The discs of the parking brakes are integrated in the reduction gears. When starting the
engine and opening the brake valve the brakes are relieved by charge pressure. When closing the brake
valve or when shutting the engine down the brakes are automatically applied by spring pressure. These
parking brakes should not be used as service brake, because the deceleration effect is extremely high
and the braking process may damage the brake discs.
The drums are equipped with an exciter shaft and two vibrator units each. The exciter shafts are driven
by hydraulic motors via Bowex couplings. Vibration of the drum is caused by the centrifugal forces
generated by the exciter shaft mounted eccentric weights.
Since the machines are designed for operation with two different frequencies and amplitudes, the sense
of rotation of the exciter shaft can be reversed. Changing the sense of rotation also changes the position
of the change-over weights inside the eccentric weights on the exciter shafts.
This also changes the centrifugal force and the amplitude. The rotary speed of the exciter shaft is also
different to both directions of rotation. This means, that the vibration frequency will also change.
In combination with the hydraulic vibration drive the change-over weights are arranged in such a way,
that the high amplitude works with low frequency and vice-versa.
The combination of high amplitude and low frequency is particularly suitable for compaction work in
earthwork with high lift heights and for preliminary compaction. For soil compaction the combination of
low amplitude and high frequency should be used for the finishing passes.
The individual machine functions like travel system, vibration and steering are described in more detail
in the corresponding chapters. Optional equipment, such as BAM, BOMAG Asphalt Manager
(Variomatic) and chip spreader etc. is not included in this training manual.
BW 141 - 154 AD/AC-4 -A3-
318 BOMAG 008 910 92

from brake valve
008 910 92
Fig. 1
gears.
Service Training
5
T2: Leak oil to tank
T1: Connection to vibration pump
BW 141 - 151 AD/AC-4

6
Charging
2
Y30
440 Leak oil with flushing oil

1 from brake valve
3
Travel drive BW 141/151 AD
Hydraulic diagram travel drive BW 141/151

440 420 22
3 25 4
BOMAG
5
6
1 Travel pump 20) Rear travel motor
2 Servo control 21) Rear travel gear

23
3 High pressure limitation 22 Front travel motor
4 Pressure override 23) Front travel gear Leak oil with flushing oil
5 Brake in travel gear

On the machines described in this training manual the travel system consists of a closed hydraulic
6) Flushing valve
circuit. It mainly consists of travel pump with integrated safety elements and travel motors with travel
Service Training
-E1-
11.1
319
Service Training
The installation of a hydraulic pump with variable displacement into a closed hydraulic circuit is a perfect
solution for a hydrostatic travel system, because with this design the travel direction can be reversed
without any problems.
The travel pump is flanged to the flywheel side of the diesel engine. It is directly driven by the engine
with constant speed.
The tandem gear pump driven by the auxiliary output of the engine is responsible for steering, crab walk
with additional functions and charge system. The tandem gear pump also serves as charge pump,
because the oil flow from steering valve and crab walk valve is flowing to the charge ports on travel and
vibration pumps.
The oil is cleaned by pressure filters, which are hydraulically arranged directly after the tandem gear
pumps.
Besides its function of supplying the closed circuit with cool and filtered oil as replacement for leakage
and flushing losses, the oil from the charge circuit is also needed for the following machine functions:
• to control the variable displacement pumps for travel and vibration systems,
• to release the hydraulic multi-disc brakes.
All safety and control elements needed for the operation in a closed hydraulic circuit are integrated in
the travel pump. These are:
• High pressure relief valves (440 bar) with integrated boost check valves
• Charge pressure relief valve (26 bar)
• Pressure override (400 bar)
• Servo control
The travel motors are plug-in motors mounted to travel gears and hydraulically connected in parallel
mode.
Both travel motors are fitted with an additional flushing valve for the closed hydraulic circuit.
BW 141 - 151 AD/AC-4 -E2-
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Service Training
travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement from Bosch
Rexroth-Hydromatik, type A4 VG 56 HW.
to the
T1: Connection to vibration pump travel motors
Charge pressure
440
2
1 5
M
440 400
4
5 26 6
Charge pressure
to the
to vibration
travel motors
pump
Fig. 2 Hydraulic diagram for travel pump
1 Pump drive
2 Control piston
3 4/3-way servo valve
4 Charge pressure relief valve
5 High pressure relief valves
6 Pressure override
The pump is fitted with all control and safety elements needed for operation in a closed hydraulic circuit.
These are:
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Service Training
• Servo control
• High pressure relief valves with integrated boost check valves
• Charge pressure relief valve
• Pressure override
Travel pump and vibration pump are connected to a tandem pump unit.
The travel pump unit is directly driven by the flywheel side of the engine via an elastic coupling. The
pump speed is therefore identical with the engine speed.
8
5
7
2 4
1
3
Fig. 3 Travel pump, cross-section
1 Drive shaft
2 Swashing cradle with swashing lever
3 Cylinder block
4 Working pistons
5 Control piston
6 Control unit with feedback lever
7 Slipper pad
8 Valve plate
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Service Training
Pilot pressure is used to operate the pump out of neutral position to the desired pumping direction
(direction of oil flow).
A manually operated 4/3-way valve directs the pilot oil flow (from the charge circuit) to the corresponding
control piston side in the servo control. The 4/3-way valve is controlled by the travel lever and the travel
cable.
In neutral position both control chambers are loaded with case pressure. When opening the 4/3-way
valve pilot oil (from the charge circuit) is directed to one of the control piston sides and moves the control
piston to the corresponding direction.
The swashing lever between the control piston and the swash plate transfers the control piston
movement to the swash plate. The needle bearing mounted swash plate swivels to the chosen direction.
This causes the axial movement of the pistons inside the cylinder block. The axial movement draws oil
into the pump and presses it to the travel motors.
All working pistons are drilled through their entire length. Pressure fluid flows through these bores into
the areas between the slipper pads and the surface of the swash plate. This forms a hydraulically
balanced field, on which the slipper pads can slide without any metal to metal contact between swash
plate and slipper pads. The feedback lever on the control piston detects when the swash plate has
reached a position that corresponds with the displacement of the travel lever. This feedback lever
controls a pilot oil portioning valve which interrupts the pilot oil flow to the control chambers when the
swashing angle corresponds with the position of the travel lever. Swashing angle and displacement of
the working pistons (oil flow rate) remain constant, until a new control command requires a different
swashing angle.
When changing the swashing angle through the neutral position to the opposite side, the flow direction
of the oil and the sense of rotation of the travel motors will change. The spherical valve plate centres the
cylinder block, which is mounted on the splines of the drive shaft. This avoids the appearance of
undesired transverse forces.
The complete drive consisting of
• valve plate
• cylinder block with working pistons and
• swash plate
is held together and preloaded by Belleville springs. This immediately eliminates any appearing wear,
increases the efficiency of the pump and prolongs the lifetime considerably.
When controlling the travel pump pressure will build up in the line between pump outlet and motor inlet.
This pressure depends on the load acting on the travel motors. This pressure keeps the boost check
valve inside the high pressure relief valve for this particular side of the closed hydraulic circuit closed.
Cool and filtered oil can now only enter into the closed circuit on the opposite side (low pressure side).
The high pressure relief valve limits possibly occurring extreme pressure peaks to the adjusted value.
If one of these valves responds, hydraulic oil will flow out of the high pressure side and enter the low
pressure side through the corresponding boost check valve.
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Service Training
Since the cross-sections of these valves are very small and the hydraulic oil enters the low pressure
side already inside the pump, the system would very quickly overheat if the pressure in the system
would be permanently relieved via the high pressure relief valves. For this reason the pump is fitted with
an additional pressure override valve. The pressure override valve interrupts the pilot oil flow to the
control piston, thereby maintaining the pressure level at the adjusted value of the pressure override
valve. If the pressure drops again, the pressure override valve will open and the pump can swash back
to the previously chosen position. This installation prevents overheating of the hydraulic system and
overloading of the diesel engine.
Control
The servo control of the pump is an integral part of the pump housing and consists mainly of:
• the manually controlled 4/3-way valve (1)
• the control piston (2)
• the feedback lever (3)
• the pilot oil portioning valve (not visible in illustration) and
• the swashing lever with the swashing cradle (see Fig. 3).
Fig. 4 Travel pump control
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.
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Service Training
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 can now deliver oil to the travel motors.
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.
to – from motor
from the charge pump

Leak oil
4/3-way valve
travel pump
Control piston
to – from motor
Fig. 5 Control in neutral position
BW 141 - 151 AD/AC-4 -E7-
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Service Training
The feedback lever controls the pilot oil portioning valve so that the swashing angle remains unchanged,
until the introduction of a new control command.
to – from motor
from the charge pump Leak oil
4/3-way valve
travel pump
Control piston
to – from motor
Fig. 6 Control actuated
When the 4/3-way valve is in neutral position, the pressure values in both control chambers are identical
(case pressure = max. 3 bar).
BW 141 - 151 AD/AC-4 -E8-
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Service Training
Charge pressure relief valve
The charge pressure relief valve belongs to the group of safety elements in a closed hydraulic circuit.
This valve limits the pressure in the charge circuit to the adjusted value.
The charge pressure relief valve is installed in the travel pump and internally connected with the
vibration pump.
pilot oil
fixed spring
to the oil tank
Fig. 7 Charge pressure relief valve
The charge circuit is needed for the compensation of leak oil and flushing quantities in the closed
hydraulic circuit. Charge oil is also required to control the pumps and to release the parking brake.
Since feeding of cool and filtered oil is only possible on the low pressure side of the closed circuit, the
pressure in the low pressure side is identical with charge pressure. If the travel pump is in neutral
position, both boost check valves can open and let in oil from the charge circuit. In this case the pressure
in both sides of the closed circuit is identical with charge pressure.
BW 141 - 151 AD/AC-4 -E9-
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Service Training
High pressure relief valves, (with bypass for towing)
High pressure relief valves are safety elements, which are needed in every hydraulic circuit.
These valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.

bypass
Fig. 8 Valve plate with high pressure relief valves
1 Pressure override
2 High pressure relief valves, (fixed adjustment) with bypass for towing
3 Charge pressure relief valve (fixed)
High pressure relief valves are safety elements, which are needed in every hydraulic circuit. These
valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.
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Service Training
.
to the travel motor
1
4
2
from the travel motor
Fig. 9 Hydraulic diagram
1 Travel pump
2 Control piston (actuated)
3 4/3-way valve (actuated)
4 High pressure relief valves, fixed
The high pressure relief valves in both sides of the hydraulic circuit protect the hydraulic system, the
diesel engine and all other machine components against overloads.
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 compensate leaks and flushing quantities.
BW 141 - 151 AD/AC-4 - E 11 -
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Service Training
Pressure override
Since the cross-sections of the high pressure relief valves are very small, longer responding of these
valves would cause very quick overloading of the hydraulic circuit and would subsequently lead to
severe damage in pump or other components. In order to avoid this, the travel pump is equipped with
another safety device, the pressure override.
2
5
1 3
4
Fig. 10 Pressure override
1 Charge pump
2 Pressure override
3 Travel pump
4 Control piston
5 3/4-way valve
6 Shuttle valve
The pressure override is hydraulically arranged in the pilot oil flow to the pump control before the 4/3-
way valve and consists mainly off:
• axial spool with control edges,
• adjustment spring and
• adjustment screw with counter nut.
BW 141 - 151 AD/AC-4 - E 12 -
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Service Training
Since the cross-sections of the high pressure relief valves are very small, longer responding of these
valves would cause very quick overloading of the hydraulic circuit and would subsequently lead to
severe damage in pump or other components. In order to avoid this, the travel pump is equipped with
another safety device, the pressure override.
Fig. 11 Pressure override
1 Valve piston 8 Pressure spring

2 Bore 9 Adjustment screw
3 Valve seat 10 Pilot pressure channel
4 Piston 11 Housing channel
5 Valve bush 12 High pressure circuit
6 Control piston 13 High pressure circuit
7 Spring plate
BW 141 - 151 AD/AC-4 - E 13 -
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Service Training
A shuttle valve ensures that the spool of the pressure override is always subjected to the highest
pressure in the closed circuit. As long as the pressure in the closed circuit is lower than the adjustment
value of the pressure override, the pilot oil connection via the 4/3-way valve to the corresponding control
chamber is released. The pump can now be actuated up to maximum displacement.
If the pressure reaches the setting of the pressure override, the spool inside the valve will move and cut
off the pilot oil flow to the control piston. The pump cannot be actuated any further. The system pressure
is maintained at the setting of the pressure override, until the resistance causing this high pressure in
the system is overcome or the pump is returned to neutral position by the operator.
Should the pressure in the closed circuit drop below the setting of the pressure override, the valve spool
will be forced back by spring force, whereby the passage between charge circuit and pump control is
opened again. Now pilot oil can flow to the corresponding control piston side again and the pump can
be actuated.
The spring force of the pressure override and its reaction value can be adjusted via the adjustment
screw.
Due to its design and the hydraulic arrangement of the pressure override, the high pressure relief valves
will not respond. This type of pressure limitation does not relieve any oil from the closed hydraulic circuit
via the very tight cross-sections of the high pressure relief valves. This avoids overheating of the
hydraulic oil.
As a measure to ensure correct function the pressure setting should always be 10% lower than the
setting of the high pressure relief valves.
High pressure relief valve = 440 bar

Pressure override = 400 bar
BW 141 - 151 AD/AC-4 - E 14 -
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Service Training
Travel motors BW 141/151
The two travel motors are plug-in fixed displacement bent axle motors of series A2FE 32 ccm from
Bosch-Rexroth, which drive a travel gear 705 C2H from Bonfigioli.
2 3
1
Leakage with
flushing quantity
from/to the
from/to the travel pump
travel pump
Fig. 12Hydraulic diagram travel motor with travel gear
22 Travel motor
23 Travel gear
1 Travel motor drive
2 Brake housing in travel gear
3 Flushing valve with flushing pressure limitation valve
BW 141 - 151 AD/AC-4 - E 15 -
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Service Training
2 6
8
1
3
Fig. 13: Drum drive motor A2FE 32
1 Drive 5 Piston
2 Drive shaft 6 Tapered roller bearing
3 Valve plate 7 Radial seal
4 Center journal 8) Flushing valve
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Service Training
Flushing valve on motor deckel
10
8
8 Flushing valve 9 Flushing spool

10 Flushing pressure limitation valve
Function
The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.
The flanged mounted flushing valve flushes out approx. 6-8 litres from the low pressure side into the
motor housing. The flushing pressure relief valve limits the flushing pressure to 16 bar, so that it does
not fall below the charge pressure of 16 bar.
BW 141 - 151 AD/AC-4 - E 17 -
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Service Training
Drum drive reduction gear BW 141/151
2 3 7
4
1
11
5 6 10
8
Fig. 14 Planetary gear 705 C2H with plug in motor A2FE32
1 Travel motor 7 Planet gear 2nd stage

2 Brake piston 8 Sun gear
3 Brake discs 9 End cover
4 Seal 10 Planet carrier 2nd stage
5 Tapered roller bearing 11 Hollow wheel
6 Planet gear stage 1
BW 141 - 151 AD/AC-4 - E 18 -
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Service Training
Test and adjustment points travel pump
3
7
6
4
8 15
4 3
5
2
6
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

diagram
1 travel pump 5
2 Pressure test port, charge pressure 5 26 bar
3 Pressure test port, travel pressure 5 max. 400 bar
forward
4 Pressure test port, travel pressure 5 max. 400 bar
forward
5 Pressure override travel pump 5 400 bar
6 Port travel forward 5
7 Port travel reverse 5
8 Travel control cable 5
BW 141 - 151 AD/AC-4 - E 19 -
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Service Training
Travel motor with travel gear
1
5 4
2
4
2
3
1
2
3

diagram
1 Port travel motor forward 20 and 22
2 Port travel motor reverse 20 and 22
3 Flushing valve on travel motor 20 and 22
4 Leakage travel motor 20 and 22
5 Brake connection travel gear 21 and 23
BW 141 - 151 AD/AC-4 - E 20 -
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Service Training
Brake valve with hand pump for emergency brake release
5 1
2
4 3

diagram
1 Brake valve Y04 Page 003 10
2 Solenoid valve Y04 Page 003 10, Y04 0V closed/12V
open
3 Hand pump 30
4 Emergency release button 30
5 Pressure test port, brake pressure 30, MA Normal 26bar,
pressure relief
valve setting 37
bar
BW 141 - 151 AD/AC-4 - E 21 -
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Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
BW 141 - 151 AD/AC-4 - E 22 -
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Service Training
TROUBLE SHOOTING TRAVEL
Machine does not travel (forward and reverse)
Machine moves with travel lever in 'Neutral'

SYSTEM
Machine travels to mone direction only

BW 141- 4-FAMILY
Max. travel speed is not reached

Hydraulic oil overheating
SYMPTOMS
POSSIBLE CAUSES
Brake valve (electrically/mechanically/hydraulically) 1
Brake in drum drive travel gear (mechanically/hydraulically) 2 2 3
Speed range selector switch position/defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override / travel pump high pressure limitation
3 2 3 3
dirty/out of adjustment/defective
Travel cable adjustment 1 2
Travel pump mechanical neutral position 3 3
Travel pump(s) defective 3 3 2
Control valve travel motor(s) (electrically/mechanically/hydraulically) 1 2
Flushing valve for travel motor(s) stuck 3
Travel motor(s) defective 3 3
Drum drive travel gear defective 3
Hydraulic oil cooler dirty (internally/externally) 1
Thermostat (hydraulics) dirty/jammed/defective 2
Coupling diesel engine- pumpe 2
Diesel engine 1
BW 141 - 151 AD/AC-4 - E 23 -
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Service Training
Travel system BW 154 AD
circuit. It mainly consists of travel pump with integrated safety elements, travel motors with travel gears
and a flow divider.
Hydraulic diagram BW 154 AD-4

5) Travel pump with flushing block
16) Flow divider
23) Travel motor with travel gear
BW 154 AD-4 -F1-
342 BOMAG 008 910 92

Service Training
Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement from Bosch
Rexroth-Hydromatik, type A4 VG 56 HW.
T1: Connection to vibration pump from/to the
T2: Leak oil to tank travel motors
Charge pressure Via flow
divider
3
3
440
22
1 5
5
M 1
440 400
4
5 26 66
4
7
5
from/to the
travel motors
Hydraulic diagram for travel pump

1 Pump drive
2 Control piston
3 4/3-way servo valve
6 Pressure override
7) Flushing valve
BW 154 AD-4 -F2-
008 910 92 BOMAG 343

Service Training
The pump is fitted with all control and safety elements needed for operation in a closed hydraulic circuit.
These are:
• Servo control
• Charge pressure relief valve
Travel pump and vibration pump are connected to a tandem pump unit.
The travel pump is fitted with a flushing valve for the closed circuit
All safety and control elements needed for the operation in a closed hydraulic circuit are integrated in
the travel pump. These are:
• High pressure relief valves (440 bar) with integrated boost check valves
• Charge pressure relief valve (26 bar)
• Pressure override (400 bar)
• Servo control
The travel motors are bent axle motors plugged into a travel gear with an upstream or downstream flow
divider.
BW 154 AD-4 -F3-
344 BOMAG 008 910 92

Service Training
Charge pressure relief valve
The charge pressure relief valve belongs to the group of safety elements in a closed hydraulic circuit.
This valve limits the pressure in the charge circuit to the adjusted value.
The charge pressure relief valve is installed in the travel pump and internally connected with the
vibration pump.
pilot oil
fixed spring
to the oil tank
Fig. 1 Charge pressure relief valve
The charge circuit is needed for the compensation of leak oil and flushing quantities in the closed
hydraulic circuit. Charge oil is also required to control the pumps and to release the parking brake.
Since feeding of cool and filtered oil is only possible on the low pressure side of the closed circuit, the
pressure in the low pressure side is identical with charge pressure. If the travel pump is in neutral
position, both boost check valves can open and let in oil from the charge circuit. In this case the pressure
in both sides of the closed circuit is identical with charge pressure.
BW 154 AD-4 -F4-
008 910 92 BOMAG 345

Service Training
High pressure relief valves, (with bypass for towing)
High pressure relief valves are safety elements, which are needed in every hydraulic circuit.
These valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.

bypass
Fig. 2 Valve plate with high pressure relief valves
1 Pressure override
2 High pressure relief valves, (fixed adjustment) with bypass for towing
3 Charge pressure relief valve (fixed)
High pressure relief valves are safety elements, which are needed in every hydraulic circuit. These
valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.
BW 154 AD-4 -F5-
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Service Training
.
to flow divider
from there to the travel moto
1
4
2
from the travel motors
Fig. 3 Hydraulic diagram
1 Travel pump
2 Control piston (actuated)
3 4/3-way valve (actuated)
4 High pressure relief valves, fixed
The high pressure relief valves in both sides of the hydraulic circuit protect the hydraulic system, the
diesel engine and all other machine components against overloads.
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 compensate leaks and flushing quantities.
BW 154 AD-4 -F6-
008 910 92 BOMAG 347

Service Training
Travel motor BW 154
The two travel motors are plug-in fixed displacement bent axle motors of series
A2FE 32 ccm from Bosch-Rexroth, which drive a travel gear GFT 07 from Bosch Rexroth.
BW 154 AD-4 -F7-
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Service Training
Travel gear BW 154
BW 154 AD-4 -F8-
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Service Training
BW 154 AD-4 -F9-
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BW 154 AD-4 - F 10 -
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Service Training
Flow divider BW 154
from or to
the travel pump
High pressure port B
Pos.16 Flow divider

with four high pressure
relief valves
and anti-cavitation functi
Pos.23 four travel gears with

travel motors
from or to the travel pump

High pressure port A
Fig. 1:Flow divider from hydraulic schematic
BW 154 AD-4 - F 11 -
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Service Training
On machines of series BW 154 AD/AC with split drums all drum halves or drum halves and wheels or
Wheel halves and wheels are driven by own travel motors. These machines are therefore equipped with
4 travel motors.
In order to assure that all motors are always supplied with the required oil quantity, a four-fold flow
divider is installed between travel pump and travel motors.
Flow dividers are used where several consumers have to be hydraulically arranged in parallel mode and
wherever the use of the consumers requires a differential lock, as it is necessary on rollers of type BW
154.
The hydraulic diagram (Fig. 1) shows the flow divider (16) with the integrated secondary pressure relief
and boost check valves.
Here four travel gears (23) for drum or wheel drive (AC) are hydraulically linked in parallel mode. In order
to avoid that a motor of any drum half will start to spin, the installation of a ”differential lock” is necessary.
To be able to understand the function of a 4-fold flow divider MH4FA one should first examine the
function of a 2-fold flow divider based on the constant orifice principle:
Fig. 2: 2-fold flow divider
BW 154 AD-4 - F 12 -
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Service Training
The control piston of the flow divider is fitted with measuring orifices. Since the diameter of the orifice
bore remains of identical size and does not change during operation, these orifices are called constant
orifices.
During operation of the hydraulic system a pressure differential (p) is created at these constant orifices.
If the flow rate at the two consumer ports (1 and 2) is of identical size, the pressure difference p1 =
pressure difference p2 and the control piston is centred in middle position. If the pressure differential p
between inflowing and outflowing oil is bigger on one side, the piston will be forced in this direction.
During this process the cross section of the discharge orifice for this outlet is decreased, the discharged
oil flow is throttled. This restriction of flow volume to the corresponding consumer is maintained, until an
equilibrium of the pressure differentials returns the control piston to middle position and the discharge
nozzles have identical cross sections again.
In this case the division ratio is determined by the opening cross sections of the discharge orifices.
The division accuracy depends on the accuracy of the measuring orifices, the spring rate and the friction
of the piston in the housing. With low pressure differentials the division accuracy is quite low, i.e. at low
flow volumes the flow divider works quite inaccurate. If the volume flow increases and with it also the
pressure differential at the constant measuring orifices, the division accuracy will also enhance. Higher
pressure differentials at the orifices result in a higher energy conversion. Hydraulic energy is converted
to heat energy. The influence of the spring has thereby not yet taken into account.
If uniformly adjustable measuring orifices, the cross sections of which would change in dependence on
the arriving oil flow, were used instead of constant measuring orifices, both the level of energy
conversion (loss) as well as the division fault could be maintained at an almost constant level. Another
negative factor for the division accuracy is the effect of the regulating spring. Stronger springs require
higher forces to move the control piston, i.e. the flow divider will only control at higher pressure
differentials p.
For the 2-fold flow divider described above it would also be possible to use two control pistons with only
one control edge each, instead of the control piston with two control edges.
BW 154 AD-4 - F 13 -
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Fig. 3 Two control pistons with one control edge each
Each consumer port would then have its own measuring orifice and control piston. When changing the
flow direction, the mobile sleeve with the control edge on the control piston enables an automatic
change to summarizing mode, i.e. in the flow divider the oil flow returning from the consumers are joined
and returned to the pump.
Form this description it is clear that this principle is not only suitable for two-fold flow dividers, but also
for a multiple division of the flow volume from the pump.
BW 154 AD-4 - F 14 -
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Service Training
Fig. 4 Principle sketch of a four-fold flow divider
If the flow rates are identical on all consumer ports, all control edges are open. If the pressure drops in
one of the consumer lines (e.g. ”C”), this is a sign that a higher flow volume flows to this consumer. The
related control edge on the control piston moves towards closing, thereby trying to compensate this
difference. At the same time this pressure drop in consumer line ”C” causes a relatively bigger opening
to consumer ”B” and from there to consumer ”A”, until a condition of equilibrium is reached on all 4
control pistons or in all consumer lines.
Fig. 5: Control piston
BW 154 AD-4 - F 15 -
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Design and function of MH4FA
The flow divider consists mainly of housing (1), single edge control piston (2), sleeve (3), pressure spring
(10) and piston (11).
Port P1
not available
Fig. 6
In housing (1) sleeve (3) is retained by pin (5). Sleeve (3) contains worked in measuring orifices
(windows), according to the division and summarizing ratio. These measuring orifices have the function
to compare the arriving and out flowing flow volumes in the consumer channels
A, B, C and D.
The flow volume arriving from the pump flows from port ”P” via bush (13) into chamber (15) and moves
the piston (11) against the preloaded pressure spring . This alters the cross section of the measuring
orifices (windows) in dependence on the magnitude of the flow volume and the pressure fluid flows
through bore (12) into the consumer channels A, B, C and D. The necessary corrective movements to
reestablish the state of equilibrium in all consumer lines are performed by the single edge control pistons
(2), as described above. For the automatic change-over from dividing to summarizing function and vice-
versa the single edge control pistons (2) are fitted with additional rings (4).
BW 154 AD-4 - F 16 -
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Service Training
Since the single edge control pistons (2) only start to regulate after a certain pressure differential is
reached, the wheels or drum halves will not start to spin, the machine is maintained in a manoeuvrable
condition.
The flow divider used in the machine types BW 154 works like a differential lock. Due to this type of
operation a lack of oil in the consumer lines may occur when driving around curves. This would
obviously cause cavitation, or, in case of sudden reversing operations, pressure peaks in the system.
In order to avoid this and resulting damage each consumer port is fitted with a secondary pressure relief
and boost check valve.
Fig. 7 Secondary pressure relief and boost check valves
The flow divider is connected with the charge circuit of the machine via two “Y”-ports. This charge
pressure is permanently applied to the boost check valves. In case of a lack of oil in one of the consumer
lines the corresponding boost check valve will open and feed in the required oil quantity.This protects
the system against cavitation.
If pressure peaks occur e.g. when changing the travel direction all of a sudden, the corresponding
secondary pressure relief valves will respond and protect the system against overloads.
Note:
Port P1 is not available on machines of series BW 154. In other applications this port is needed to enable
and disable the differential lock via an external 2/3 way valve.
BW 154 AD-4 - F 17 -
358 BOMAG 008 910 92

Service Training
Trouble shooting flow divider
If a malfunction in the travel system is detected during operation of the machine, the function of the flow
divider can be tested by jacking the complete machine up (all drums must be able to rotate freely).
If the drums rotate with strongly different speeds at full engine speed and maximum travel speed (slight
speed differences can be caused by resistances in bearings and between the drum halves), the flow
divider must be replaced.
BW 154 AD-4 - F 18 -
008 910 92 BOMAG 359

Service Training
Test and adjustment points
Travel pump
10 9
5
4
3
6
1
2
7
8

diagram
1 Travel pump 5
2 Pressure test port, charge pressure M5, SP, G 26 bar
3 Pressure test port, forward travel M6, MA 400 bar
4 Pressure test port, reverse travel M7, MB 400 bar
5 Flushing valve block 5
6 Pressure override 5 400 bar
7 High pressure valve, forward 5 440 bar
8 High pressure valve, reverse 5 440 bar
BW 154 AD-4 - F 19 -
360 BOMAG 008 910 92

Service Training
Travel motor with travel gear
7
6
1 4
3 4
2 1
2
3
5
5
2

diagram
1 Travel motor 23
2 Travel gear 23
5 Port for cross flushing 23
6 Leak oil port 23
7 Brake port in travel gear 23
BW 154 AD-4 - F 20 -
008 910 92 BOMAG 361

Service Training
Flow divider

diagram
1 Flow divider 16
BW 154 AD-4 - F 21 -
362 BOMAG 008 910 92

Service Training
Trouble shooting
Procedure:
BW 154 AD-4 - F 22 -
008 910 92 BOMAG 363

Service Training
TROUBLE SHOOTING TRAVEL
Machine does not travel (forward and reverse)
Machine travels with travel lever in 'Neutral'

DRIVE
Machine travels to one direction only

BW 154- 4
Max. travel speed is not reached

Hydraulic oil overheating
SYMPTOMS
POSSIBLE CAUSES
Brake valve (electrically/mechanically/hydraulically) 1
Brake in drum drive gear (mechanically/hydraulically) 2 2 3
Speed range selector switch position/defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/ travel pump high pressure limitation
3 2 3 3
Travel cable adjustment 1 2
Travel pump mechanical neutral position 3 3
Travel pump(s) defective 3 3 2
Control valve travel motor(s) (electrically/mechanically/hydraulically) 1 2
Flushing valve for travel motor(s) stuck 3
Travel motor(s) defective 3 3
Drum drive gear defective 3
Hydraulic oil cooler dirty (internally/externally) 1
Thermostat (hydraulics) dirty/jammed/defective 2
BW 154 AD-4 - F 23 -
364 BOMAG 008 910 92

Service Training
Vibration
The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit.
The main components of this circuit are
• vibration pump,
• vibration motors
• vibration shut-off valve to shut off both vibration motors
• and the pressure resistant hydraulic hoses.
Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the
diesel engine.
When operating a 4/3 way solenoid valve, pilot oil is guided to one of the control piston sides. This
actuates the pump from neutral position to one of the two possible maximum displacement positions. If
the vibration shut-off valve is not activated the pump now pumps oil to the vibration motors, which are
connected in series mode.
of the oil and the sense of rotation of the vibration motors will change.
Since the displacements are different to both pumping directions, the speed of the vibration motors to
the two directions of rotation is also different.
The vibration motor output shafts are joined with the exciter shafts in the drums via Bowex coupling. The
rotation of the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically
suspended drums.
The eccentric weights on the vibrator shaft are fitted with additional change-over weights.
Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract
from the basic weights.
• Basic weight + change-over weight = high amplitude
• Basic weight - change-over weight = low amplitude
The displacement of the pump is different to both flow directions. This results is different exciter shaft
speeds in dependence on the sense of rotation of the vibration motors.
The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled
with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.
BW 141 - 154 AD/AC -4 -G1-
008 910 92 BOMAG 365

366
11.1
Charge pressure port from leak oil port front travel motor
T1: to tank
Fig. 1
T2: travel pump connection
BW 141 - 154 AD/AC -4

9
3
19
1 4 7
Vibration circuit BW 141 - 154 AD-4

2
5 6
BOMAG
4 18
8
Charge oil
from travel pump
to tank
1 006 Vibration pump 9 Pressure relief valve from leak oil port
2 Control piston 18 Rear vibration motor rear travel motor
3 4/3-way control solenoid valve 19 Front vibration motor Cross-flushing
5 Pressure override Y54 Solenoid valve, front vibration
6 Shuttle valve Y55 Solenoid valve, rear vibration
7 Flushing valve Y56 Solenoid valve, low amplitude
8 007 Vibration shut-off valve Y57 Solenoid valve, high amplitude
Service Training
-G2-
Service Training
008 910 92
Service Training
Vibration pump
The vibration pump is a swash plate operated axial piston pump with variable displacement of type A10
VG 45 EZ from Hydromatik. The pump is fitted with all control and safety elements needed for operation
in a closed hydraulic circuit. These are:
• servo control
T2: Connection to travel pump
T1: to tank
3
to / from
Vibration
shut-off
valve
1 4
2
4 5
from/to
Vibration
shut-off
valve
Charge oil from
Travel pump
Fig. 2 Vibration pump, hydraulic diagram
1 Pump drive
2 Control piston
3 Solenoid valve
4 High pressure relief valves (405 bar)
5 Pressure override (380 bar)
BW 141 - 154 AD/AC -4 -G3-
008 910 92 BOMAG 367

Service Training
3 4 5
2
9 8 7 6
Fig. 3 Vibration pump, hydraulic diagram
1 Drive shaft
2 Control piston
3 Pilot pressure port (X1/X2)
4 Servo control
5 Pressure override
6 Cylinder block
7 Working pistons
8 Slipper pad
9 Swash plate
The complete drive consisting of valve plate, cylinder block and swash plate is held together by Belleville
springs. This results in a high efficiency over the entire lifetime of the pump.
The spherical valve plate centres the cylinder block which is driven by the drive shaft via a splined
connection. This avoids the appearance of undesired transverse forces.
BW 141 - 154 AD/AC -4 -G4-
368 BOMAG 008 910 92

Service Training
Pilot pressure is used to operate the pump out of neutral position to the desired pumping direction
(direction of oil flow). A 4/3-way valve guides this pilot oil to the corresponding control piston side in the
servo control. Due to the use of a remote control (electrically operated via solenoids) the pump can only
be actuated from neutral to one of the two possible maximum displacement positions.
In neutral position both control chambers are loaded with case pressure. When opening the 4/3-way
valve pilot oil (from the charge circuit) is directed to one of the control piston sides and moves the control
piston to the corresponding direction. The pump swashes to the adjusted maximum displacement.
of the oil and the sense of rotation of the exciter shaft will change.
The displacements to both pumping directions have different adjustments.
This results in different speeds of the vibration motor to both travel directions.
This means:
• High displacement – high speed (frequency).
• Low displacement – low speed (frequency).
The position of the change-over valves depends on the sense of rotation of the exciter shaft. The
different positions of the change-over weight in relation to the basic weight results in the following
vibration effects:
• High displacement – high frequency – low amplitude
• Low displacement – low frequency – high amplitude
The resistance affecting the rotation of the exciter shaft causes pressure to build up between pump and
motor. This pressure closes the boost check valve in the high pressure side of the closed circuit.
Feeding of cooled and filtered hydraulic oil can therefore only take place in the low pressure side.
Once the pressure reaches the adjusted value of the pressure override valve the pilot oil flow to the 4/
3 way solenoid valve is interrupted. The pressure cannot increase any further.
Sudden pressure peaks are eliminated by high pressure relief valves. In this case hydraulic oil flows
from the high pressure side through the boost check valve directly into the opposite side, the low
pressure side.
BW 141 - 154 AD/AC -4 -G5-
008 910 92 BOMAG 369

Service Training
High pressure relief valves
8 3*
6 5
Fig. 4 High pressure relief valves
1 Setscrew for pressure override

2 High pressure relief valve with integrated boost check valve
3* not available on vibration pump
5 High pressure relief valve
6 Valve plate
7 Pressure override
When switching the vibration off the vibration motors for a short while have the function of a pump. They
pump the oil back to the vibration pump. This effect is caused by the rotating exciter shafts with the
attached eccentric weights.
Since the vibration pump is already in neutral position, the oil cannot pass through the pump. In this case
the pressure override valve has no function. Under this condition the high pressure relief valves work as
brake valves.
The functions of pressure override valve and high pressure relief valves in the vibration circuit are
identical with the functions of these valves in the travel circuit. The description of these components
does therefore not need to be repeated.
BW 141 - 154 AD/AC -4 -G6-
370 BOMAG 008 910 92

Service Training
Control
The control is part of the pump and consists mainly of the 4/3-way solenoid valve, the control piston and
the swash plate with swashing lever.
If one of the two magnets is energized by actuating the frequency selector switch and the vibration
control switch, the 4/3 way solenoid valve is switched to open position. Pilot oil flows now to the
corresponding control piston side. The control piston slides to the corresponding direction and moves
the swash plate via the swashing lever. The pump delivers oil.
6
2
Fig. 5 Pump control
1 Solenoid valve 4 Neutral setting spring

2 Valve spool 5 Control piston
3 Setscrew for mechanical neutral position 6 Control chamber
The oil from the opposite control chamber flows through the 4/3-way valve as leak oil into the pump
housing.
When the 4/3-way valve is in neutral position, the pressure values in both control chambers are identical
(case pressure = max. 3 bar).
BW 141 - 154 AD/AC -4 -G7-
008 910 92 BOMAG 371

Service Training
Vibration motors
The vibration motors are fixed displacement axial piston motors of bent axle design, type A4 FM 22, from
Hydromatik. These motors are designed for two directions of rotation and can therefore subjected to
pressure from both sides.
The pressure oil provided by the pump flows through the kidney shaped control slots in the valve plate
into the cylinder block with the working pistons. The pressure oil causes a stroking movement of the
working pistons. Due to the swash plate design this axial movement of the pistons is converted to a
radial movement of the motor drive. The output shaft transfers this rotary movement via an elastic
Bowex coupling to the exciter shaft with the two eccentric weights.
2 4 5
3 6
1 7 8
Fig. 6 Vibration motor A4 FM 22
1 Radial seal 2 Housing

3 Cylinder roller bearing 4 Working pistons
5 Cylinder block 6 Output shaft
7 Valve plate 8 Cylinder roller bearing
9 Swash plate, not adjustable
When switching the vibration on the vibration motors must first accelerate the resting exciter shaft up to
nominal speed. This resistance causes a hydraulic starting pressure, which is limited to 380 bar by the
pressure override valve.
Once the exciter shaft has reached its final speed, the pressure will drop to an operating pressure of
approx. 60 - 160 bar. This operating pressure depends on the state of compaction of the soil.
BW 141 - 154 AD/AC -4 -G8-
372 BOMAG 008 910 92

Service Training
Vibration shut-off valve
Charge pressure Leak oil from front travel mo
from/to vibration pump
Leak oil Leak oil from rear

to tank travel motor
Fig. 7 Vibration shut off valve 007
1 Front vibration motor

2 Rear vibration motor
Y54 energized: only rear vibration motor running
Y55 energized: only front vibration motor running
With this vibration shut-off valve the vibration motors can be switched on or off individually.
The vibration shut-off valve is a solenoid operated pilot controlled valve. It controls start, stop of vibration
and flow direction of the flow volume.
BW 141 - 154 AD/AC -4 -G9-
008 910 92 BOMAG 373

Service Training
Flushing valve
The housing of the vibration shut-off valve contains a flushing valve. The flushing valve is connected
with both sides of the closed circuit.
When the vibration is switched on the high pressure side of the closed circuit moves the flushing piston
and opens a discharge channel for oil from the low pressure side.
Oil flows now from the low pressure side back to the tank. This oil is immediately replaced by fresh,
cooled and filtered oil from the charge circuit.
The flushing quantity is limited by the orifice or nozzle with a bore of (d=2mm).
If the flow direction of the oil changes (when changing the vibration frequency), the flushing valve shifts
to the other side and opens the discharge channel for the opposite side of the closed circuit (now low
pressure side).
If the vibration is not operated the flushing spool is centred in neutral position by two pressure springs.
The flushing valve has the function to maintain the temperature in the hydraulic system at a permissible
level.
BW 141 - 154 AD/AC -4 - G 10 -
374 BOMAG 008 910 92

Service Training
Drum BW 141 AD-4
10
13
12
10
4 52 12
53 13
8 7
7
8
9
6 2
3 64
11
11
1
9 9
1
Fig. 8 Drum BW 141 AD/AC-4
1 Drum shell 2 Vibration bearing

3 Basic weight 4 Change-over weight
5 Vibrator housing 6 Coupling shaft
7 Vibration motor 8 Elastic coupling
9 Rubber buffer 10 Travel bearing
11 Oil drain 12 Oil filling
13 Travel drive unit
BW 141 - 154 AD/AC -4 - G 11 -
008 910 92 BOMAG 375

Service Training
Drum BW 154 AD-4
13 13
12 12
13
5 10 10
8 14 12
3 4 5 15 7
2
8
7
11 6 11
3 6 4 9
2
11
1
9 9
1
Fig. 9 Drum BW 154 AD/AC-4
1 Drum shell 2 Vibration bearing

3 Basic weight 4 Change-over weight
5 Vibrator housing 6 Coupling shaft
7 Vibration motor 8 Elastic coupling
9 Rubber buffer 10 Live ring four-point bearing
11 Oil drain 12 Oil filling
13 Travel drive unit
BW 141 - 154 AD/AC -4 - G 12 -
376 BOMAG 008 910 92

Service Training
Exciter weights
Fig. 10 Exciter unit travel drive side BW 141 - 154 AD/AC-4
1 Basic weight
2 Change-over weight
3 Oil paddle
BW 141 - 154 AD/AC -4 - G 13 -
008 910 92 BOMAG 377

Service Training
Vibration pump
5 4
1
6
3
2
diagram
1 Vibration pump 6
2 Pressure test port, charge pressure 6 26 bar
3 Pressure test port, vibration 6 max. 380 bar
pressure high amplitude
4 Pressure test port, vibration 6 max. 380 bar
pressure low amplitude
5 Solenoid for high amplitude Y57 Page 008 6
6 Solenoid for low amplitude Y56 Page 008 6
BW 141 - 154 AD/AC -4 - G 14 -
378 BOMAG 008 910 92

Service Training
Vibration pump
4 3 5
2
1

diagram
1 High pressure valve, high amplitude 6 405 bar fixed
2 High pressure valve, low amplitude 6 405 bar fixed
3 Vibration pump port high amplitude 6
4 Vibration pump port low amplitude 6
5 Pressure override 6 380 bar
BW 141 - 154 AD/AC -4 - G 15 -
008 910 92 BOMAG 379

Service Training
Vibration shut-off valve
1
2
1
5
2
3
3
5 4 4

diagram
1 Solenoid valve, rear vibration off Y 55 Y 55 0 / 12V
2 Solenoid valve, front vibration off Y 54 Y 54 0 / 12V
3 Pressure test port MM (between 007, MM max. 380 bar
motors)
4 Pressure test port MA before/after 007, MA max. 380 bar
front vibration motor
5 Pressure test port MB before/after 007, MB max. 380 bar
front vibration motor
BW 141 - 154 AD/AC -4 - G 16 -
380 BOMAG 008 910 92

Service Training
Vibration motor front/rear
1 3 4
2
2
4
2
3
2
1

diagram
1 Vibration motor port B high 18 or 19
amplitude
2 Vibration motor port A low 18 or 19
amplitude
3 Leak oil port T 18 or 19
4 Port for cross flushing 18 or 19
BW 141 - 154 AD/AC -4 - G 17 -
008 910 92 BOMAG 381

Service Training
Trouble shooting
Procedure:
BW 141 - 154 AD/AC -4 - G 18 -
382 BOMAG 008 910 92

Service Training
Front and/or rear vibration cannot be switched off

TROUBLE SHOOTING
VIBRATION
too low exciter shaft speed front and rear

BW 141-4-FAMILY
No vibration (charge pressure OK)

Only one vibration amplitude
SYMPTOMS
POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1 1
Push button vibration (on/off) 1
Electrics defect / wiring 2 2 2
Vibration shut off valve magnets defective /
1 1
dirty / jammed
Pump control (electrically / hydraulically) 1 1
Pressure override/ high pressure limitation vibration pump
2
Charge pump(s) / charge pressure relief valves
2
dirty/defective
Flushing valve in vibration shut-off valve dirty/jaqmmed/defective 2 2 2
Vibration pump frequency setting 2
Vibration pump defective 2 2 2
Coupling between engine and travel pump defective
Exciter shaft bearings defective 3
Vibration motor coupling defective 2
Vibration motor(s) defective 2 1
Diesel engine 1
BW 141 - 154 AD/AC -4 - G 19 -
008 910 92 BOMAG 383

Service Training
Steering
The machines described in this manual are equipped with a hydraulically operated articulated steering.
12
to charging
to blower motor
Suction lines
Hydraulic diagram steering system

002 Tandem steering/charge pump 008 Pressure filter
009 Priority valve 014 Steering valve
015 Steering cylinder 011 Crab walk valve
012 Crab-walk cylinder
BW 141 - 154 AD/AC -4 -H1-
384 BOMAG 008 910 92

Service Training
The steering system consists mainly of:
• the steering/charge pump (1st pump of tandem gear pump),
• the priority valve,
• the steering valve,
• the steering cylinders and
• the pressure resistant connecting hoses
As the steering pump also supplies the hydraulic oil for the charge circuit for travel and vibration drives
as well as the crab walk facility besides the steering, the system is equipped with a priority valve. The
priority valve ensures that the steering will always be prioritized under any condition. The priority valve
is triggered by the steering valve through the LS-line. This valve restricts the oil flow to charge circuit
and crab-walk whenever oil is needed for the steering. However, this does not mean that in such a case
there would be a lack of oil for the charge circuit, because the return flow from the steering is directly
fed into the charge circuit.
The steering pump supplies the hydraulic oil from the hydraulic oil tank through the pressure filter to the
priority valve. If the steering is not operated, the complete oil flow will flow through the crab walk valve
to the charge ports for the travel and vibration circuits.
When operating the steering the steering valve will generate a load signal „LS“, informing the priority
valve that more oil should be directed to the steering.
When turning the steering wheel the distributor valve guides the oil flow to the corresponding steering
cylinder sides.
A rating pump inside the steering unit measures the exact oil quantity corresponding with the turning
angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders extend or retract and articulate the machine.
The steering valve contains also a pressure relief valve. This valve limits the steering pressure to 170
bar. Since the oil is available for the charge circuit after it as left the steering unit, the charge pressure
of 26 bar must be added to this value. The maximum steering pressure is therefore approx. 196 bar.
Suddenly occurring pressure peaks, which may be caused by e.g. external influences like driving
against a curb stone, are compensated by two shock valves (setting 235 bar), which are integrated in
the steering valve.
Note
This steering system is a dynamic steering system, i.e. a small quantity of oil (approx. 1 - 2 l/min) will
always flow via the LS-line.
BW 141 - 154 AD/AC -4 -H2-
008 910 92 BOMAG 385

Service Training
Steering pump
The steering/charge pump is a tandem gear pump with fixed displacement. Pump section 1, which is
directly mounted to the engine (11 ccm), supplies the steering and the crab-walk valve, the second
pump unit (8 ccm) serves the fan motor. After serving the above mentioned functions both pump flows
are united for the charge oil supply.
The tandem pump is driven by the auxiliary drive of the diesel engine and draws the hydraulic oil directly
out of the oil tank. The oil then flows through a pressure filter to the priority valve, the steering valve or
the crab walk valve or the blower motor, and from there to the charge circuit.
9 9 6 1 7
3
8
2
4 5
Steering pump, individual

1 Housing 4, 5 Bearing plates 9 Seals
2 Flange 6 Cover
3 Shaft 7, 8 Pinions
Function of the gear pump
The drive pinion of the steering pump is driven by the auxiliary drive of the engine. Drive gear and driven
gear are positioned by a bearing plate in such a way, that the teeth of both gears mesh with minimum
clearance when rotating.
The displacement chambers are formed between the tooth flanks, the inside wall of the housing and the
faces of the bearing plates. The chambers transport the hydraulic oil from the suction side to the
pressure side. This generates a vacuum in the suction line, which draws the hydraulic oil out of the tank.
These tooth chambers transport the hydraulic oil along the inside wall of the housing from the suction
side to the pressure side, from where it is pressed to the consumers. To ensure a safe function of the
pump the tooth chambers must be so tightly sealed that the hydraulic fluid can be transported from the
suction side to the pressure side without any losses.
Outer gear pumps are fitted with gap seals. This results in pressure level dependent fluid losses from
the pressure side to the suction side. An axial pressure field presses the bearing plate on the cover side
against the front face of the gears, making sure that only a very little quantity of oil will leak from the
pressure side to the suction side when the pressure increases during operation.
The pressure field is always under system pressure.
BW 141 - 154 AD/AC -4 -H3-
386 BOMAG 008 910 92

Service Training
Priority valve
Since the pressure oil from the steering pump is also needed for the working hydraulics, i.e. the crab
walk valve, the machine is fitted with a priority valve. This valve ensures that the steering will always be
prioritized under any condition. The priority valve guides the oil to the following consumers:
• to the steering valve (port CF)
• to the crab-walk valve and from there to the charge circuit (port EF)
Priority valve
Distribution of the oil is determined by the switching position of the valve spool.
This position depends on the following values:
• the requirements caused by the steering load (LS-signal) arriving from the steering valve
• the load (pressure) in the steering system (max. 196 bar)
The load signal (LS) from the steering valve controls the position of the valve spool in such a way, that
the oil flow is at any time determined by the steering speed.
Note
BW 141 - 154 AD/AC -4 -H4-
008 910 92 BOMAG 387

Service Training
Steering valve
The steering valve consists mainly of:
• the distributor valve,
• the rating pump,
• the steering pressure relief valve and
• the shock valves.
1
2
9
3
8
6
Steering unit
1 Neutral setting springs 6 Ring gear
2 Housing 7 Gear
3 Inner spool 8 Check valve
4 Outer spool 9 Pressure relief valve
5 Universal shaft
BW 141 - 154 AD/AC -4 -H5-
388 BOMAG 008 910 92

Service Training
When turning the steering wheel the oil flow from the pump is guided through the distributor valve to the
rating pump and from there to the respective sides of the steering cylinders.
The rating pump determines the exact oil quantity in dependence on the turning angle of the steering
wheel.
The high pressure relief valve in the steering unit limits the pressure in the steering system to 170 bar
+ charge pressure.
The steering unit is equipped with so-called shock valves for both pressure sides to the steering cylinder.
These valves are adjusted to 235 bar. They compensate extreme pressure peaks, which can be
introduced from outside, e.g. when driving over obstacles. The system is thereby protected against
overloads.
Each of these shock valves is fitted with an additional anti-cavitation valve. These anti-cavitation valves
protect the system against cavitation which could be caused by the reaction of the shock valves.
A check valve inside the steering unit makes sure that the hydraulic oil cannot flow to the steering pump
if forces are introduced from outside. In such a case the steering cylinders would act as pumps and
press the oil back to the pump.
Note
BW 141 - 154 AD/AC -4 -H6-
008 910 92 BOMAG 389

Service Training
The machines are equipped with two steering wheels. However, the machines are fitted with only one
steering valve, which is arranged between the steering wheels. Two circulating chains connect both
steering wheels with the steering valve.
BW 141 - 154 AD/AC -4 -H7-
390 BOMAG 008 910 92

Service Training
Articulated joint
The articulated joint is the connection between front and rear frames.
Fig. 1Articulated joint
The rear console is tightly bolted to the rear frame via a live ring.
The live ring serves as oscillation joint.
The front console is fastened with screws to the rear cross-member of the front frame. The front console
is additionally fitted with the welded on bearings eyelets for the steering cylinders.
When turning the steering wheel the steering will extend or retract. The piston rods swivel the front
console around the vertical bolts. The machine articulates and steers.
All bearing points on the articulated joint are maintenance free, lubrication is not required.
BW 141 - 154 AD/AC -4 -H8-
008 910 92 BOMAG 391

Service Training
BW 141 - 154 AD/AC -4 -H9-
392 BOMAG 008 910 92

Service Training
Articulated joint
BW 141 - 154 AD/AC -4 - H 10 -
008 910 92 BOMAG 393

Service Training
3 1
2 4
2
Steering pump and pressure filter

diagram
1 Steering pump 11ccm 2
2 Steering pressure test port 8 max.170+26 bar
3 Differential pressure switch of B21 Page 004 8 Δp 3,5 bar
steering circuit pressure filter
4 Pressure filter 8
BW 141 - 154 AD/AC -4 - H 11 -
394 BOMAG 008 910 92

Service Training
Steering valve
3 2
9
5
6
4 3
4 2 1
5

diagram
1 Steering valve 14
2 LS-port to priority valve 14
3 L-port to steering valve 14
4 R-port to steering cylinder 14
5 Port P from priority valve 14
6 Port T to charge system 14
BW 141 - 154 AD/AC -4 - H 12 -
008 910 92 BOMAG 395

Service Training
Priority valve
4 3
2 1

diagram
1 Port P from steering pump 9
2 Port CF to steering valve 9
3 Port EF to crab walk valve 9
4 Port LS to priority valve 9
BW 141 - 154 AD/AC -4 - H 13 -
396 BOMAG 008 910 92

Service Training
Trouble shooting:
Procedure:
BW 141 - 154 AD/AC -4 - H 14 -
008 910 92 BOMAG 397

Service Training
TROUBLE SHOOTING STEERING

BW 141-4 FAMILY
Crab walk without function / too slow
End stops are not reached
Steering hard to move
No steering function
SYMPTOMS
POSSIBLE CAUSES
Steering valve 2 2 1
Steering/charge pump 11 ccm 1 1 2
Blower/charge pump 8 ccm 2
Priority valve 3 3 3 2
Steering cylinder 3 3 3
Articulated joint 3 3 2
Crab walk cylinder 3
Crab walk valve 2
electr. control/solenoid valve for crab walk 1
BW 141 - 154 AD/AC -4 - H 15 -
398 BOMAG 008 910 92

Service Training
Working hydraulics - crab walk and optional equipment
12 13
y20
y18
to
y19 y21 charging
to the
blower motor
Suction lines
Hydraulic diagram of working hydraulics

002 Tandem steering/charge pump 008 Pressure filter
009 Priority valve 011 Crab walk valve
Optional equipment
013 KSG edge currer zylinder 024 Chip spreader
BW 141 - 154 AD/AC -4 -J1-
008 910 92 BOMAG 399

Service Training
Crab-walk valve
The crab walk facility enables lateral offsetting of the front frame to the rear frame. The max. offset value
is approx. 170 mm.
This offset between front and rear frame is of great help when pressing edges and cornering along curb
stones.
The crab-walk control valve consists of the actual electro-magnetically operated valve, the 160 bar
(pressure differential) pressure relief valve and the two unlockable non-return valves (pressure retaining
valves).
12
2
y18
3
1
from
priority valve y19
port EF to charging
Hydraulic diagram of crab walk valve

1 6/3-way spool valve
2 Unlockable check valves
3 Pressure relief valve
11 Crab-walk valve
If the crab-walk is not operated, the complete oil flow is directed through the open channel in the closed
valve to outlet T and from there to the charge circuit.
If the control valve is actuated out of neutral to one of the two active positions, the open oil flow passage
is closed and the oil flows through the valve to the corresponding side of the crab-walk cylinder. The
unlockable non-return valves lock the oil in the cylinder chambers, until a new control command opens
these valves and allows the oil to flow out.
BW 141 - 154 AD/AC -4 -J2-
400 BOMAG 008 910 92

Service Training

diagram
1 Pressure test port, max. pressure 160+26 bar
crab walk valve
2 Pressure differential switch B21 Page 004 008 Δp 3,5 bar
3 Priority valve 009
BW 141 - 154 AD/AC -4 -J3-
008 910 92 BOMAG 401

Service Training
Proximity switch
The proximity switch indicates the position of the crab walk, i.e. middle position front frame to rear frame.

diagram
1 Proximity switch, articulated joint B10 Page 017
BW 141 - 154 AD/AC -4 -J4-
402 BOMAG 008 910 92

Service Training
Crab-walk valve
1
3 2
1
5
6

diagram
1 Solenoid valve for crab-walk, left Y 19 Page 017 11, Y 19 0/12 V
2 Solenoid valve for crab-walk, right Y 18 Page 017 11, Y 18 0/12 V
3 Port P from priority valve 11
4 Port T to charge system 11
5 Crab walk cylinder ports 11
6 PRV 11 Set to 160 bar
BW 141 - 154 AD/AC -4 -J5-
008 910 92 BOMAG 403

Service Training
Crab-walk cylinder

diagram
1 Crab-walk cylinder 12
BW 141 - 154 AD/AC -4 -J6-
404 BOMAG 008 910 92

Service Training
Trouble shooting
Procedure:
The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience:
BW 141 - 154 AD/AC -4 -J7-
008 910 92 BOMAG 405

Service Training
TROUBLE SHOOTING
Crab walk without function / hard to move

BW 141-4 FAMILY
End stops are not reached

Steering hard to move
No steering function
SYMPTOMS
POSSIBLE CAUSES
Steering/charge pump 11 ccm 1 1 2
Blower/charge pump 8 ccm 2
Priority valve 3 3 3 2
Crab walk cylinder 3
Crab walk valve 2
electr. control/crab walk solenoid valve 1
TROUBLE SHOOTING
BW 141 - 154 AD/AC -4 -J8-
406 BOMAG 008 910 92

Service Training
Blower drive
On the new articulated tandem rollers of series 4 the external blower is hydraulically driven
Check valve or
anti-cavitation valve
to the
priority
valve,
Steering
to charging
Suction lines
Hydraulic diagram blower drive

02 Tandem steering/charge pump
08 Pressure filter
16 flanged on pressure relief valve
17 Blower motor
The check valve is externally piped and serves as anti-cavitation valve to prevent the occurrence of
cavitation in the P-line while the blower is after-running!
The hydraulic blower motor is driven by the second pump (8ccm) of the tandem gear pump on the
auxiliary drive of the engine.
BW 141 - 154 AD/AC -4 -G1-
008 910 92 BOMAG 407

Service Training
Blower motor
The blower motor is an 8ccm gear motor with a pressure relief valve flange mounted on the motor inlet
side P.
The blower speed is identical with the diesel engine speed (when the pressure relief valve is not active),
because the displacements of pump (8 ccm) and motor (8 ccm) are identical.
Flange mounted pressure relief valve (set to 210bar)
BW 141 - 154 AD/AC -4 -G2-
408 BOMAG 008 910 92

Service Training
3 1
2
2

diagram
1 Blower pump 8ccm 002
2 Blower pressure test port 008 max. 210+26 bar
3 Differential pressure switch of B21 Page 004 008 Δp 3,5 bar
blower circuit pressure filter
BW 141 - 154 AD/AC -4 -G3-
008 910 92 BOMAG 409

Service Training
Blower motor
1
2
1
P
4 3

diagram
1 Blower motor 16
2 PRV 17 max. 210+26 bar
3 Check valve, anti-cavitation valve
4 Circular fan
BW 141 - 154 AD/AC -4 -G4-
410 BOMAG 008 910 92

Service Training
Return flow block with thermostat valve
4
2
3
1
1
1 1
1
1

diagram
1 Leak oil return lines 4
2 Tank port 4
3 Cooler port 4
4 Thermostat valve 4 opens at 55°C
BW 141 - 154 AD/AC -4 -G5-
008 910 92 BOMAG 411

Service Training
Trouble shooting
Procedure:
TROUBLE SHOOTING
BW 141-4 FAMILY
Blower speed not correct
No blower speed
SYMPTOMS
POSSIBLE CAUSES
Blower / charge pump 8 ccm 1 2
PRV 2 1
3
Blower motor
TROUBLE SHOOTING
BW 141 - 154 AD/AC -4 -G6-
412 BOMAG 008 910 92

Service Training
Water sprinkling system
The new articulated tandem rollers of series 4 are equipped with two independently working water
pumps. Both pumps can be operated as desired.
These water pumps are direct controlled diaphragm pumps, solenoid valves are therefore not required.
The water filter is located behind the water tank cover or water pump suction port, at the lowest position
of the water tank.
The water sprinkler system is controlled by means of the travel lever monitoring and water sprinkler
module A03
2
1
3
4
5

diagram
1 Water pump left M 02 Page 005 0/12 V
2 Water pump right M 18 Page 005 0/12 V
3 Water level sensor R 14 Page 004 4- 20 mA
4 Switch - residual water quantity B 33 Page 004 Ground activated
5 Covering lid with filter
BW 141 - 154 AD/AC -4 -G1-
008 910 92 BOMAG 413

Service Training
Circuit diagram, water sprinkler system
BW 141 - 154 AD/AC -4 -G2-
414 BOMAG 008 910 92

Service Training
AC-Variants: BW 141 - 154 AC-4
circuit. It mainly consists of travel pump with integrated safety elements and travel motors with travel
gears. The AC wheel set is equipped with radial piston travel motors.
23
from brake valve
from brake valve
5
22
Leak oil with flushing oil

6
20) Rear travel motor
21) Rear travel motor
22 Front travel motor
23) Front travel gear

Charging
T1: Connection to vibration pump
4
420
25
3
3High pressure limitation

5 Brake in travel gear

3
440
440
4Pressure override
6) Flushing valve
2Servo control
1Travel pump
2
Fig. 1Hydraulic diagram travel system BW 141/151 AC-4
BW 141 - 154 AC-4 -M1-
008 910 92 BOMAG 415

Service Training
Travel motors of the AC wheel set
The two travel motors in the AC wheel set are radial piston motors
from / to travel pump

from brake valve from / to travel pump
Leakage with
flushing quantity
Leakage
from/to the
from/to the travel pump
travel pump
Hydraulic diagram
20 Travel motor, back right

21 Travel motor, back left
BW 141 - 154 AC-4 -M2-
416 BOMAG 008 910 92

Service Training
Travel motor Poclain MS 08
The AC wheel set is driven by a hydraulic radial piston motor.
These travel motors consist of three housing parts, the flat distributor, the cylinder block with the working
pistons and the output shaft.
2 3
4
1
43090070
8 7 6 5
Fig. 1: Travel motor
1 Drive shaft with output flange

2 Piston with roller
3 Oil distributor
4 Brake piston
5 Multi-disc brake
6 Cylinder block
7 Cam ring
8 Bearing plate
BW 141 - 154 AC-4 -M3-
008 910 92 BOMAG 417

Service Training
The housing consists of:
• bearing section (drive shaft bearings),
• torque section (cam race) and
• oil distributor.
Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure
oil presses the working pistons with the rollers against the cam race of the torque section and forces the
rollers to roll along the cam race. This transforms the axial movement of the pistons to a radial
movement of the cylinder block. The cylinder block transfers this rotation via a splined connection to the
output shaft. The output shaft runs in two tapered roller bearings. It transfers the rotary movement via
the drive disc and the rubber elements to the drum. The function of the radial piston motor is described
hereunder. The piston positions described in this explanation can be seen in the related illustration. The
movement of a piston along the cam race must be examined in several phases during a full rotation:
5
2
3
Fig. 2: Function of the radial piston motor
BW 141 - 154 AC-4 -M4-
418 BOMAG 008 910 92

Service Training
Piston position 1:
The oil enters into the oil distributor under pressure, flows through the distributor and presses against
the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the
roller along the cam and causes a rotation of the cylinder block.
Piston position 2:
At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The
piston continues his travel along the cam race towards the valley between two cams. As the movement
continues the opening cross-section for the oil supply decreases.
Piston position 3:
Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston
is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first
piston out of the dead centre.
Piston position 4:
Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now
connected with the low pressure side and the reverse movement of the piston presses the oil back to
the pump.
Piston position 5:
The pumping movement of the motor back to the pump comes to an end, the connecting bore between
cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre
position. This point is the start of a new working cycle.
Reversing the oil flow reverses also the rotation of the motor.
The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc
and the rubber elements to the drum.
BW 141 - 154 AC-4 -M5-
008 910 92 BOMAG 419

Service Training
BW 141 - 154 AC-4 -M6-
420 BOMAG 008 910 92

Service Training
Travel system
5
6
1 2
3 4
2

diagram
1 Travel motor forward, rear left 21
2 Travel motor forward, rear right 20
3 Travel motor reverse, rear left 21
4 Travel motor reverse, rear right 20
5 Leakage line 20 and 21
6 Brake 20 and 21
BW 141 - 154 AC-4 -M7-
008 910 92 BOMAG 421

Service Training
AC sprinkler system
Emulsion tank

diagram
1 Emulsion tank
2 Filter emulsion sprinkling system
3 Emulsion pump M 03 Page 005
BW 141 - 154 AC-4 -M8-
422 BOMAG 008 910 92

Service Training
Emulsion pump
1
2
3
4

diagram
1 Pump M 03 Page 005
2 Inlet from emulsion tank
3 Inlet from water tank
4 Outlet sprinkling fpr rubber tires
The AC sprinkler system is controlled via the sprinkler system module A04
BW 141 - 154 AC-4 -M9-
008 910 92 BOMAG 423

424 BOMAG 008 910 92

008 910 92 BOMAG 425

426 BOMAG 008 910 92

008 910 92 BOMAG 427

428 BOMAG 008 910 92

12 Engine
008 910 92 BOMAG 429

12.1 General information on diesel engine
12.1 General information on diesel

engine
Fig. 1 Engine compartment, left hand side toothed timing belt, compared with the predecessor
Tandem rollers series BW141/154 AD/AC-4 are pow- 1011 F.
ered by a Deutz diesel engine series BF4M 2011.
The engines are characterized by the following posi-
tive features:
In contrast to the 1011/2011 engines already used by
BOMAG this engine is fitted with an external oil cool-
ing system, i.e. a separate oil cooler with hydraulically
driven fan, instead of the established integrated oil
cooler/fan system.
The engine is characterized by the following positive
features:
●
short and compact design
●
low noise level
●
low vibration operation
●
low fuel consumption
●
low exhaust emissions
● excellent access to all service locations.
● due to the automatic tensioning device and an im-
proved enclosure for the belt drive, extended main-
tenance interval (5000 operating hours) for the
430 BOMAG 008 910 92

General information on diesel engine 12.1
Fig. 2 Engine compartment, right hand side

The engine is an 4-cylinder 4-stroke inline engine with
direct fuel injection
The combustion method with direct fuel injection ena-
bles the use of a less complicated cast part for the cyl-
inder head, excellent utilization of the fuel and minimal
heat dissipation.
This in turn allows for the use of a smaller and more
compact radiator.
Both crankcase with cylinders as well as the cylinder
head of this engine are made of a grey cast iron alloy.
This provides stability and high wear resistance.
The forged steel conrods are designed with balancing
weights in the area of the conrod bearing seats. These
weights compensate manufacturing tolerances with
respect to weight and position of the centre of gravity.
The pistons are made of aluminium alloy. The com-
bustion chamber trough is specially shaped to serve a
more efficient combustion. All pistons are fitted with
three piston rings and are oil mist lubricated.
Each of the cylinders has an intake and an outlet
valve. The valve guides are shrunk into the cylinder
head.
008 910 92 BOMAG 431

12.2 Operation side
12.2 Operation side
Fig. 1 Operation side 17 Injection valve(s)

1 Suction pipe 18 Glow plugs
2 Fan, not used on BW 141/151/154
3 V-belt pulley on crankshaft
4 Narrow V-belt
5 Engine solenoid
6 Toothed belt cover
7 Shut down lever
8 Control lever
9 Oil filler neck (on side of crankcase)
10 Oil dipstick
11 Fuel lift pump
12 Fuel filter
13 Oil heater connection
14 Replaceable lubrication oil filter
15 Injection pump(s)
16 Oil cooler connection
432 BOMAG 008 910 92

Exhaust side 12.3
12.3 Exhaust side
Fig. 1 Exhaust side

1 Valve cover
2 Exhaust manifold
3 SAE-housing
4 Starter motor
5 Crankcase
6 Oil pipe (old)
7 Exhaust turbo charger
8 Generator with cover plate
9 Charge air line
10 Oil filler neck
008 910 92 BOMAG 433

12.4 Lubrication oil circuit
Fig. 1 Lubrication oil circuit 17 Oil return flow through crankcase into oil sump
1 Oil sump 18 Lubrication oil flow to exhaust turbo charger
2 Oil suction pipe 19 Exhaust turbo charger
3 Oil pump 20 Return flow from exhaust turbo charger to oil
4 Main oil channel sump
5 Oil cooled cylinders
6 Cylinder head cooling groove
7 Oil gallery for rocker arm lubrication
8 Rocker arm
9 Oil manifold to thermostat
10 Feed to external engine oil cooler
11 Return flow from external engine oil cooler
12 Thermostat housing with slide-type thermostat
13 Oil gallery to oil filter
14 Oil filter
15 Oil gallery to camshaft, conrod and crankshaft
bearings
16 Spray nozzle for piston cooling
434 BOMAG 008 910 92

Lubrication oil circuit 12.4
Hydraulic injection timing mechanism HSV (ar- General
row) The oil inside the combustion engine has the function
The injection timing must be delayed in order to com- of lubricating and cooling all drive components, re-
ply with the statutory exhaust regulations. This de- moving impurities and neutralizing chemically effec-
layed injection causes an increasing amount of white tive combustion products, transferring forces and
smoke from the engine during cold starting. In order to damping vibrations.. The oil is only able to fulfil this
avoid white smoke the manufacturer developed a so- function, if sufficient quantities are transported to the
called "White Smoke Kit", which mainly enables critical points in the engine and if its properties are
switchable injection timing in dependence on the en- adapted to the prevailing requirements by corre-
gine temperature. This "switchability" is realized by sponding manufacturing processes and refining (addi-
the installed hydraulic pump plungers, which change tives).
their start of delivery in dependence on the oil temper- (Fig. 1) shows pressure circulation lubrication in com-
ature. bination with splash and oil mist lubrication. Here oil is
A, engine is cold (the pistons inside the pump plung- transported under pressure to all bearing locations by
ers are supplied with oil, in order to advance the start the oil pump (3), while sliding surfaces are splash or
of delivery). oil mist lubricated. After flowing through the bearing
B, engine is warm. locations and along sliding surfaces the oil is collected
in the oil sump (1) under the drive, where the oil is
cooled, defoamed by calming and stored.
i Note
The oil filter (14) removes solid foreign particles from
Due to continuous further development of the injection the engine oil (combustion residues, metal abrasion,
system and the very tight manufacturing and adjust- dust) and thus maintains the function of the lubrication
ment tolerances used in series 2011 engines, a tech- oil during the maintenance intervals.
nical status has been reached, which requires the use
of the installed hydraulic injection timing mechanisms
in suction and turbo chanrged engines only under very
specific boundary conditions.
The conversion to without hydraulic injection tim-
ing mechanism was launched at the 1st of April
2005!
Fig. 2 Engine oil cooler

The engine oil is cooled in an external engine oil cool-
er (Fig. 2).
008 910 92 BOMAG 435

Heating
The heat generated in the cooling oil circuit is dissipat-
ed through a heat exchanger and used to heat the
driver's cab. For this purpose the cooling oil flow from
the engine is routed through a heat exchanger. At
cooling oil temperatures above 93° C the cooling oil
flow through the engine oil cooler is enabled by ther-
mostat 2 (Fig. 3) and (Fig. 4).
Fig. 4
Pressure relief valves and thermostat are located be-
hind the plugs.
Tightening torque 2 (Fig. 4) 75 Nm
Fig. 3 Cooling oil circuit with heat exchanger heating Tightening torque (3, 5, 6 and 7) 111 Nm
1 Oil pump with pressure relief valve
2 Thermostat
3 Pressure relief valve 3.0 bar (without heating con-
nection, pressure spring with green colour mark)
4 Heat exchanger
5 Pressure relief valve 1.0 bar (with heating connec-
tion, pressure spring with yellow colour mark)
tion, pressure spring with blue colour mark)
tion, pressure spring with red colour mark)
8 Engine oil cooler
Fig. 5
i Note
Observe the assembly direction of the pressure relief
valves (Fig. 5).
Fit the plugs with new copper sealing rings.
436 BOMAG 008 910 92

Oil pressure switch and low oil pressure circuitry 12.5
12.5 Oil pressure switch and low oil
pressure circuitry
Fig. 1
1 Oil pressure switch
Pos. Designation in Designation Technical data

circuit diagram
1 B06 Oil pressure switch Below 0.8 bar the contact switches to
engine ground, closed without pres-
sure. Tightening torque 20 ± 2 Nm
with copper ring. Max current con-
sumption 130 mA.
General:
After starting the oil pressure switch (B06) reports
when a safe operating pressure has been reached
and causes the warning light (H09) in the monitoring
board (A15) to light, if the engine oil pressure drops
below approx. 0.8 bar.
In case of too low engine oil pressure with the engine
running, the module (A68, terminal 8) will send a time
delayed (10 sec.) signal to relay K22 (terminal 85).
The relay interrupts the electric power supply to the
solenoid valve (Y13) and the diesel engine is shut
down.
008 910 92 BOMAG 437

12.6 Coolant temperature switch
12.6 Coolant temperature switch
Fig. 1 Coolant temperature switch

circuit diagram
B30 Coolant temperature switch Contact switches to engine ground
(switch off point 5°C below switch on
point)
Tightening torque 25 ± 2.5 Nm
Switching power 1.2 to 3 Watt.
1. Step changeover from 130 ± 3°C to 135 ± 3°C;

i Note
from production December 2003.
On series 2011 engines the temperature monitoring
system was changed to a switching point 140°C. This 2. Step changeover from 135 ± 3°C to 140 ± 3°C; ap-
change was made in two steps. prox. from production April 2004.
438 BOMAG 008 910 92

Fig. 1
1 Generator (G02)

circuit diagram
B+ B+ Battery Plus 14.4 Volt, 90 Amp.
D+ D+ Dynamo Plus 14.4 Volt, maximum load 0.2 Amp.
W W Rotational speed signal pulsing D.C. voltage to determine the
engine speed
008 910 92 BOMAG 439

When cleaning the generator with a steam or wa-

General ter jet make sure not to direct the steam or water
The generator should be of light weight, have a high jet directly on or into the generator openings or
rate of efficiency and supply all consumers in the ve- ball bearings. After cleaning the generator should
hicle with electric current at a steady voltage already be operated for about 1 - 2 minutes to remove any
at idling speed. deposits of water from the generator.
i Note
The generator is maintenance free. Function tests and
repair work must only be performed in authorized
workshops.
Fig. 2
! Caution
Tightening torque D+ maximum 2.7 to 3.8 Nm.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be
loosened. This nut must in this case be retight-
ened.
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
disconnect the generator while the engine is run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
ly limited.
Plus and minus cables must be disconnected dur-
ing rapid charging of the battery or electric weld-
ing on the vehicle.
440 BOMAG 008 910 92

Fuel circuit 12.8
12.8 Fuel circuit
Fig. 1 Fuel circuit

1 Fuel line from fuel tank to fuel lift pump
2 Fuel lift pump
3 Fuel line from fuel lift pump to fuel filter
4 Fuel filter
5 Fuel line from filter to injection pump
6 Injection pump
7 Injection line
8 Injection valves
9 Fuel overflow valve
Connections:
x, fuel supply line
y, fuel return line
008 910 92 BOMAG 441

12.9 Fuel supply
12.9 Fuel supply
Fig. 1 Fuel supply

1 Fuel pre-filter
2 Sensor water separator
3 Supply line
4 Return line
442 BOMAG 008 910 92

Injection system 12.10
Work in the low pressure system 12.10Injection system
Service and repair work in the low pressure system,
including main fuel filter changes, are only permitted The injection system serves the fuel supply for the die-
under absolutely clean environmental conditions, be- sel engine.
cause even smallest dirt particles entering into the The low pressure side of an injection system includes
high pressure fuel system will cause considerable fuel tank, fuel filter and fuel lines.
damage. Air pollution, like dirt, dust, moisture etc. In the high pressure side the injection pump generates
must be strictly avoided. Before starting work in the the pressure required for injection. The fuel is pumped
fuel system (including filter changes) the engine must through the pressure line to the injection pump, from
be thoroughly cleaned and dried (steam cleaning where it is injected into the combustion chamber.
equipment). Engine compartments in which dirt de-
Load and speed of the diesel engine are adjusted via
posits may come loose, must be covered with new
the fuel quantity without throttling the intake air. With
and clean foil. When working in the open you may
a sufficient injection quantity the speed of an unloaded
need to apply protective measures against dust enter-
diesel engine may therefore rise up to the point of self
ing because of wind.
destruction. A governor for engine speed limitation is
therefore required.
! Danger
For diesel fuel the ignition temperature, i.e. the Plug-in injection pumps
temperature at which fuel will ignite when coming
Deutz diesel engines series 2011 are equipped with
into contact with air, is approx. 220°C, but may de-
plug-type injection pumps.
viate strongly because of impurities.
The concept of plug-in injection pumps enables the re-
Fuel conducting components and lines therefore alization of high injection pressures, combined with
are a source of danger inside the engine compart- short injection lines, which is necessary to ensure a
ment, because leaks may lead to fire resulting in high hydraulic stiffness of the injection system. This, in
considerably damage to material and persons. turn, creates the prerequisite for maintaining low ex-
haust emission values (soot) in combination with low
fuel consumption values.
008 910 92 BOMAG 443

12.10 Injection system
Fig. 2 Injection pump design

Elements with a leak oil return passage to the suction
1 Pressure valve holder chamber are used to avoid lubrication oil dilution. A
2 0-ring ring groove 6 (Fig. 3) in the pump cylinder, which is
3 Spring for plug connected with the injection pump suction chamber by
a bore, serves this purpose. This groove guides leak
4 Plug
fuel and leak oil back into the suction chamber.
5 Washer
6 Intermediate piece
7 Filler
8 Shim
9 Valve spring
10 Seal ring
11 Relief valve
12 Pump element
13 Locating pin
14 Bushing
15 0-ring seal
16 Grub screw (cavitation protection)
17 Cavitation protection
18 Seal ring
Fig. 3
19 Locking disc
1 Control bore
20 Excentric bolt
2 Longitudinal groove
21 0-ring seal
3 Cylinder
22 Housing
4 Control edge
23 Protection ring
5 Leak oil return
24 Driver ring
6 Ring groove
25 Valve spring cup (top)
7 Piston
26 Piston spring
27 Valve spring cup (bottom)
28 Roller-type plunger
444 BOMAG 008 910 92

Injection pump replacement during service 12.11
Injection valves 12.11Injection pump replacement
Injection valves have the following functions: during service
● Preparation of fuel
● Forming of the injection sequence Disassembly
● Sealing against the combustion chamber
The peak injection pressure of the diesel fuel is up to !Caution
1000 bar. Under these conditions the fuel no longer Ensure strict cleanliness when working on the in-
behaves like a rigid fluid, but it is compressible. During jection system.
the short injection period (1ms) the injection system is
"blown up" and, depending on the nozzle size, more
or less fuel will enter into the combustion chamber.
Fig. 4 Design of injection valve

1 Tensioning nut
Fig. 1
2 Nozzle
● Disassemble injection and leak oil lines (Fig. 1).
4 Pressure bolt
5 Pressure spring i Note
6 Shim Use claw-type spanner 8018 for the injection lines.

Close connections on injection pumps and injection
valves.
i Note
A thicker shim 6 (Fig. 4) increases the opening pres- ● Unscrew the fastening nuts.
sure. ●
Remove the injection pumps.
Fig. 2
●
Take out the roller-type plunger for the injection
pump (use outer circlip pliers) (Fig. 2).
008 910 92 BOMAG 445

12.11 Injection pump replacement during service
Assembly
i Note
For installation of the injection pump the roller-type
plunger must be placed on the basic circle of the cam-
shaft drive cam.
Both the installation measurement "X" and the depth
"A" must also be measured.
Fig. 3
●
Move governor rod and throttle control lever to mid-
dle position and hold.
● Turn the governor rod adjustment bolt into the
crankcase until it bottoms (Fig. 3) and (Fig. 4).
i Note
Special tool 079 947 03.
Fig. 1
1 Roller-type plunger
2 Compensation gasket
3 Camshaft
Fig. 4
●
Release the throttle control lever.
Fig. 2
● Unscrew the plug from the crankcase (Fig. 2).
Fig. 5
●
Crank the engine by the crankshaft pulley, until the
plunger stroke of the corresponding cylinder
reached BDC (Fig. 5).
446 BOMAG 008 910 92

Fig. 6 Fig. 8
●
Assemble the roller-type plunger (Fig. 6).
Caution
!
i Note The installation measurement "X" (Fig. 8) serves

Use a flexible magnetic lifter. the calculation of the compensation gasket and
cannot be measured on the dismounted injection
Determining the compensation gasket pump.
i Note
The nominal measurement "X" on the injection pump
can be enquired from the BOMAG Service Depart-
ment or the Deutz Customer Service by submitting the
data on the engine type plate. (There are various ver-
sions and adjustment measurements).
●
Calculate the difference between installation meas-
urement "X" and depth "A".
Example:
"X"= 60.00 mm
"A"=59.35 mm
Fig. 7
● Measure the depth "A" from crankcase contact sur- Difference = 0.65 mm
face to spring cup rest on the plunger. (Fig. 7)
Fig. 9
● Choose the compensation gasket from the table ac-
cording to the identification (Fig. 9).
008 910 92 BOMAG 447

Calculated Measurement BOMAG No.

difference of identification
(mm) (mm) (Fig. 9)
up to 0.4 9 057 115 44
0,401 - 0,5 12 057 115 45
0,501 - 0,6 15 057 115 46
0,601 - 0,7 18 057 115 47
0,701 - 0,8 21 057 115 48
0,801 - 0,9 24 057 115 49
0,901 - 1,0 27 057 115 50
Fig. 12
● Remove the locking pin 1 (Fig. 12) from the injection
pump.
Fig. 10
i Note
Since the compensation gasket is not marked with
part-no. and thickness of gasket, the thickness of the
gasket can be checked with the special tool 103 020 Fig. 13
(Fig. 10). ● Insert the locking wire (Fig. 13).
i Note
Special tool 100 880.
!Caution
Before assembling the injection pump make sure
that the locking wire has engaged in the control le-
ver.
Fig. 11
● Attach the selected gasket (Fig. 11).
i Note
Mind the installation position.
448 BOMAG 008 910 92

Fig. 14 Fig. 17
●
Assemble the injection pump. Press the injection ●
Remove the governor rod adjustment bolt (Fig. 17).
pump centrally in until it bottoms.
●
Tighten the nuts (Fig. 14).
Tightening torque: 21 Nm
Fig. 18
● Fit the plug with a new copper sealing ring (Fig. 18).
Fig. 15
●
Pull the locking wire back out (Fig. 15).
Fig. 19
● Connect the fuel line with new copper sealing rings..
Fig. 16 ● Tighten the banjo fittings (Fig. 19).
● Close the bore with the locking pin (Fig. 16).
008 910 92 BOMAG 449

Tightening torque: 29 ± 2 Nm
Fig. 22
Fig. 20
●
Connect the rubber hose to the overflow line and
fasten with a hose clamp (Fig. 22).
● Install and tighten the injection lines (Fig. 20).
i Note
i Note
Use clamping pliers 8011.
Use a claw spanner 8018.
Tightening torque: 25 ± 2,5 Nm
Fig. 23
●
Connect the rubber hose to the fuel line and fasten
Fig. 21 with a hose clamp (Fig. 23).
● Connect the rubber hose to the fuel line and fasten
with a hose clamp (Fig. 21).
i Note
●
Pull the protective hose over the rubber hose. Use clamping pliers 8011.
● Run the engine and check for leaks.
i Note
Use clamping pliers 8011.
450 BOMAG 008 910 92

Injection valve replacement during service 12.12
12.12Injection valve replacement Installation
during service
i Note
Injection valves may wear mechanically over the
course of time. Spray pattern and injection pressure
should be tested on an injection valve test bench ("hy-
drostesting"). The nozzles must be disassembled for
this purpose. In case of excessive deposits on the
nozzles these may be cleaned in an ultrasonic bath
with gasoline. The injection pressure can be corrected
by means of shims.
!Caution
Ensure strict cleanliness when working on the in- Fig. 1
jection system. Use only clean testing oil acc. to ● Slide the seal ring with some grease over the injec-
ISO 4113 or clean diesel fuel to test the injection tion valve (Fig. 1).
valves.
Removal
Fig. 2
●
Insert the injection valves (Fig. 2).
Fig. 1
i Note
●
Disassemble the injection lines. The leak fuel connection must face towards the ex-
haust side.
i Note
Use claw-type spanner 8018 for the injection lines.
Close connections on injection pumps and injection
valves.
● Remove the clamping claws (Fig. 1).
● Disassemble the injection valves.
Fig. 3
● Attach the clamping claws (Fig. 3).
008 910 92 BOMAG 451

12.13 Checking / repairing injection valves
i Note 12.13Checking / repairing injection

Mind the installation position of the clamping claws. valves
Special tools:
Nozzle tester 8008
Holder for Injection valve 110 110
Long socket OW 15, 8021
!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.
Fig. 4
●
Tighten the screws (Fig. 4).
● Install and tighten the injection lines.
i Note
Use a claw spanner 8018.
Tightening torque: 25 ± 2,5 Nm

●
Run the engine and check for leaks.
Fig. 5
● Mount the injection valve to the nozzle tester (Fig.
5).
Checking the opening pressure
Fig. 1
Danger
!
Keep your hands away from the nozzle spray jet.

Fuel will penetrate deeply into the flesh and may
cause blood poisoning.
452 BOMAG 008 910 92

Checking / repairing injection valves 12.13
i Note
Slowly press the lever of the nozzle tester down with
the pressure gauge connected . The opening pres-
sure is reached, when the pointer stops or suddenly
drops.
Opening pressure for new adjustment: 210 + 8 bar.
Adjusting tze opening pressure on the in-

jection valve
Fig. 3
!Caution
Nozzle needle and nozzle body have been fitted
by lapping and must never be mixed up by mis-
take or replaced individually. Do not touch the
nozzle needle with your fingers. With the nozzle
body in vertical position, the nozzle needle must
smoothly slide on its seat just by its own weight
(Fig. 3).
Fig. 1
● Unscrew the spigot nut and remove all parts (Fig. i Note
1). If the needle slides down jerkily, wash out the nozzle
body with diesel fuel again, replace if necessary.
Clean the new injection nozzle also in clean diesel fu-
el.
Fig. 2
Sequence of disassembly (Fig. 2):
1 Spigot nut
2 Injection nozzle
Fig. 4
● Check the seat areas of the intermediate piece for
4 Pressure bolt
signs of wear. Make sure that the centring pins are
5 Pressure spring present (Fig. 4).
6 Shim
● Clean all parts with clean diesel fuel and blow off
with compressed air.
008 910 92 BOMAG 453

Fig. 5 Fig. 8
●
Assemble the shim (Fig. 5). ●
Insert the centring pins of the intermediate piece
into the bores of the nozzle holder (Fig. 8).
i Note
A thicker shim increases the opening pressure. i Note
The chamfer points towards the pressure bolt.
Fig. 6
Fig. 9
●
Assemble the pressure spring. ● Attach the centring bores of the injection nozzle to
the centring pins of the intermediate piece (Fig. 9).
i Note
The nozzle needle must not drop out of the nozzle
body.
Fig. 7
● Install the pressure bolt with the centring collar to-
wards the pressure spring (Fig. 7).
454 BOMAG 008 910 92

Checking / repairing injection valves 12.13
Leak test
Fig. 10
●
Turn on the spigot nut . Fig. 1
● Dry nozzle and nozzle holder - blow dry with com-
pressed air.
● Press the hand klever of the tester slowly down, to
a point about 20 bar before the previously indicated
opening pressure (Fig. 1).
Fig. 11
● Tighten the spigot nut.
Tightening torque: 45 ± 5 Nm
Fig. 2
i Note
The nozzle is leak tight, if no drop drips off within a pe-
riod of 10 seconds.
! Caution
If a drop drips off (Fig. 2), the injection valve must
be dismantled and the leak must be eliminated by
thorough cleaning. If this does not lead to a suc-
cess, replace the injection nozzle.
Rework is not permitted!
008 910 92 BOMAG 455

Rattle and spray pattern test
Fig. 1
●
Switch off the pressure gauge on the tester.
i Note
The rattle test enables audible testing of the nozzle
needle movement inside the nozzle body. In compar-
ison with used injection valves, new ones have a dif-
ferent rattling behaviour. It becomes worse as the
wear in the needle seat area progresses.
!Caution
A used injection valve must audibly rattle and
spray off well atomized fuel when operating the le-
ver quickly. The spray pattern may be noticeably
different from the one produced by a new injection
valve.
If an injection nozzle does not rattle despite of
cleaning, it nees to be replaced by a new one!
456 BOMAG 008 910 92

Fuel filter 12.14
12.14Fuel filter
Fig. 1 Fuel pre-filter

1 Hand pump
2 Bleeding valve
3 Filter element
4 Water and dirt collecting bowl
5 Drain valve
6 Water separator sensor connection (B124)
7 Fuel pre-heating connection (R79) 200 Watt (op-
tion)
008 910 92 BOMAG 457

12.14 Fuel filter
General ● Open the drain valve and drain off approx. 0.5 l of
The quality of the fuel filter and the compliance with fuel. The fuel above the filter element presses
the specified service intervals are decisive for the life- through the filter element and frees the underside
time of the fuel injection system. The heart of the fuel from dirt.
filter is made of hydrophobic special paper, which is ● Close the drain valve again.
spirally wound in form of a bag in order to offer the
largest possible filtering area under the prevailing spa- Perform
tial conditions and thus to achieve a high lifetime in
combination with a high dirt retaining capacity. A power drop or poor starting of the engine is mainly
caused by leaks in the fuel system. If you suspect a fil-
The fuel pre-filter / water separator mainly consists of:
ter problem, you should check whether bleeding
●
the dirt / water collecting bowl screw and drain valve are tightly closed and the filter
element is flush with the sight glass. Check the filter
● and the filter element
connections for leaks and the lines for clogging or po-
rous points.
Function
The fuel lift pump draws the fuel through this filter.
Any water contained in the fuel deposits on the dirt
side of the filter paper and separates from the fuel in
form of large drops on the clean side of the filter (coa-
lescence effect).
Water is heavier than diesel fuel, it settles as a differ-
ent colour fluid on the bottom.
Once the water level reaches the height of the warn-
ing connections (sensor B124), the warning lamp
(H70) in the monitoring board (A15) will come on.
Fuel pre-heating (option)

In diesel engines the pre-heating of the fuel prevents
malfunctions caused by the formation of jelly (paraffin
separation) in the fuel under low temperatures.
The integrated heating is a starting aid for cold weath-
er applications. The heating is delivered with an auto-
matic thermostat to start the heating when the fuel
temperature drops below 7°C. The generated heat
works directly under the filter element and melts the
wax crystals that have formed, so that the fuel can
flow through the filter element without restriction. The
heating automatically shuts down at a fuel tempera-
ture of 24°C. The 200W heating is supplied with 12V
D.C-current. The heater is activated when operating
the ignition switch; this should take place at least 5
minutes before starting the engine.
A normal On/Off switch may be installed to operate
the relay. This can be used to e.g. interrupt the current
flow to the relay in the summer season.
Draining off water or fuel

Should the filter element be clogged prematurely (no-
ticeable e.g. by a drop in power), operation of the ma-
chine can be continued with the following procedure:
● Open the bleeding screw (this applies atmospheric
pressure to the filter element and loosens larger dirt
particles from the underside of the filter, which will
then drop down).
458 BOMAG 008 910 92

Checking the compression 12.15
12.15Checking the compression
● Adjust the valves.
● Disassemble the injection valves.
Fig. 3
Compression:
FL/M 25 - 30 bar
BFL/M 22 - 27 bar
Fig. 1
●
Install the adapter with special seal (Fig. 1). i Note
●
Attach the clamping claw. The measured compression (Fig. 3) depends on the
starter speed during the measuring process and the
●
Tighten the screw. altitude of the engine location. Limit values can there-
fore not be specified exactly. It is recommended to
use the compression measurement to compare the
cylinders of an engine among each other. Should a
deviation of more than 15% be measured, the affected
cylinders should be dismantled to examine the cause.
● Disconnect the compression tester.
● Install the injection valves.
Fig. 2
● Connect the compression tester (Fig. 2).
●
Crank the engine with the starter.
008 910 92 BOMAG 459

12.16 Boost fuel and minus balancing solenoid valve
12.16Boost fuel and minus balanc-

ing solenoid valve
Fig. 1 2 Boost fuel solenoid valve

1 Solenoid valve to shut off the LDA-function

circuit diagram
1 Y139 Minus balancing solenoid valve 12 Volt, approx. 4,5 Amp.
2 Y01 Boost fuel solenoid valve 12 Volt, approx. 3,5 Amp.
General quantity that matches the available amount of com-

During the starting process both solenoid valves are bustion air.
supplied with 12 Volt. The minus balancing solenoid valve (Y139) disables
This injection adaptation serves the purpose of com- the charge pressure dependent full load stop during
pensating for condensation and leakage losses and starting.
for rising the engine torque during the acceleration
phase after starting. For this compensation and to as-
sure starting of the cold engine additional fuel needs
to be injected at the time of starting and accelerating.
i Note
In order to avoid soot emissions on turbo charged en-
gines when suddenly changing from low to full load,
the governor is equipped with a charge pressure de-
pendent full load stop. This device will only allow a fuel
460 BOMAG 008 910 92

Boost fuel and minus balancing solenoid valve 12.16
Fig. 2
With the boost fuel suppression switch S182 (Fig. 2)
the boost fuel quantity can be switched over to sum-
mer or winter operation.
008 910 92 BOMAG 461

12.17 Engine shut-down solenoid
12.17Engine shut-down solenoid
Fig. 1
1 Engine shut-down solenoid

circuit diagram
1 Y13 Engine solenoid 12 Volt, approx. 4 Amp.
General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the module (A68) in case of too low oil pres-
sure (terminal 8).
462 BOMAG 008 910 92

Air filter, differential pressure switch 12.18
12.18Air filter, differential pressure
switch
Fig. 1
1 Differential pressure switch

circuit diagram
1 B03 Differential pressure switch switched to ground at a differential
pressure of > 50 mbar.
!Caution General
Combustion air lines between filter and engine The air filter retains the dust contained in the intake air
("clean air lines") must be absolutely leak tight and keeps it away from the engine in order to avoid
and withstand mechanical loads caused by en- engine wear.
gine vibrations and pressure pulsation. On paved roads the dust content in the air is 1 mg/m3
on average, on sealed roads or construction sites the
dust content can rise up to 40 mg/m3.
Dry air filters with integrated dust separator are char-
acterized by a good filtering effect (irrespective of en-
gine speed and inclination) and thus enable long
lasting and low wear engine operation.
The air filter has the additional function of damping the
air intake noise. This damping is achieved by the de-
sign of the air filter in from of a reflection silencer
008 910 92 BOMAG 463

12.18 Air filter, differential pressure switch
based on the principle of a Helmholz resonator, damp-

ing the intake noise by its resonance frequency.
The differential pressure switch 1 (Fig. 1) in the air in-
take hose energizes the control light (H15) in the mon-
itoring board (A15) when the pressure difference
between atmospheric pressure and intake pressure
exceeds > 50 mbar. This indicates that the air filter
does not allow sufficient air flow to the combustion
chamber.
Crankcase ventilation
During the combustion process in a diesel engine cer-
tain waste gas quantities escape through the ring
gaps on pistons and piston rings into the crankcase.
The crankcase ventilation serves the discharge of
these waste gases.
The engines are by standard and currently only
equipped with open crankcase ventilation. A crank-
case ventilation valve with oil separator separates
most of the oil from the waste gas and returns it into
the engine. The waste gas itself escapes into the at-
mosphere.
464 BOMAG 008 910 92

Electric throttle control 12.19
12.19Electric throttle control
Fig. 1 Engine solenoid
Throttle control switch
Fig. 2 Throttle control switch

The throttle control switch (S120) is used to change
from "MIN" to "MAX" idle speed and vice versa.
008 910 92 BOMAG 465

12.19 Electric throttle control
Throttle control solenoid Y120

i Note
When switching on, the solenoid plunger is pulled
against the stop. The limit switch then switches the
pick-up and holding winding in series. The current flow
is reduced from approx. 70 A to approx. 3.5 A.
Fig. 3 Electric circuit of solenoid

The throttle control solenoid 5 (Fig. 3)) is equipped
with a pick-up winding (4) and a holding winding (3), Fig. 5
both switched in series. The holding winding has a ●
Measure the gap between stop screw 1 (Fig. 5) and
much higher resistance than the pick-up winding. The
throttle lever (2).
"aux"-connection is connected between the two wind-
ings. The engine solenoid is equipped with a limit
switch (2), which is mechanically connected with the ! Caution
governor rod (1) on the diesel engine. This switch The gap should be min. 0.1 mm and max. 0.5 mm.
bridges the holding winding until the end position of
the governor rod is reached (high engine speed) If the gap is too small, the limit switch in the sole-
noid may not be able to operate.
This bridging has the effect, that the "aux"-terminal
has the same potential as the "+"-terminal. If the In case of a too wide gap the engine will not reach
bridge is open, the "aux"-terminal has almost the its maximum speed.
same potential as the "-" terminal, because of the low
resistance of the pick-up winding and the high resist-
ance of the holding winding.
Adjusting the solenoid
Fig. 4
● Switch on the ignition.
● Turn the rotary switch (Fig. 4) to position "MAX".
466 BOMAG 008 910 92

Glow plugs 12.20
12.20Glow plugs
The heating power improves the cold starting charac-
teristics and the exhaust emissions (white smoke) of
the diesel engine.
Fig. 1 Glow plugs

circuit diagram
1 R02 Glow plugs 12 Volt, current consumption approx.
50 Amp.
008 910 92 BOMAG 467

12.20 Glow plugs
Fig. 2 Glow plug control

circuit diagram
1 K14 Preheating relay 12 Volt
2 A13 Heating control unit 12 Volt
3 S182 Switch for boost fuel suppression 12 Volt
Above 0°C the control unit 2 (Fig. 2) is without func-

tion.
The control unit is able to control the glowing time for
the glow plug optimally.
Here we talk about a function range from minus 30°C
to plus 10+5 °C, so that post-heating for improving the
white smoke characteristic at temperatures abobe 0
°C is also possible
468 BOMAG 008 910 92

Glow plugs 12.20
Fig. 3 Fuses

circuit diagram
1 F158 Fuse for glow plug 1 12 Volt, 50 Amp.
2 F159 Fuse for glow plug 2 12 Volt, 50 Amp.
3 F00 Main fuse 12 Volt, 125 Amp.
008 910 92 BOMAG 469

12.21 Engine monitoring
12.21Engine monitoring
Fig. 1 Monitoring module, old design
Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time
10 sec. 2 min.
a H49, control light en- red, flashing X X Switch off vibration, run
gine overheating engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
b H09, engine oil pres- red, flashing X X Check the engine oil lev-
sure control light el, if necessary repair the
engine.
c H15, engine air filter yellow, lights If necessary clean or re-
control light place engine air filter
d H08, charge control yellow, lights Check V-belt, if neces-
light sary repair the generator
i H70, control light, yellow, lights Check, clean the water
water in diesel filter separator
k H52, pre-heating yellow, lights
control light yellow, flashes see chapter "Check heat-
in case of fault ing flange control"
j Coolant provision not used
470 BOMAG 008 910 92

Engine monitoring 12.21
Fig. 2 Monitoring module, new design
Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time
10 sec. 2 min.
i H49, control light en- red, flashing X X Switch off vibration, run
gine overheating engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
e H09, engine oil pres- red, flashing X X Check the engine oil lev-
sure control light el, if necessary repair the
engine.
h H15, engine air filter yellow, lights If necessary clean or re-
control light place engine air filter
g H08, charge control yellow, lights Check V-belt, if neces-
light sary repair the generator
b H70, control light, wa- yellow, lights Check, clean the water
ter in diesel filter separator
c H52, pre-heating con- yellow, lights
trol light yellow, flash- see chapter "Check heat-
es in case of ing flange control"
fault
f Coolant provision not used
008 910 92 BOMAG 471

12.21 Engine monitoring
Checking the engine monitoring system

i Note
The following control lights and shut-down functions Control light i (Fig. 1) b (Fig. 2) lights up.
can be checked with the engine running:
●
Push the plug back together, the plug interlock
Air filter clicks into place.
● Check the plug interlock by lightly pulling on the wir-
ing loom.
Engine oil pressure
Fig. 3 Differential pressure switch

● Press on the locking wire and pull the plug off the
differential pressure switch 1 (Fig. 3).
● Bridge both contacts on the plug of the wiring loom. Fig. 5 Oil pressure switch
●
Pull off plug 1 (Fig. 5).
i Note
● Connect the plug contact to engine ground.
Control light c (Fig. 1) h (Fig. 2) lights up. No audible
will sound and the engine will not be shut down.
●
Push the plug back on, the plug interlock clicks into
i Note
place. The control light b (Fig. 1) e (Fig. 2) flashes. An audi-
ble warning will sound and the engine is shut down af-
● Check the plug interlock by lightly pulling on the wir- ter 10 seconds.
ing loom.
●
Push the plug back on.
Water separator
Engine overheating
Fig. 4 Sensor water separator

Fig. 6 Coolant temperature switch
● Press the plug interlock and disconnect the plug
(Deutsch plug).
● Pull off plug (Fig. 6).
●
Bridge both contacts on the plug of the wiring loom.
● Bridge both contacts on the plug of the wiring loom.
472 BOMAG 008 910 92

Engine monitoring 12.21
i Note
Control light a (Fig. 1) i (Fig. 2) flashes. An audible
warning will sound and the engine is shut down after
2 minutes.
●
Push the plug contacts back on.
Emergency stop switch
Fig. 7 Emergency stop switch

● Press the emergency stop switch (Fig. 7). The en-
gine should stop immediately.
008 910 92 BOMAG 473

12.22 Engine
12.22Engine
Faults Possible cause Remedy
The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank
Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.
Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.
Fuel lines leaking Check all line connections for leakages

and tighten the fittings.
Battery discharged or not connected Tighten the pole clamps, check the cable
connections
Injection valves or injection pump defec- Have examined by a specialist

tive
The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature
Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Incorrect valve clearance Adjust the valve clearance
Injection valve defective Have examined by a specialist
Injection lines leaking Check the lines for leakages
Turbo charger defective Have examined by a specialist
Dry air filter dirty clean, replace if necessary
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary
Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance
474 BOMAG 008 910 92

Engine 12.22
Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Engine oil level too low Top up engine oil to the upper dipstick
mark
Filling capacity of the injection pump not Have adjusted by a specialist

correctly adjusted
Cooling air flow restricted Clean the cooling air duct
V-belt loos or broken Tension or replace the V-belt
Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark
Dry air filter dirty clean, change if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Charge air hose leaking Check fastening and connections
Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine oil pressure" lights, the warning
buzzer sounds)
Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective
008 910 92 BOMAG 475

12.23 Check the engine oil level
12.23Check the engine oil level 12.24Change the engine oil
! Danger
Danger of scalding!
Danger of scalding when draining off hot engine
oil!
i Note
Drain the oil only when the engine is warm.
For quality and quantity of oil refer to the section

on fuels and lubricants as well as the section on
fuels, lubricants and filling capacities.
Fig. 8
Environment
i Note Do not let old oil seep into the ground, but dispose
Park the machine horizontally, shut down the engine off environmentally.
and wait for 5 minutes. ● Open the right hand service door.
●
Open the right hand service door. ●
Unscrew the oil filler cap.
●
Pull the dipstick (Fig. 8) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
● Pull the dipstick back out again.
●
Check the oil level, top up to MAX-mark if neces-
sary.
●
If the oil level is too low top up oil immediately.
For quality of oil refer to the table of fuels, lubri-

cants and filling capacities.
●
Check the oil level again after running the engine for
approx. 1 minute.
!Caution Fig. 9
Before longer work periods you should always top ● Unscrew the drain plug (Fig. 9), catch running out
the oil up to the "MAX"-mark. oil.
● Screw the plugs back in.
476 BOMAG 008 910 92

Change the engine oil filter cartridge 12.25
12.25Change the engine oil filter
cartridge
Danger
!
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the filter cartridge.
Caution
!
Catch running out oil, e.g. with a cloth.

Fig. 10
● Fill in new engine oil (Fig. 10) through the oil filler Environment
neck. Do not let old oil seep into the ground, but dispose
off environmentally.
● Screw the cover back on.
● Open the right hand service door.
Fig. 11
●
After a short test run check the oil level on the dip- Fig. 12
stick (Fig. 11). The oil level should reach the MAX- ● Loosen and unscrew the fuel filter cartridge (Fig.
mark, top up oil if necessary. 12) using an appropriate filter wrench.
● Wipe the sealing face clean.
● Cover the rubber seal of the new filter cartridge
slightly with clean oil.
● Spin the new fuel filter cartridge on and tighten it
hand tight.
● Perform a short test run and inspect the engine for
leaks and check the oil level, top up oil if necessary.
008 910 92 BOMAG 477

12.26 Check condition of engine oil and hydraulic oil cooler, clean
12.26Check condition of engine oil 12.27Check, clean the water sepa-

and hydraulic oil cooler, clean rator
i Note i Note
Dirty operating conditions, particularly lubrication oil The service intervals for the water separator depend
and fuel deposits on the cooling fins reduce the cool- on the water content in the fuel and can therefore not
ing effect. You should therefore immediately seal any be determined precisely. After taking the engine into
oil or fuel leaks near cooling fan, cylinder or oil cooler operation you should therefore check the filter bowl in-
and subsequently clean the cooling fins. itially every day for signs of water.
Danger
! Environment
Danger of injury! Catch running out fuel and dispose of environ-
mentally.
Perform cleaning work only with engine stopped
and cooled down!
Fig. 14
Fig. 13
● Slacken the drain plug (Fig. 14) for a few turns and
catch running out fuel / water.
● Remove dried on dirt from the cooling fins with a
suitable brush. ● Tighten the drain plug again and check for leaks, if
necessary replace the seal ring.
●
Blow coolers (Fig. 13) out with compressed air. Re-
move all dirt that has been blown into the engine ● Open the fuel shut-off valve .
compartment.
●
In case of oily dirt spray the cooler with a cold
cleansing agent and let it soak in for about 10 min-
utes.
Environment
Catch running off fluid and dispose of environ-
mentally.
● Clean off with water or steam jet.
● Repeat the process if necessary.
478 BOMAG 008 910 92

Change the fuel pre-filter cartridge 12.28
12.28Change the fuel pre-filter car-
tridge
Danger
!
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.
Fig. 17
●
Unscrew the water separator from the filter car-
tridge.
Fig. 15
● Close the fuel shut-off valve (Fig. 15).
Fig. 18
● Apply a thin coat of oil to the rubber seal of the water
separator 1 (Fig. 18).
●
Screw the water separator on by hand (2), until the
seal contacts.
●
Tighten the water separator for another half turn (3).
●
Fill the filter cartridge with clean diesel fuel (4).
●
Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
Fig. 16
● Tighten the filter element for another half turn (6).
●
Unscrew the fuel filter cartridge (Fig. 16) using an ●
Check the filter cartridge for leaks after a short test
appropriate filter wrench. run.
● Clean the sealing face on the filter carrier from any
dirt.
008 910 92 BOMAG 479

12.29 Change the fuel filter cartridge
12.29Change the fuel filter cartridge 12.30Check, adjust the valve clear-
ance
! Danger
Fire hazard! Caution

!
When working on the fuel system do not use open Before checking the valve clearance let the engine
fire, do not smoke and do not spill any fuel. cool down for at least 30 minutes. The engine oil
temperature must be less than 80 °C.
Catch running out fuel, do not let it seep into the
ground. Valve clearance
Do not inhale any fuel fumes. Intake valve = 0,3 mm
Exhaust valve = 0,5 mm
● Open the engine hood completely and support it
safely.
Fig. 19
●
Unscrew the fuel filter cartridge (Fig. 19) using an
appropriate filter wrench.
●
Clean the sealing face on the filter carrier from any Fig. 20
dirt. ●
Remove the valve cover (Fig. 20).
●
Cover the rubber seal on the new filter cartridge
slightly with oil and fill in clean fuel.
●
Turn the new fuel filter cartridge on by hand, until
the seal contacts.
● Tighten the fuel filter cartridge for another half turn.
●
After the test drive check the filter cartridge for
leaks.
i Note
Bleeding of the fuel system is not necessary.
Fig. 21
● Unscrew the fastening screw from the plug of the
shut-down solenoid (Fig. 21) and pull off the plug.
480 BOMAG 008 910 92

Check, adjust the valve clearance 12.30
Adjusting the valve clearance
Fig. 22
● Crank the engine with the starter until both valves
Fig. 24
on cylinder 1 (Fig. 22) are “overlapping”.
● Loosen the counter 2 (Fig. 24) and regulate the set-
screw (1), until the feeler gauge can be inserted and
i Note
pulled out with little resistance after retightening the
Overlapping means that the exhaust valve is not yet counter nut.
completely closed and the intake valve starts to open.
The valves marked black (Fig. 22) can be checked Caution
!
and adjusted.
After a short test run check the engine for leaks.
Fig. 23
● Crank the engine with the starter until both valves
on cylinder 4 (Fig. 23) are “overlapping” (360° rota-
tion of the crankshaft).
The valves marked black (Fig. 23) can be checked
and adjusted.
● Assemble the cylinder head cover with a new gas-
ket.
008 910 92 BOMAG 481

12.31 Check, clean, change the combustion air filter
12.31Check, clean, change the

combustion air filter
! Caution
Perform cleaning, maintenance and repair work
only with the engine shut down. Do not start the
engine after removing the filter element.
Do not use gasoline or hot fluids to clean the filter
element.
After cleaning the filter element must be inspected
for damage using a torch.
Fig. 25 Old design
Air filter elements with damaged paper bellows or
seal lips must be replaced in any case.
The main filter element must be replaced after 3
times cleaning, but at the latest after one year, ir-
respective of the operating hours.
Each cleaning interval must be marked with a
cross on the cover of the filter element.
Cleaning does not make sense if the air filter ele-
ment is covered with a sooty deposit. Use a new
filter element.
Incorrectly handled filter elements may become
ineffective because of damage (e.g.: cracks) and
cause engine damage.
Fig. 26 New version
Maintenance of the dry air filter is due when control
light c (Fig. 25) h (Fig. 26) in the left hand instrument
cluster lights permanently when the engine is running,
but at the latest after one year.
i Note
Once the air filter service indicator lights up, work may
be continued until the end of the day.
● Open the left hand maintenance door.
Fig. 27
●
Fold three clips up and take the filter hood (Fig. 27)
off.
●
Clean filter hood and dust discharge valve.
482 BOMAG 008 910 92

Check, clean, change the combustion air filter 12.31
Fig. 28 Fig. 30
● Carefully loosen the main filter element. ● Clean the sealing face on the outlet tube (Fig. 30).
The main filter element is located directly on the air in- Dust on the outer diameter of the outlet tube can im-
take tube, thereby providing a seal on the inside of the pair effective sealing.
filter cover. Carefully remove the main filter element, ● Check the old main filter element.
in order to reduce the released amount of dust. To re-
lease the seal pull the main filter element carefully up, The old main filter element can be of help to discover
down and sideways or turn it (Fig. 28) . foreign particles on the sealing face, which could lead
to leaks. A line of dust on the clean air side of the filter
may be a sign for such a leak. Eliminate this problem
before installing a new main filter element.
● If the main filter element is damaged, the safety el-
ement must be replaced as well.
! Caution
The safety element must not be cleaned. It must
be replaced after three times cleaning of the main
filter element, but at least once every year.
Do not run the engine without an intact safety and
main filter element.
Fig. 29
●
Clean or replace the main filter element.
Caution
! i Note
Avoid contact between main filter element and We generally recommend to change the filter. A new
housing. filter element is far less expensive than a possible en-
gine damage.
● Pull the main filter element (Fig. 29) carefully out of
the housing. ● Examine the main filter element thoroughly for dam-
age.
Before installing the new main filter element check it
for possible damage from transport, cleaning or incor-
rect handling. Especially on the inside of the open end
(sealing area). Do not install damaged filter elements.
● If necessary use safety elements.
008 910 92 BOMAG 483

12.31 Check, clean, change the combustion air filter
● Blow the main filter element out with compressed

air (max. 5 bar) from inside to outside by moving the
tube up and down inside the element, until it if free
of dust.
● Examine the main filter element with a torch for
cracks and holes in the paper bellows.
! Caution
Do not continue to use a damaged main filter ele-
ment. If in doubt use a new main filter element.
Fig. 31
● Insert the main filter element (Fig. 31).
The radial sealing area is located at the inside of the
open filter edge. This critical sealing area must be un-
der slight tension after the filter has been installed. In
order to achieve a tight seal apply pressure to the out-
er edge of the filter and not to the moveable centre.
● Reinstall the filter hood with the dust discharge
valve.
Caution
!
The dust discharge valve must point vertically

downwards.
Dry cleaning of the main filter element
Danger
!
Eye injury!
Wear protective clothing (goggles, gloves).
Fig. 32
i Note
For cleaning purposes fit a tube to the compressed air
gun (Fig. 32), the end of which should be bent for ap-
prox. 90°.
The length should reach down to the bottom of the el-
ement.
484 BOMAG 008 910 92

Special tools, Deutz engine (BFM 2011) 12.32
12.32Special tools, Deutz engine
(BFM 2011)
Deutsch English Français Español No.
Kompressionsdruckprüfer 8005
057 250 67
Compression tester
Compressiomètre
Compresímetro
Düsenprüfgerät 8008
Nozzle tester
Banc d’essais d’injecteurs
Comprobador para inyectores
Klemmenzange 8011
Clip pliers
Pince pour colliers
Alicates para abrazaderas
Klauenschlüssel 8018
Claw key
Clé à griffes
Llave de garra
008 910 92 BOMAG 485

12.32 Special tools, Deutz engine (BFM 2011)
No. Deutsch English Français Español
8021 Lange Stecknuss SW 15
Long socket a/flats 15
Clé à douille longue de 15
Llave de vaso largo de 15
8024 Ventilschaftdichtungszange
Valve stem gasket pliers
Pince à joint de tige de soupape
Alicates para juntas de vástago de válvula
8036 Stecknuss SW 32
Socket a/flats 32
Clé à douille de 32
Llave de vaso de 32
8049 Kraftvervielfältiger für Zentralschraube
Multipower tool for central bolt
Multiplicateur de force pour vis centrale
Multiplicador de fuerza para tornillo central
486 BOMAG 008 910 92

008 910 92 BOMAG 487

No. Deutsch Engl
9088 Schlauchklemmenzange
Hose clip pliers
Pince à tuyaux flexibles
Alicates para abrazaderas de mangueras
9090 Federklemmenzange
Spring clamp pliers
Pince à ressorts
Alicates para abrazaderas de resorte
9120 Torx Spezial- Bit 70 mm lang
Torx special bit 70 mm long
Embout de tournevis spécial Torx 70 mm de long
Bit especial Torx de 70 mm de longitud
9122 Torx Spezial- Bit 25 mm lang
Torx special bit 25 mm long
Embout de tournevis spécial Torx 25 mm de long
Bit especial Torx de 25 mm de longitud
488 BOMAG 008 910 92

057 250 83
008 910 92 BOMAG 489

No. Deutsch Engl
100 880 Arretierungsdraht für Anlenkhebel Einspritz-

pumpe
Locking wire for control lever, injection pump
Fil d’arrêt pour levier articulé de pompe d’injection
Alambre de sujeción para la palanca arti-

culada, bomba de inyección
103 020 Prüfschablone für E.P.-Dichtung
Test template for I.P. gasket
Gabarit de contrôle pour joint de pompe d’injection
Plantilla para comprobar juntas de b.i.
110 110 Halter für Einspritzventil
Retainer for injector
Dispositif d’immobilisation pour injecteur
Retenedor para inyector
110 140 Montagewerkzeug für Regelstangenbuchse
Assembly tool for control rod bush
Outil de montage pour douille de crémaillère
Herramienta de montaje para manguitos de

cremallera
490 BOMAG 008 910 92

Aufspannbock für Zylinderkopf 120 900
Clamping stand for cylinder heads
Chevalet d’ablocage pour culasse
Soporte de fijación para culatas
057 250 90
©
Aufspannplatte für No 120 900 120 910
Clamping plate for 120 900

057 250 91
Plaque d’ablocage pour no. 120 900
Placa de fijación para 120 900
Montagewerkzeug für Ventilschaftdichtung 121 410
Sleeve for fitting valve stem seal
Outil de montage pour joint de tige de soupape
Util de montaje para juntas de vástago de válvula
Universal-Kolbenring-Auflegezange 130 300
Universal piston ring pliers
Pince universelle à monter les segments de piston
Alicates universales para montar aros de pistón
008 910 92 BOMAG 491

130 420 Trapeznut - Verschleißlehre
Trapezoidal groove wear gauge
Jauge d'usure pour gorge trapézoïdale
Calibre de desgaste para ranuras trapezoidales
130 630 Kolbenringspannband
Piston ring compressor
Collier à comprimer les segments de piston
Compresor de aros de pistón
131 100 Demontagewerkzeug für Sprengring
Disassembling tool for spring ring
Outil de démontage de circlips
Herramienta de desmontaje para anillos

de seguridad
131 340 Montagewerkzeug für Kolbenbolzenbuchse

131 350
Assembly tool for small end bush
Dispositif de montage de bague de pied de bielle
Herramienta de montaje para casquillos de pie

de biela
492 BOMAG 008 910 92

Montagewerkzeug für Nockenwellendichtring 142 050
Assembly tool for camshaft seals
Dispositif de montage pour bagues d’étanchéité

d’arbre à cames
Dispositivo de montaje para retenes del árbol

de levas
Montagewerkzeug für Dichtringsatz, hinten 142 680
Assembly tools for the sealing ring set, rear
Outil de montage de jeu de joints, arrière
Herramienta de montaje para juego de

retén trasero
Montagewerkzeug für Dichtringsatz, vorne 142 690
Assembly tools for the sealing ring set, front
Outil de montage de jeu de joints, avant
Herramienta de montaje para juego de

retén delantero
Ausziehvorrichtung für Kurbelwellendichtringe 142 710
Puller for crankshaft seals
Extracteur pour bagues d’étanchéité de vilebrequin
Dispositivo de extracción para retenes del cigüeñal
008 910 92 BOMAG 493

142 850 Montagewerkzeug für Kurbelwellendichtring,

vorne
Assembly tool for crankshaft seals,front
Dispositif de montage de bague d’étanchéité avant

de vilebrequin
Dispositivo de montaje para el retén delantero del

cigüeñal
142 860 Montagewerkzeug für Kurbelwellendichtring,

hinten
Assembly tool for crankshaft seals, rear
Dispositif de montage pour bague d’étanchéité

arrière de vilebrequin
Dispositivo de montaje para el retén trasero del

cigüeñal
143 100 Abdrückwerkzeug für Schwungrad
Puller for flywheel
Dispositif pour extraction de volant-moteur
Dispositivo de separación para el volante
143 420 Gegenhalter für Kraftvervielfältiger
Dolly for multipower tool
Dispositif de maintien du multiplicateur de force
Dispositivo de retención para multiplicador

de fuerza
494 BOMAG 008 910 92

Zwischenscheibe für Gegenhalter 143 420 143 430
Intermediate disc for dolly 143 420
Disque intercalaire pour outil de maintien 143 420
Arandela intermedia para dispostivo de

retención 143 420
Montagewerkzeug für Nockenwellenbuchse 143 820
Assembly tool for camshaft bush
Outil de montage pour bague d’arbre à cames
Dispositivo de montaje para casquillos de árbol

de levas
Gegenhalter für Nockenwellenrad 144 130
Dolly for camshaft gear
Outil de maintien de pignon d’arbre à cames
Dispositivo de retención para rueda dentada

del árbol de levas
Ausziehwerkzeug für Rohr 150 140
Puller for pipe
Extracteur de tube
Extractor para tubos
008 910 92 BOMAG 495

150 150 Montagedorn für Rohr
Assembly arbor for pipe
Mandrin de montage pour tube
Mandril de montaje para tubos
170 050 Spezialschlüssel zum Abschrauben der

Filterpatrone
Special key for filter cartridges
Clé spéciale pour cartouches de filtre
Llave especial para cartuchos filtrantes
079 947 28
©
170 110 Spezialschlüssel für Öldruckgeber
Special wrench for oil pressure sensor
Clé spécial pour capteur de pression d’huile
Llave especial para transmisores de presión de

aceite
6067 Motormontagebock
Engine assembly stand
Chevalet de montage de moteur
Caballete de montaje de motores
496 BOMAG 008 910 92

Aufspannhalter 6067/115
Angled clamping plate
Support d’ablocage
Soporte de fijación
008 910 92 BOMAG 497

498 BOMAG 008 910 92

13 Air conditioning system
008 910 92 BOMAG 499

13.1 Physical basics
13.1 Physical basics A - heat absorption
In order to understand the working principle of an air B- Heat dissipation

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.
1. gaseous (invisible)
2. vaporous
3. liquid
4. solid
Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.
Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.
500 BOMAG 008 910 92

Physical basics 13.1
Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
● Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
● Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
● Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.
Fig. 4 Pressure - Temperature Diagram

In the pressure - temperature diagram for the refriger-
ant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direc-
tion of the arrow.
The characters A, B, C, D stand for:
Fig. 3 Steam pressure curve A - compression
Steam pressure curve for refrigerant R134a B- condensation
The steam pressure curve is a means for explaining C- relaxation
the operation principle of an air conditioning system. D- evaporation.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a.
The diagram for example shows, that R134a is liquid
at 0°C and a pressure of 5 bar, but becomes gaseous
at 40°C and 5 bar.
For better understanding one must also be aware of
the following:
1. A gas heats up when being compressed (e.g. air
pump, turbo charger, ...).
2. When relieving gas it will cool down (e.g. white frost
forms on the valve when relieving air pressure from a
car tire).
3. Condensing gas dissipates a lot of heat energy.
008 910 92 BOMAG 501

13.1 Physical basics
Excerpt from the wet steam table 1 R134a

1 This table is used for the determination of evaporation and con-
densation temperature.
Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar
reading Pe in bar) P in bar)
-20 0,33 1,33
-10 1,01 2,01
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72
502 BOMAG 008 910 92

Refrigerant R134a 13.2
13.2 Refrigerant R134a Characteristics of the refrigerant R134a:
Refrigerant R134a is currently available under the fol-
General lowing trade marks.
The evaporation and condensation process is the H-FKW 134a
method commonly used in mobile air conditioning sys- SUVA 134a
tems. The system in this case works with a substance KLEA 134a
that boils at low temperature, a substance referred to
a refrigerant. The refrigerant used is tetrafluoroethane
R134a, which boils at a temperature of -26.5°C and Colour:
under a steam pressure of 1 bar. Refrigerant in form of vapour or liquid is colourless as
Although the refrigerant circuit is a hermetically closed water. The gas is invisible. Only the bordering layer
loop, the system loses approx. 100g of refrigerant between gas and liquid is visible. (Fluid level in rising
over the course of 1 year by diffusion through hoses, pipe of filling cylinder or bubbles in inspection glass).
pipes and seals, even though the system is free of In the inspection glass the liquid refrigerant R134a
leaks. If too much refrigerant is lost the cooling power may appear coloured (milky). This turbidity results
of the system will drop. from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Physical data of the refrigerant R134a
Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous
CH2F-CF3 or CF3-CH2F refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
Chemical designation: sure and is frequently referred to as steam pressure.
Tetrafluoroethane The steam pressure is independent from the temper-
ature.
Boiling point at 1 bar:

- 26.5 °C Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
Solidification point: tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
-101.6 °C
ation oils, e.g. PAG-oils (polyalkylene glycol oils).
Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the
008 910 92 BOMAG 503

13.3 Compressor oil / refrigeration oil
liquid container has absorbed approx. 8 gr. of water, 13.3 Compressor oil / refrigeration
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle oil
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
Inflammability: until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul- Compressor oil (the oil quantity should be 10 % of the
traviolet light also cracks refrigerant (caused by refrigerant weight) mixes with the refrigerant and cir-
electric welding). This results in toxic fission products, culates permanently through the system.
these must not be inhaled. However, irritation of the In connection with R134a- air conditioning systems
mucous membranes is an early and in-time warning. special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
Filling factor: from this, the materials in the R134a air conditioning
In a container there must be a steam space above the system may be attacked when the mixture is flowing
liquid space. The liquid expands with increasing tem- through the refrigerant circuit under high pressure and
perature. The steam filled space becomes smaller. at high temperatures or if the lubrication film in the
From a certain time on the container will be filled with compressor tears off. The use of non-permitted oils
just liquid. After this only a minor temperature in- can cause damage to the air conditioning system, you
crease is enough to generate very high pressures in should therefore only used the approved oils.
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to Properties of compressor oil / refrigeration oil:
avoid overfilling of a container the pressure gas direc- The most important properties are high solvency in
tive clearly specifies how many kilograms of refriger- connection with refrigerants, good lubrication charac-
ant may be filled into the container per litre volume. teristics, that they are free of acids and their low water
Multiplied with the internal volume this "filling factor" content. For this purpose only certain oils can be
determines the permissible filling capacity For refrig- used. PAG-oils suitable for use with refrigerant R134a
erants used in motor vehicles it is 1.15 kg/l. are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
The contribution of R134a to the greenhouse effect is gressive against metals.
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.
504 BOMAG 008 910 92

Working principle of the air conditioning system 13.4
13.4 Working principle of the air 13.5 Monitoring devices
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en- Pressure switch
vironment. Everybody knows the effect: if a sweating
The pressure switch (8) is used as monitoring feature
body is exposed to wind it will cool down, because
for too high and too low pressures. The switching con-
heat is extracted. For this purpose a refrigerant circu-
tacts (4 and 5) effect the magnetic clutch of the com-
lates in a closed circuit inside the vehicle. This refrig-
pressor via a relay (6).
erant thereby continuously changes its physical state
between liquid and gaseous. If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
Fig. 1 Principle sketch of an air conditioning system
is set to approx. 1.5 bar to avoid icing. The switch on
An engine driven compressor (1) draws in gaseous re- pressure is 0.5 to 2 bar higher than the shut-off pres-
frigerant from the evaporator (5) and compresses it. sure (depending on system, see description of com-
During this process the temperature of the refrigerant ponents.)
increases tremendously.
Thermostat
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front A frost protection thermostat (3) protects the evapora-
of the vehicle radiator, so that a sufficient air flow is as- tor against icing. Similar to the pressure switch, the
sured. In the condenser (2) the gas is cooled down thermostat activates or deactivates the magnetic
and consequently liquefied. clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
In the dryer / liquid container (3) the refrigerant is then
tween the fins of the evaporator or attached to the
collected and freed of moisture and contaminants.
evaporator outlet (suction side). With fixed tempera-
The expansion valve (4) regulates the flow rate from ture controls the control switches the compressor off
the dryer / liquid container (3) back to the evaporator at about 1 °C and back on again at about 2.5°C to 5.5
(5) and the circuit starts again. °C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.
008 910 92 BOMAG 505

13.6 Description of components
Monitoring chain 13.6 Description of components
Compressor
Fig. 2 Monitoring chain consisting of:

● 1 Switch
● 2 Fuse
● 3 Thermostat
● 4 Low pressure switch contact Fig. 1
● 5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
●
6 Relay
the function of the system. Coupling and decoupling is
●
7 Connection for magnetic clutch accomplished by an electromagnetically controlled
●
8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.
Two service valves are installed directly on the com-
pressor. These are used to e.g. evacuate or fill the
system.
1 Filling port on pressure side (red) (Fig. 1)
2 Filling port on suction side (blue) (Fig. 1)
Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)
! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
or condenser, any compressor oil / refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.
506 BOMAG 008 910 92

Description of components 13.6
Environment Condenser
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.
Reason of oil loss Amount of oil lost
Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr Fig. 1
tainer
Replacement of expan- approx. 15 gr The condenser is located in front of the the radiator for
sion valve the machine. It emits heat energy from the system into
the surrounding air and liquefies the gaseous refriger-
ant.
! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. i Note
To avoid excessive oil in the A/C-system and thus The fins must be free of dirt and damage.
a poor cooling effect, the oil level in the A/C-sys-
tem must be adjusted accordingly.
! Caution
The quantity depends on the amount of oil that When replacing a heat exchanger, e.g. evaporator
may have been lost in connection with the possi- or condenser, any compressor oil lost by ex-
ble replacement of other components. changing the components, must be replaced with
The compressor oil quantity must be 10% of the fresh oil.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re-
quires a compressor oil / refrigerant oil filling of
100 gr.
Procedure:
Drain and measure the compressor oil from the
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.
i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.
008 910 92 BOMAG 507

Dryer / filter / fluid container / inspection Safety valve

glass
Fig. 2
Fig. 1 The fluid container is equipped with a safety valve.

Opening pressure 32 +/- 4 bar
Dryer / filter
Tightening torque 10 - 15 Nm
The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve. Inspection glass
Moisture that has entered during assembly of the re-
frigerant circuit is absorbed by a dryer in the fluid con-
tainer.
At evaporation temperatures below zero the refriger-
ant will deposit previously absorbed moisture on the
expansion valve, where this water turns into ice and
thus adversely affects the controllability of the expan-
sion valve. Moreover, moisture in the refrigerant cir-
cuit causes corrosion, forms acids and enters into
chemical compositions.
Inside the refrigerant container the heavy liquid refrig-
erant collects in the lower part of the container, flows
through a rising pipe to the outlet marked "A" and thus
ensures bubble free operation of the expansion valve.
Fig. 3
i Note During operation the refrigerant must flow through the
Since the absorbing capacity of this filter/dryer is lim- inspection glass without air bubbles. In most cases
ited, it must be changed within certain service inter- the presence of air bubbles is a sign for a too low re-
vals. We recommend to replace it 1 x per years, frigerant level in the system. Apart from this, the refrig-
before the start of the season. erant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
! Caution down to a level, at which gaseous refrigerant could
The filter/dryer must generally be replaced when- flow through the rising tube to the inspection glass.
ever opening the refrigerant circuit, because This results in abnormally high temperatures in and on
moisture will enter in such a case. the fluid lines (between refrigerant container and ex-
This requires emptying the air conditioning sys- pansion valve), as well as very high pressures in the
tem! pressure side.
Installation position: However, incorrect evacuation or filling may also be

the reason for air entering into the system and since
The arrow marks on the filter/dryer must point in air cannot be condensed, one will not be able to get
flow direction, i.e. towards the expansion valve. rid of these bubbles by topping up refrigerant. In this
Filter/dryer cannot be treated for further use! case the air conditioning system needs to be evacuat-
ed and refilled.
508 BOMAG 008 910 92

i Note Expansion valve
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.
! Danger
In case of mechanical damage or corrosion on

this pressure container this collector unit must be
replaced, to avoid bursting and further damage. Fig. 1
The expansion valve is mounted inside the HKL-mod-
ule in the cabin. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup-
plied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
008 910 92 BOMAG 509

Evaporator Defroster thermostat
Fig. 1 Fig. 1
The evaporator is mounted inside the HKL-module in The feeler of a defroster thermostat to switch off the
the cabin. It consists of a heat exchanger (inside air - magnetic clutch in case of icing up or to switch the
refrigerant), with refrigerant flowing to a pipe system clutch back on after defrosting, is mounted on the
with cooling flanges. evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
As with the condenser, correct operation of all fans
should be checked during maintenance.
and cleanliness of the fins must be assured.
Switching point on: + 1°C (+/- 1°C)
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator, Switching point off: + 5.5°C (+/- 1°C)
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. i Note
A condensation water filter is mounted in the air flow It is very important that the feeler is mounted down-
after the evaporator. This filter has the function to col- stream of the evaporator, but before the pressure sen-
lect the water that has condensed from the air in the sor, in countercurrent direction, with full length and
evaporator block and to discharge this water into the insulated against the outside temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
! Caution
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.
510 BOMAG 008 910 92

Pressure switch Pipes and hoses
Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
Fig. 1
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure Recommended tightening torques for O-ring
side, the pressure switch will switch of the magnetic sealed fittings
clutch of the compressor, thus to avoid destruction of
system components by excessive pressure or draw- Thread Spanner width Torque
ing in external gases and foreign matter as a result of 5/8“ 17 or 19 13,6 - 20,3 Nm
too low pressure. 3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
Working pressure:
1 1/16“ 32 40,7 - 47,5 Nm
Low pressure off: 1,5 +/- 0,5 bar M30X2 36 105,0 - 115,0 Nm
Low pressure on: 3,5 bar M36X2 41 165,0 - 175,0 Nm
Overpressure off: 25,0 +/- 1,5 bar Bending radii for air conditioning hoses
Overpressure on: 18,0 +/- 1,5 bar Hose type Nominal width Bending radius
GH 134 NW8 min. 50 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm
008 910 92 BOMAG 511

13.7 Checking the compressor oil level
13.7 Checking the compressor oil

level
Checking the compressor oil level / refrig-

eration oil level
!Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404).
● Run the compressor for 10 minutes at engine idle
speed.
● In order to avoid any compressor oil losses you
should slowly drain all refrigerant from the air condi- Fig. 2
tioning system. ● Turn the nut that hold the armature clockwise with a
socket wrench, until the counterweight is correctly
positioned.
i Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
● Insert the oil dipstick.
● Pull out the dipstick and count the notches covered
by oil.
● Drain off oil or fill up as specified in the table.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
Fig. 1
Fastening angle (de- Oil dipstick in incre-
● Measure the fastening angle (Fig. 1) of the com- gree) ments
pressor (oil plug at top) 0 5-7
●
Remove the oil filler plug. 10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
●
Screw the oil filler plug back in.
! Caution
The contact area must be clean and should be free
of damage.
Use a new O-ring.
Tightening torque 15 to 25 Nm
● Refill the air conditioning system.
512 BOMAG 008 910 92

Checking the magnetic clutch 13.8
13.8 Checking the magnetic clutch i Note
● Measure the voltage. The gap should be 0.4 to 0.8 mm.
●
Take off the drive V-belt and rotate the V-belt pulley
by hand while the magnetic clutch is disengaged.
i Note
Nominal value = vehicle voltage
●
Check the magnetic coil locking ring for secure fit.
i Note
In case of excessive flatness faults or deviations the
●
Check the current consumption. magnetic clutch needs to be replaced.
Cross-section of magnetic clutch

Fig. 3 shows a cross-section of the magnetic clutch. If
the coil (7) is not supplied with operating voltage,
there is no contact between the front plate of the
clutch (1) and the V-belt pulley (2). A spring presses
the front plate away from the belt pulley. The V-belt
pulley rotates with the bearing (3) in idle speed, the
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is
generated and pulls the front plate of the clutch. Both
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works.
Fig. 1
i Note
Nominal value approx. 3.5 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.
Fig. 3 Cross-section of magnetic clutch
Fig. 2 Measuring the air gap

●
Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).
008 910 92 BOMAG 513

13.9 Inspection and maintenance work
13.9 Inspection and maintenance 13.10Checking, tensioning, replac-

work ing the refrigerant compressor
● Visual inspection of the complete system for dam- V-belt
age.
● Check the compressor mounting bracket on the ve- Danger
!
hicle engine for tight fit and damage. Danger of injury!
● Check the condition, alignment and tightness of the Work on the V-belt must only be performed with
V-belt. the engine shut down.
●
Check the routing of refrigerant hoses and cables in
the area of the vehicle engine and transmission, as Check the V-belt
well as on the chassis for chafing and rectify any de-
tected faults. Ensure sufficient clearance to hot
parts, such as the exhaust; install a protective
shield, if necessary.
● Check the routing of hoses and hoses on the at-
tachment box or in the cabin.
● Check all hose and screw fittings for leaks.
● Check the fastening of the condenser unit.
●
Clean the condenser fins, replace the condenser
block if damaged fins are found.
●
Check the fastening of the evaporator unit.
●
Check the function of evaporator and condenser
fans. Fig. 4
●
Check the electric control panel. If discolorations on
● Inspect the entire circumference of the V-belt (Fig.
conductors are found, these should be replaced 4) visually for damage and cracks. Replace dam-
and possibly also the corresponding relays. aged or cracked V-belts.
●
Switch on the cooling system and check the refrig-
● Check with thumb pressure whether the V-belt can
erant level. be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
●
Filter/dryer and filter/dryer/fluid container combina- essary.
tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
Tighten the V-belt.
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
● Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
out air temperature - The temperature difference
should be at least 8-10 K.
●
Measuring the pressure in the refrigerant circuit
Fig. 5
● Slightly slacken fastening screws 1, 2 and 3 (Fig. 5).
● Press the compressor in direction of arrow, until the
correct V-belt tension is reached.
● Retighten all fastening screws.
514 BOMAG 008 910 92

Servicing the air conditioning (summer operation) 13.11
Changing the V-belt 13.11Servicing the air conditioning1
(summer operation)
!Caution
Under very dusty conditions clean every day in or-
der to maintain the cooling power of the air condi-
tioning system.
Danger
!
Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
Fig. 6 age or explosion of the system.
● Slightly slacken the fastening screws 1, 2 and 3
(Fig. 6). Cleaning the condenser
● Press the compressor against the direction of arrow
completely against the engine.
● Take the old V-belt off.
● Fit the new V-belt to the V-belt pulleys.
● Tension the V-belt as previously described.
● Fasten the fan again.
! Caution
Check the V-belt tension after a running time of 30
minutes.
Fig. 7
● Unscrew the condenser fastening screws and fold
the condenser forward.
●
Clean the condenser fins on front and back with
compressed air or cold water (Fig. 7).
!Caution
During cleaning work do not damage the cooling
fins and realign bent fins.
Checking the refrigerant level

● Start the engine.
1 Optional equipment
008 910 92 BOMAG 515

13.11 Servicing the air conditioning (summer operation)
Fig. 8 Fig. 10
● Switch the air conditioning (Fig. 8) on. ● Check whether the white float (Fig. 10) inside the in-
spection glass of the drier/collector unit floats right
at the top.
i Note
The refrigerant level is correct.
Fig. 9
● Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 9) in the blue section.
●
Open the air outlet nozzles.
●
Check, whether the out flowing air is noticeably
cooler. Fig. 11
●
If the white float (Fig. 11) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
i Note
the service department.
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on. i Note
● Open the right hand service door. The refrigerant level is not correct.
● Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.
516 BOMAG 008 910 92

Servicing the air conditioning (summer operation) 13.11
Checking the moisture level of the drying
agent
Fig. 13
● Check the drier/collector unit (Fig. 13) for mechani-
cal damage or rust.
Fig. 12
● Check the moisture indication pearl (Fig. 12) inside
the inspection glass of the drier/collector unit.
blue = drying agent o.k.
purple = moisture level of drying agent too high.
● Inform the service department. Replace drier/col-
lector unit, check air conditioning system.
Caution
!
Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.
Checking the condition of the drier/col-

lector unit
!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
with this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.
! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.
008 910 92 BOMAG 517

13.12 Drying and evacuation
13.12Drying and evacuation 13.13Emptying in case of repair

Evacuation of air conditioning systems using R-type For repair work the air conditioning systems must very
refrigerants not only has the purpose of emptying the often be emptied of all refrigerant.
system of all air before filling in refrigerant, but also to Especially with expensive refrigerants and larger
verify the leak tightness over a longer lifetime in the amounts of oil it may be necessary to keep the refrig-
achieved vacuum. However, the most important factor erant for later use.
in this work step is the drying of the system.
For later use these refrigerants must be drawn out
Any water residues in the refrigerant circuit will com- with suitable equipment and intermediately stored in
bine with the refrigerant, which will lead to the previ- collecting containers.
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
Environment
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration Contaminated refrigerant must be disposed of en-
system. vironmentally
The refrigerant compressor is not suitable for the pur- Releasing refrigerant into the atmosphere is pro-
pose of evacuation, because it is not able to achieve hibited (see restrictive injunction concerning
a sufficient final vacuum and, apart from this, may be CFC, day of enforcement 01. 08. 1991, § 8)
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
! Danger
It is common practice to evacuate the refrigeration For draining refrigeration systems you should not
system to a final vacuum of 1 Torr, i.e. 1.33 mbar. simply use any delivery containers, but only ap-
An exact time for evacuation and drying cannot be propriate pressure bottles, which must be special-
predicted. It can only be determined by means of a ly marked and should comply with the pressure
vacuum meter. However, if there is no vacuum meter gas directive.
at hand it is generally better to evacuate 1 hour longer
When transferring refrigerant you must make sure
than 1 hour too less.
that the bottle does not contain more than the per-
Function drying: mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced, In order to reduce the evacuation period in case of
water will already evaporate, e.g. under a pressure of short repairs, you may fill the refrigerant circuit with
10 mbar, at an ambient temperature of almost 7°C, approx. 0.5 bar nitrogen when opening. This ensures
but the water will not evaporate all at once. Since it is that nitrogen will flow out of the refrigerant circuit while
very difficult to separate the steam from the vacuum in it is open and no air or moisture can enter. However,
the system, the evacuation process is supported by the necessity for vacuum generation and a dryer
the co-called vacuum breaking (filling the circuit with change remains.
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.
518 BOMAG 008 910 92

Leak test 13.14
13.14Leak test
! Caution
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.
Leak test with electronic leak tester
Fig. 1 Electronic leak tester

Small leaks with only very low amounts of refrigerant
escaping can be detected, e.g. with an electronic leak
tester. Such equipment is able to detect leaks of less
than 5 gr. per year.
The leak tester used must be specially designed for
the refrigerant composition in the air conditioning sys-
tem. For example, leak detectors for refrigerant R12
are not suitable for R134a, because the refrigerant
R134a is free of chlorine atoms, meaning that this leak
detector will not respond.
Leak test with soap bubbles
Fig. 2 Soap bubble test

Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.
008 910 92 BOMAG 519

13.15 Filling instructions
13.15Filling instructions
Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).
! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.
i Note
White frost on the suction line is no measure for as-
sessing the filling.
520 BOMAG 008 910 92

Filling instructions 13.15
Fig. 1 10 Filter dryer

1 High pressure - gaseous 11 Fluid container
2 High pressure - liquid 12 Condenser
3 Low pressure - gaseous 13 Manual shut-off valve (not used)
4 Compressor 14 Pressure switch with high and low pressure con-
5 Compressor pressure switch (not used) tacts
6 not used 15 Defroster thermostat
7 Evaporator 16 Vacuum meter
8 Expansion valve 17 Low pressure gauge
9 Inspection glass 18 High pressure gauge
008 910 92 BOMAG 521

13.15 Filling instructions
19 Pressure reducing valve 16 Switch off the vacuum pump, watch the pressure
20 Vacuum pump gauges to see whether the vacuum is maintained.
21 Nitrogen bottle 17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
22 Refrigerant bottle
gauge bar. Fill refrigerant into the system, until a
23 Pressure gauge bar pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
Filling instructions es).
1 Connect the service adapter with the blue hand 18 Close the red hand wheel.
wheel in the suction side. 19 Perform a leak test with the electronic leak detec-
2 Connect the service adapter with the red hand tor.
wheel in the pressure side (the hand wheels on 20 Start the engine and switch on the system.
the service adapters must be fully backed out - left 21 Open the blue hand wheel and continue filling in
hand stop) refrigerant until the inspection glass is free or air
3 Connect the blue suction hose below the blue bubbles (in fluid container/dryer combinations the
hand wheel on the pressure gauge bar to the blue white pearl should float in the upper third of the in-
service adapter. spection glass). Then close the refrigerant bottle.
4 Connect the red pressure hose below the red 22 Close the blue hand wheel on the pressure gauge
hand wheel on the pressure gauge bar to the red bar.
service adapter. 23 Preparing the test run: -Close windows and doors
5 Connect the yellow hose below the yellow hand -Fan on full speed stage -Mount measuring feel-
wheel on the manometer bar to the 2-stage vacu- ers to air discharge and air intake.
um pump. 24 Run the system for approx. 20 minutes with medi-
6 Connect the last hose below the black hand wheel um engine speed.
on the nitrogen bottle via the pressure reducing 25 The temperature difference between air discharge
valve. and air intake should be (depending on type of air
7 Check on the pressure gauge bar that all hand condition) 8-10°C. The ambient temperature
wheels are closed. thereby is approx. 20°C. (These data are only ref-
8 Turn the hand wheels on both service adapter erence values, which may be influenced by possi-
clockwise. This opens the valves (right hand ble insolation)
stop). 26 Switch off system and engine and check for leaks
9 Open the valve on the nitrogen bottle (only via again.
pressure reducer); pressure approx. 20 bar. 27 Turn out (left hand stop) and remove the hand
10 Open the black and red hand wheels on the pres- wheels on both service adapters.
sure gauge bar and fill nitrogen into the system, 28 Fit all valves with dust caps.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 29 Perform a leak test.
ed on the suction side.
30 Mark the system with the corresponding type
11 Then open the blue hand wheel and raise the plates and information decals, such as type of oil
pressure in the suction side (max. 10 bar). Check and refrigerant.
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
522 BOMAG 008 910 92

Trouble shooting in refrigerant circuit, basic principles 13.16
13.16Trouble shooting in refriger-
ant circuit, basic principles
Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
● Expert knowledge
● technical equipment
Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
●
Service station
Filling the system with refrigerant causes an excess
●
Pressure gauge pressure of Pe = 3 bar.
●
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
●
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
●
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
●
Container for old oil
●
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
●
Hoses
● Scales
● Suction station
● Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.
Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)
008 910 92 BOMAG 523

13.16 Trouble shooting in refrigerant circuit, basic principles
Pressure gauge with saturation temperature scale If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.
Common overheating values

The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
Fig. 3 Absolute pressure gauge is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
Temperature scales on the pressure gauges always
ates within a range between 4 and 12 Kelvin. The in-
refer to the absolute pressures Pabs. Please note that
fluence of the ambient air on the suction line causes
it is not possible to measure a temperature directly
an additional overheating effect.
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper- Overheating is calculated as follows:
ature is assigned to the measured pressure.
Δ to2h = to2h - to
If the refrigerant is fluid, the temperature is below the
saturation temperature. Δ to2h, overheating at evaporator outlet in K
If the refrigerant is gaseous, the temperature is above to2h, temperature at evaporator outlet in °C
the saturation temperature. to, evaporation temperature in °C
Pressure gauges must indicate 0 bar when not con- „h“ represents "overheated"
nected to the system.
Low pressure gauges have a blue, high pressure Supercooling
gauges a red border.
Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause
524 BOMAG 008 910 92

Trouble shooting in refrigerant circuit, basic principles 13.16
a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.
Common supercooling values

In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.
Supercooling is calculated as follows:
Δ tc2u = tc - tc2u
Δ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"
008 910 92 BOMAG 525

13.16 Trouble shooting in refrigerant circuit, basic principles
Fig. 1 Refrigerant circuit with t, h- diagram

1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion
526 BOMAG 008 910 92

Trouble shooting, refrigerant circuit diagram 13.17
13.17Trouble shooting, refrigerant
circuit diagram
Fig. 1 Refrigerant circuit diagram 13 Compressor

1 Cold air 14 Condenser
2 Evaporator 15 Cooling air
3 Thermostat 16 Pressure gauge, low pressure
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air
008 910 92 BOMAG 527

13.18 Trouble shooting procedure
13.18Trouble shooting procedure ● Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
● The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
● Ambient temperature above 15 °C.
about the system design, the installed components ● The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:
Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.
i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.
Test prerequisites
● Cooler and condenser are clean, clean if neces-
sary.
● The ribbed belt for compressor and generator is
correctly tightened.
● All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
● The engine has operating temperature.
528 BOMAG 008 910 92

Trouble shooting procedure 13.18
Measuring points and measurements
Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
● C, condenser measuring points tainer the inspection glass is most suitable to check
● E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
● O, evaporator measuring points
The hot gas temperature can be used to check wheth-
● V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
● a) Which measuring equipment is required ?
can be used to derive the overheating of the evapora- ● b) Where to measure with which size ?
tor. Overheating is a clear indicator for the evaporator ● c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is ●
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- ● e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „Δto2h“ ?
Pressure and temperature at the condenser outlet can ●
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used
008 910 92 BOMAG 529

Solution: be a defect in the expansion valve or problems in the

● a) Pressure gauge, thermometer, steam table oil recirculation.
● b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
● c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
●
d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
● e) Δto2h = to2h - to, „Overheating at evaporator out-
Ambient temperature in °C Excess pressure in bar
let = evaporator outlet temperature - evaporation
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
● f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
● a) Which measuring equipment is required ?
●
b) Where to measure with which size ?
●
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
●
d) How high is the condensing temperature "tc" ?
●
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "Δtc2u" ?
●
f) Evaluation of the measured supercooling.
Solution:
●
a) Pressure gauge, thermometer, steam table
●
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
● c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
● d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
● e) Δtc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
● f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.
Typical faults and possible causes

Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist. r Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also
530 BOMAG 008 910 92

Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X
008 910 92 BOMAG 531

Suction pressure too low (1), high pressure too

low to normal (2)
Fig. 3
Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspec- Check for leaks, refill
tion glass, high overheating, hoar-
frost on evaporator
Evaporator fins or air filter soiled Cooling power too low clean
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vac- Replace the valve
uum, because the valve has closed
Screen or nozzle in expansion valve high overheating clean
clogged
Filter dryer clogged Bubbles in inspection glass, high Change filter dryer
overheating, filter dryer cold
Heat power too low Frequent low pressure shut off, Check the control
thawing thermostat / rotary thermo-
stat switching too frequently
532 BOMAG 008 910 92

Suction pressure normal (1), high pressure too
high (2)
Fig. 4

Condenser dirty high hot gas temperature, low cool- clean
ing power
Condenser fan failed high hot gas temperature, high pres- repair
sure shut down
overfilled high hot gas temperature, low su- Correct the filling capacity
percooling, low cooling power
Leak gas (air) high hot gas temperature, low renew filling
measured supercooling, low cooling
power
Restriction between compressor and high hot gas temperature, low cool- Check lines and valves
condenser ing power
008 910 92 BOMAG 533

Suction pressure too high (1), high pressure too

low to normal (2)
Fig. 5

Compressor defective Cooling power too low Replace the compressor
534 BOMAG 008 910 92

Suction pressure too high (1), high pressure too
high (2)
Fig. 6

Expansion valve defective overheating too low, wet operation Replace the valve
of compressor
008 910 92 BOMAG 535

Other faults
Symptom Cause Possible effect Remedy

Hot gas temperature too Lack of refrigeration oil increased compressor Refill refrigeration oil
high, the hot gas line be- wear
comes so hot that it cannot
be touched long with a
hand
Compressor does not start Pressure switch or any oth- System stopped Check the control units,
er safety feature has trig- check cause for switching
gered, electrical fault, and rectify
cylinder filled with liquid re-
frigerant
Compressor switches con- Switching difference too Cycling of compressor, in- Check the control units,
tinuously small, triggering of a creased wear, too low cool- check cause for switching
switching element (over- ing power and rectify
pressure switch, low pres-
sure switch), lack of
refrigerant, fan defective,
overfilled
Excessive overheating Expansion valve deadjust- low cooling power, hot gas Replace the expansion
ed or screen blocked, lack temperatures too high valve, clean the screen, fill
of refrigerant in refrigerant, leak test
Hoarfrost on inlet side of incorrectly working expan- too low infeed of refrigerant Check the expansion
evaporator sion valve, lack of refriger- into the evaporator valve, check the refrigerant
ant filling
Evaporator fully covered Load problem, too low air low cooling power of sys- Clean the evaporator,
with hoarfrost flow volume tem check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, low cooling power Eliminate the pressure
shows condensation filter dryer clogged drop, replace the filter dryer
Exceptionally cold pres- "Wet intake" of the com- low cooling power, exces- Clean the compressor, re-
sure lines pressor due to insufficient sive wear of compressor place if necessary, replace
overheating of evaporator the expansion valve if nec-
essary
Noise in system

V-belt loose or excessively worn V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch loud Magnetic clutch runs until high pres- Repair or replace the magnetic
sure builds up, then the clutch starts clutch
to slip
Refrigerant compressor is loud Mounting bracket is loose, internal Repair the mounting bracket, re-
parts worn, low oil level in compres- place the compressor, renew the re-
sor frigeration oil
Fan is loud, fan motor excessively Replace the fan motor
worn
Whistling and rattling noise in opera- V-belt pulley and bearing worn Replace the bearing, check V-belt
tion, noticeable unevenness when pulley for wear
turning by hand
Rattling noise or vibration of high System overfilled Draw out refrigerant
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, refrigerant level in system too low Perform a leak test, fill up the system
on expansion valve, turbidity in in-
spection glass or ball does not float
536 BOMAG 008 910 92

Inspection glass

Steam bubbles in inspection glass No supercooling before expansion Fill up the system, replace the filter
valve, lack of refrigerant in system, dryer, perform a leak test
pressure loss in system, supercool-
ing caused by excessively soiled fil-
ter dryer
Discolouration of inspection glass Lubricant destroyed by excessive Replace the refrigeration oil, exam-
(black from inside) operating temperatures ine the temperature increase
Moisture indicator changes to pink Moisture level of drying agent too Replace the filter dryer
high
Ball floats at bottom lack of refrigerant Fill the system
Monitoring devices

The high pressure contact has System pressure exceeded, con- Clean the condenser, replace the
switched off the magnetic clutch denser excessively soiled, condens- expansion valve, check the con-
er fan defective, expansion valve denser fan
defective
The low pressure contact has System pressure fallen short of, re- Clean the evaporator, replace the
switched off the magnetic clutch frigerant level too low, expansion expansion valve, check the evapora-
valve defective, evaporator fan de- tor fan
fective, heat load too low, ambient
temperature below 1.5 °C
The thermostat has switched off the Ambient temperature below 1°C, Check the thermostat switching
magnetic clutch expansion valve defective, thermo- point, replace the expansion valve,
stat defective, air flow volume too clean the evaporator, check the
low evaporator fan
008 910 92 BOMAG 537

13.19 Steam table for R134a
Tempera- Pres- Density spec. volume spec. enthalpy Evapora-

ture sure tion heat
of the fluid of the of the fluid of the of the fluid of the
steam steam steam
538 BOMAG 008 910 92

Steam table for R134a 13.19
008 910 92 BOMAG 539

540 BOMAG 008 910 92

Steam table for R134a 13.19
008 910 92 BOMAG 541

542 BOMAG 008 910 92

14 Replacing the cab window panes
008 910 92 BOMAG 543

14.1 Assembly of window panes
Fig. 1
1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap
544 BOMAG 008 910 92

Special tools 14.2
14.2 Special tools
1. Locking handle for fastening element
Fig. 1
2. Suction lifter
commercial
Fig. 2
008 910 92 BOMAG 545

14.3 Auxiliary materials
14.3 Auxiliary materials

Safety gloves
3. Cutter
Commercial
Fig. 1
4. Window glass bonding agent
Fig. 2
5. Activator
Fig. 3
546 BOMAG 008 910 92

Auxiliary materials 14.3
6. Silicone sealant
Fig. 4
008 910 92 BOMAG 547

14.4 Removing and installing the window pane
14.4 Removing and installing the window

pane
Environment
Environmental damage
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.
! Danger
Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).
Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.
Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).
Fig. 3
548 BOMAG 008 910 92

Removing and installing the window pane 14.4
6. Turn the fixing and spacer washer hand-tight onto
the thread of the fastening element (Fig. 4).
i Note
Do not overtighten the thread.
Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).
i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.
Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.
Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).
i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.
Fig. 7
008 910 92 BOMAG 549

14. Remove the suction lifter (Fig. 8).
Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).
i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.
Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).
Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).
Fig. 11
550 BOMAG 008 910 92

Removing and installing the window pane 14.4
19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).
Fig. 12
20. Treat the inside joint (Fig. 13)
Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.
i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.
Fig. 14
008 910 92 BOMAG 551

552 BOMAG 008 910 92

15 Frame cracks in front frame
008 910 92 BOMAG 553

15.1 Repair overview for welding the frame
15.1 Repair overview for welding the

frame
Fig. 1
1 Front frame cracks left or right
554 BOMAG 008 910 92

Repair overview for welding the frame 15.1
Fig. 2
008 910 92 BOMAG 555

15.1 Repair overview for welding the frame
Fig. 3
556 BOMAG 008 910 92

Welding the frame 15.2
15.2 Welding the frame
! Danger
Fire hazard!
Follow the safety regulations and general re-
pair instructions!
1. Clean engine and engine compartment.
! Caution
Keep hydraulic hoses, fuel hoses and wiring
looms away from welding points, or tie them
up.
i Note
(Fig. 1) shows engine compartment left
(Fig. 2) shows engine compartment right.
If necessary pull the plugs of the solenoid valves
for brake and vibration.
Fig. 1
2. Cover combustible parts.
Fig. 2
3. Remove paint at fasten the earth strap (Fig. 3).
Fig. 3
008 910 92 BOMAG 557

4. Drill an 8 mm hole 10 mm from the end of the

crack.
i Note
The length of the crack may be different on inside
and outside.
Fig. 4
5. Grind the crack out completely ad weld it.
6. Grind the welding points (Fig. 5) metallic blank.
! Caution
The bore must not be closed by welding, it
should protect against a possible continua-
tion of the crack.
Fig. 5
7. Grind the gusset (Fig. 6) approx. 45°.
i Note
(Fig. 6) shows gusset on left hand side of frame.
Grind the gusset on the right hand side of the
frame from the opposite side.
Fig. 6
8. Attach the gusset (Fig. 7).
Fig. 7
558 BOMAG 008 910 92

Welding the frame 15.2
! Caution
The gusset must be positioned so that:
a) a continuous contour 1 (Fig. 8) is achieved
after welding and grinding (thick black line).
b) there is sufficient space (approx. 8mm) for
a welding seam on the outer side.
Fig. 8
The gusset must be continuously welded in
this area 1 (Fig. 9) (therefore the 45° chamfer).
9. Weld the gusset to the frame.
i Note
Lay the welding seam all the way around.
(Fig. 10) shows the finished welding seam on the
left hand side of the frame.
(Fig. 11) shows the finished welding seam on the
right hand side of the frame.
Fig. 9
! Caution
After welding this area (Fig. 10) must be
ground, it must be free of notches. Here the
frame crack developed.
Fig. 10
10. Clean, prime and paint the welding seams.
i Note
Round off the gussets and the welding seams to
avoid any chafing points for wiring looms and
hoses.
11. Reroute hydraulic lines and wiring looms correct-
ly.
Fig. 11
008 910 92 BOMAG 559

560 BOMAG 008 910 92

16 Replacing the travel control cable
008 910 92 BOMAG 561

16.1 Replacing the travel control cable
Removing the driver's seat

1. Slide the driver's seat (Fig. 1) to middle position.
Fig. 1
2. Unplug the wiring loom (Fig. 2).
Fig. 2
3. Unscrew all fastening screws and lift off the driv-
er's seat (Fig. 3).
Fig. 3
562 BOMAG 008 910 92

Replacing the travel control cable 16.1
4. Disassemble the protection plate (Fig. 4).
Fig. 4
5. Unscrew the hexagon screws on both sides (Fig.
5).
Fig. 5
Disassembling the travel control ca-

ble
6. Detach the travel control cable from the lever arm
(seat carrier top) (Fig. 6).
Fig. 6
008 910 92 BOMAG 563

i Note
Note on assembly:
Assemble the holding angle so that the travel
control cable is flush with the hexagon nut (Fig.
7).
Fig. 7
7. Carefully fold the seat carrier forward (Fig. 8).
Fig. 8
8. Detach the travel control cable from the bottom of
the seat carrier (Fig. 9).
Fig. 9
9. Unhook the travel control cable from the counter-
bracket (Fig. 10).
i Note
Notes on assembly:
Engage the parking brake (travel lever "0"-posi-
tion), then adjust the travel control cable on the
counter-bracket so, that the screw on the travel
pump lever (Fig. 11) can be installed without ten-
sion.
The travel pump control lever is automatically in
neutral position.
Fig. 10 Adjust the travel cable accurately on the clevis.
564 BOMAG 008 910 92

Replacing the travel control cable 16.1
10. Detach the travel control cable from the control
lever (Fig. 11).
Fig. 11
11. Remove hexagon nuts and washers 1 (Fig. 12).
Fig. 12
i Note
Tightening torque 150 Nm (Fig. 13).
Fig. 13
Machine with ROPS
12. Attach lifting gear to ROPS and operator's stand
(Fig. 14).
Fig. 14
008 910 92 BOMAG 565

Machines with cab

13. Attach lifting gear to cab with operator's stand
(Fig. 15).
Fig. 15
14. Slightly lift cab with operator's stand (Fig. 14) or
ROPS with operator's stand (Fig. 15).
! Caution
Only lift as much as required to remove the
travel control cable.
Mind wiring looms and hoses (Fig. 16) and
(Fig. 17).
Fig. 16
!Danger
Danger of accident!
Do not stand or step under loads being lifted.
Secure the operator's stand with square tim-
ber beams.
Fig. 17
15. Cut the cable straps under the operator's stand
(Fig. 18).
16. Remove the travel control cable.
i Note
Reassemble in reverse order.
Fig. 18
566 BOMAG 008 910 92

17 Drum
008 910 92 BOMAG 567

17.1 Special tools, drum (BW 141/151-4)
17.1 Special tools, drum (BW 141/151-4)

1. Lifting device for vibrator unit
Fig. 1
2. Guide bolts M16 x 270
Fig. 2
3. Guide bolts M12 x 270
Fig. 3
4. Screw bolt for vibrator unit lifting device
Fig. 4
568 BOMAG 008 910 92

Special tools, drum (BW 141/151-4) 17.1
5. Puller for coupling half
Fig. 5
008 910 92 BOMAG 569

17.2 Repair overview AD-drum
Fig. 1 7 Vibration motor

1 Drum shell 8 Elastic coupling
2 Vibration bearings 9 Rubber buffer
3 Basic weight 10 Travel bearing
4 Change-over weight 11 Oil drain
5 Vibration housing 12 Oil filler opening
6 Coupling shaft 13 Travel drive unit
570 BOMAG 008 910 92

Repair overview AD-drum 17.2
Fig. 2
008 910 92 BOMAG 571

17.2 Repair overview AD-drum
Fig. 3 3 Oil paddle

1 Basic weight 4 Claw-type coupling
2 Change-over weight 5 Centring point for assembly
572 BOMAG 008 910 92

Removing and installing the drum 17.3
17.3 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 appropriate side of the machine up (Fig.
1), until the rubber buffers on the drive disc are re-
lieved.
! 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
2. Disconnect the main battery switch (Fig. 2).
! Caution
Do not start the engine during repair work!
Fig. 2
3. Unscrew the guard 1 (Fig. 3) and remove the
hose clamps (2).
Fig. 3
008 910 92 BOMAG 573

4. Unscrew the guard 1 (Fig. 4) and remove the

hose clamp (3).
5. Disconnect the water hose (2).
Fig. 4
i Note
(Fig. 5) shows the machine without AM.
(Fig. 6) shows the machine with AM.
6. Mark the hydraulic hoses and disconnect these
from vibration motor and travel motor (Fig. 5) or
(Fig. 6).
Environment
Catch running out hydraulic oil and dispose
of environmentally.
7. Close hydraulic connections and hydraulic hoses
Fig. 5 with dummy plugs
8. Pull the hydraulic hoses up and out of the support
leg and lay them down in the frame.
Fig. 6
574 BOMAG 008 910 92

i Note
from the travel motor (Fig. 7) or (Fig. 8).
Environment
Catch running out hydraulic oil and dispose
of environmentally.
Fig. 7
from the swivel motor (Fig. 8), only on AM ma-
chines.
12. Close hydraulic connections and hydraulic hoses
with dummy plugs
Fig. 8
14. Remove the head lights 1 (Fig. 9).
Fig. 9
15. Pull plug 1 (Fig. 10) off the head lights.
16. Pull the wiring harness through bore (2) out of the
cross member.
Fig. 10
008 910 92 BOMAG 575

17. Unscrew nuts 1 (Fig. 11) from the rubber buffers

on vibration and travel motor side.
Fig. 11
18. Attach the lifting tackle (Fig. 12) to the support
leg.
! Danger
Do not stand or step under loads being load-
ed.
19. Unscrew the fastening screws (1).
20. Unscrew the fastening screws (2) for the cross
member.
Fig. 12
21. Separate the support leg with fastening angles
(Fig. 13) from the frame and lay it to the side.
Fig. 13
22. Attach the lifting tackle to the cross-member 1
(Fig. 14).
Fig. 14
576 BOMAG 008 910 92

23. Unscrew fastening screws for cross member 1
(Fig. 15).
! Danger
Do not stand or step under loads being lifted.
Fig. 15
24. Lift off cross member 1 (Fig. 16).
Fig. 16
25. Fasten the lifting gear to the support leg and un-
screw fastening screws 1 (Fig. 17).
! Danger
ed.
Fig. 17
26. Separate the support leg with fastening angles
(Fig. 18) from the frame and lay it to the side.
Fig. 18
008 910 92 BOMAG 577

27. Roll the drum (Fig. 19) out of the frame.
! Danger
Fig. 19
28. Secure the drum (Fig. 20) against unintended
rolling.
Fig. 20
578 BOMAG 008 910 92

Installing the drum
29. Examine all rubber buffers 1 (Fig. 21) for wear, re-
place if necessary.
i Note
Tighten the rubber buffers with 300 Nm.
Fig. 21
30. Place the drum (Fig. 22) parallel in the frame.
!Danger
Fig. 22
31. Attach the lifting tackle to the support leg (Fig. 23)
and mount it to the rubber buffers of the drum.
!Danger
ed.
Fig. 23
32. Attach the lifting tackle to the support leg (Fig. 24)
and mount it to the rubber buffers of the drum.
! Danger
ed.
Fig. 24
008 910 92 BOMAG 579

Adjusting the preload of the rubber buffers

33. Unscrew or loosen the connecting screw for sup-
port leg 2 (Fig. 25) and holding angle (1).
i Note
The slots (4) in holding angle (1) are to be used
to adjust the pretension of the rubber buffers.
34. Pull support leg (2) fully out and retighten again
with the fastening screws.
35. Screw nuts and washers on the rubber buffers (3)
and tighten with 300 Nm.
Fig. 25 36. Adjust the support leg on the opposite side in the
same way.
! Caution
Pretension of rubber buffers!
Fasten the support legs (Fig. 26) under
preload to the frame.
The preload of the rubber buffers is achieved
by the gap (X) between support leg and frame
or cross-member when tightening.
Fig. 26
37. Retighten fastening screws 1 (Fig. 27).
Fig. 27
38. Retighten fastening screws 1 (Fig. 28).
Fig. 28
580 BOMAG 008 910 92

39. Lift the machine up, so that the drum is slightly
above the ground.
40. Measure the distance between drum (Fig. 29)
and support legs (both sides).
! Caution
The distance must be the same on both sides,
compensate if necessary.
41. Lower the machine to the ground.
Fig. 29
i Note
42. Feed the hydraulic lines (Fig. 30) or (Fig. 31) from
above through the support legs and connect as
required.
Fig. 30
Fig. 31
i Note
43. Feed the hydraulic lines (Fig. 32) or (Fig. 33) from
above through the support legs and connect as
required.
Fig. 32
008 910 92 BOMAG 581

Fig. 33
44. Insert cross member 1 (Fig. 34) into the frame.
! Danger
ed.
Fig. 34
45. Turn screws 2 (Fig. 35) into the cross member
from both sides and tighten correctly.
46. Install head light (1) and connect the wiring har-
ness.
! Caution
Ensure correct routing of the wiring harness-
es. Avoid chafing.
Fig. 35
47. Install guard 1 (Fig. 36) and hose clamp (3) for the
hydraulic hoses.
48. Reconnect the water hose (2).
Fig. 36
582 BOMAG 008 910 92

49. Install guard 1 (Fig. 37) and hose clamp (2) for the
hydraulic hoses.
Fig. 37
50. Check the hydraulic oil level (Fig. 38), top up if
necessary.
! Caution
Bleed the hydraulic system before starting
operation.
51. Perform a test drive, check function of travel sys-
tem, vibration and water sprinkling system.
52. Check all connections and fittings for leak tight-
ness.
Fig. 38
008 910 92 BOMAG 583

17.4 Dismantling the AD-drum
! Danger
Do not stand or work under suspended loads!
53. Move the drum, until the drain plug (Fig. 1) is in
bottom position.
54. Clean and unscrew drain and filler plugs.
55. Drain off and catch old oil.
Environment
Dispose of old oil environmentally.
Disassembly (vibration motor side)
Fig. 1
56. Unscrew both fastening nuts (Fig. 2).
57. Remove the vibration motor.
Fig. 2
58. Loosen clamping screws 2 (Fig. 3) and pull off
coupling hub (1).
Fig. 3
584 BOMAG 008 910 92

Dismantling the AD-drum 17.4
59. Attach the lifting tackle to the bearing cover (Fig.
4).
60. Unscrew the hexagon screws.
! Danger
Fig. 4
61. Force the bearing cover off with two forcing
screws (Fig. 5).
Fig. 5
62. Lift the bearing cover off and lay it to the side (Fig.
6).
Fig. 6
63. Remove the intermediate shaft with the elastic
coupling element (Fig. 7).
Fig. 7
008 910 92 BOMAG 585

64. Disassemble the bearing race (Fig. 8).
Fig. 8
65. Screw in two guide bolts (Fig. 9) and unscrew all
screws.
66. Force the flange off the drum using two forcing
screws (arrow).
Fig. 9
67. Attach the lifting tackle to the bearing flange and
lift it off the drum (Fig. 10).
!Danger
Fig. 10
68. Pull the travel bearing off with a puller (Fig. 11).
Fig. 11
586 BOMAG 008 910 92

69. Press both cylinder roller bearings out of the
bearing housing using a suitable mandrel (Fig.
12).
Fig. 12
008 910 92 BOMAG 587

Disassembly (travel motor side)

70. Unscrew both fastening screws (Fig. 13).
Fig. 13
71. Lift off the travel motor (Fig. 14).
Fig. 14
72. Attach the lifting tackle to the drive disc (Fig. 15).
!Danger
73. Unscrew the hexagon screws.
74. Lift the drive disc off and lay it to the side .
Fig. 15
75. Cover the travel gear opening (Fig. 16).
Fig. 16
588 BOMAG 008 910 92

76. Screw in two guide bolts (Fig. 17) and remove all
fastening screws from the travel gear flange.
77. Force the travel gear off the drum using two forc-
ing screws (arrow).
Fig. 17
78. Attach the lifting tackle to the travel gear (Fig. 18)
and lift it off.
! Danger
79. Turn the guide bolts back out.
Fig. 18
80. Unscrew the pipe elbow (Fig. 19).
81. Unscrew the magnetic plug.
Fig. 19
82. Unscrew the fastening screws (Fig. 20).
Fig. 20
008 910 92 BOMAG 589

83. Attach the lifting tackle to the exciter unit (Fig. 21).
84. Press the exciter unit out of the drum with three
forcing screws and lift it out.
! Danger
Hold the exciter unit in horizontal position.
Take care that the exciter unit does not slip
out of the flange.
Fig. 21
85. Take the bearing flange off the exciter unit (Fig.
22).
Fig. 22
86. Remove circlip 1 (Fig. 23) and pull the cylinder
roller bearing (1) with a puller out of the travel
gear flange.
Fig. 23
590 BOMAG 008 910 92

Disassembling the bearing flange (vi-
bration motor side)
87. Unscrew the fastening screws (Fig. 24).
Fig. 24
88. Remove the bearing housing with three forcing
screws (Fig. 25).
Fig. 25
89. Take off the bearing flange (Fig. 26).
Fig. 26
008 910 92 BOMAG 591

90. Unclip circlip 1 (Fig. 27).
Fig. 27
91. Drive out the cylinder roller bearings with a suita-
ble mandrel (Fig. 28).
Fig. 28
592 BOMAG 008 910 92

Dismantling, assembling the AD exciter unit 17.5
17.5 Dismantling, assembling the AD excit-
er unit
i Note
Depending on the version of machine a differen-
tiation is made between:
Exciter unit with short shaft 1(Fig. 1).
Exciter unit with long shaft (2).
After factory assembly the exciter unit was addi-

tionally reworked to 100% concentricity.
! Caution
In case of a repair the complete unit needs to
Fig. 1 be changed.
When dismantling several units, parts like
flanged covers, weights and housing must
not be mixed up by mistake
Each exciter unit is an individually manufac-
tured unit!!
Strict cleanliness is mandatory when per-
forming repair work.
Dismantling
1. Unscrew the fastening screws (Fig. 2) and take
off the oil paddle.
i Note
The illustration shows a small oil paddle, depend-
ing on the machine version these paddles are of
different sizes.
Fig. 2
2. Unclip the circlip (Fig. 3).
3. Extract the inner bearing race with a puller.
Fig. 3
008 910 92 BOMAG 593

17.5 Dismantling, assembling the AD exciter unit
Disassembling the claw-type coupling

4. Remove the claw-type coupling (Fig. 4).
i Note
Depending on the exciter unit design a differenti-
ation is made between:
Claw-type coupling without centring point (Fig. 4).
Claw-type coupling with centring point.
Shaft coupling (Fig. 5).
5. Unclip the circlip.
Fig. 4
Disassembling the shaft coupling
7. Loosen the clamping screws. (Fig. 5).
! Caution
Loosen the clamping screws evenly one after
the other. Each screw may only be loosened
for half a turn with each revolution. Back out
all clamping screws for 3 to 4 turns.
Non-observance of this sequence can ad-
versely affect the function of the coupling.
8. Take off the shaft coupling.
Fig. 5 9. Unclip the circlip.
11. Unscrew the fastening screws (Fig. 6) and take
off the flange.
i Note
Observe the roll pin.
Fig. 6
12. Take off the O-ring (Fig. 7).
Fig. 7
594 BOMAG 008 910 92

13. Screw the transport eyelet into the change-over
weight and lift the change-over weight out of the
exciter housing (Fig. 8).
14. Pour the oil out of the exciter housing.
Environment
Catch old oil and dispose of environmentally.
Fig. 8
008 910 92 BOMAG 595

Assembly
1. Screw the transport eyelet into the change-over
weight (Fig. 9).
Fig. 9
2. Insert the change-over weight into the exciter
housing (Fig. 10).
Fig. 10
3. Rotate the change-over weight and check
smooth running (Fig. 11).
Fig. 11
4. Fill the exciter housing with approx. 1.2 litres of oil
Silicon 1000 cST (Fig. 12).
Fig. 12
596 BOMAG 008 910 92

5. Attach a new O-ring (Fig. 13) to the recess of the
flange.
Fig. 13
6. Attach the flange . Install the roll pin with LOC-
TITE 243 (Fig. 14).
Fig. 14
7. Wet the fastening screws with LOCTITE 542 and
tighten as specified (Fig. 15).
Fig. 15
Assembling the inner bearing race
8. Heat both inner bearing races up to approx. 80 °
and slide them on against the stop (Fig. 16).
! Danger
Danger of burning!
Wear protective gloves.
Fig. 16
008 910 92 BOMAG 597

9. Assemble the circlips (Fig. 17).
Fig. 17
Assemble the claw-type coupling.
i Note
Depending on the exciter unit design a differenti-
ation is made between:
Claw-type coupling without centring point (Fig.
18).
Claw-type coupling with centring point (Fig. 19).
Shaft coupling (Fig. 20).
Fig. 18
10. Install the fastening screws with LOCTITE 2701
and tighten them (Fig. 19).
Fig. 19
Assembling the shaft coupling
11. Clean hub bore and shaft and apply a thin coat of
thin flowing oil (Fig. 20).
i Note
Suitable oil is e.g. Castrol 4 in 1 or Klüber Quitsch
EX).
12. Clean tapered areas of clamping ring hub and
clamping ring and apply a thin coat of thin flowing
oil.
Fig. 20
598 BOMAG 008 910 92

! Caution
Oils with molybdenum disulphide or other
high pressure additives and sliding grease
pastes must not be used.
13. Assemble the coupling halves.
14. Slightly slacken all clamping screws (3) and pull
the clamping ring (1) slightly off the clamping ring
hub (2), so that the clamping ring is loosely at-
tached.
15. Slide the coupling half over the exciter shaft (Fig.
21).
16. Assemble the fastening screws with Loctite 243.
17. Tighten the clamping screws evenly in stages
with at least two intermediate steps crosswise
with a final tightening torque of 8.5 Nm .
i Note
Intermediate tightening steps with 3 Nm and 5
Nm.
Fig. 21
! Caution
Repeat this process, until the tightening
torque is correct on all clamping screws. In
the intermediate stages this process must
also be repeated, until the respective tighten-
ing torque has been reached for all screws.
Assembling the oil paddle
18. Assemble the fastening screws (Fig. 22) with
Loctite 243.
Fig. 22
008 910 92 BOMAG 599

17.6 Assembling the drum
! Danger
! Caution
Ensure strict cleanliness.
Preassembly of travel bearing flange

19. Clean the flange (Fig. 1).
Fig. 1
20. Press the seal ring into the groove (Fig. 2).
Fig. 2
21. Mount the V-ring on the flange (Fig. 3).
Fig. 3
600 BOMAG 008 910 92

Assembling the drum 17.6
22. Fill the groove with grease (Fig. 4).
Fig. 4
23. Clean the bearing housing (Fig. 5).
Fig. 5
24. Press the grooved ball bearing in until it bottoms
(Fig. 6).
! Caution
Open bearing side up.
Fig. 6
25. Slide the bearing housing with grooved ball bear-
ing over the flange (Fig. 7).
Fig. 7
008 910 92 BOMAG 601

26. Press the bearing housing with the grooved ball

bearing in until it bottoms (Fig. 8).
! Caution
Apply the pressing force via the grooved ball
bearing.
Fig. 8
27. Fill the grooved ball bearing with grease (Fig. 9).
Fig. 9
28. Fill the second grooved ball bearing with grease
(Fig. 10).
Fig. 10
29. Mount the ring on the flange (Fig. 11).
Fig. 11
602 BOMAG 008 910 92

30. Attach the second grooved ball bearing (Fig. 12).
! Caution
Open bearing side down.
Fig. 12
31. Press the second grooved ball bearing in until it
bottoms (Fig. 13).
Fig. 13
32. Install the new O-ring and apply a thin coat of oil
(Fig. 14).
Fig. 14
008 910 92 BOMAG 603

Preassembly of bearing flange (vibra-

tion motor side)
33. Clean the flange and oil the inside (Fig. 15).
Fig. 15
34. Cool the vibration bearing down to -25 ° Celsius
and slide it into the flange (Fig. 16).
! Danger
Wear gloves.
Fig. 16
35. Press the bearing down to full contact (Fig. 17).
Fig. 17
604 BOMAG 008 910 92

36. Insert the circlip into the groove (Fig. 18).
Fig. 18
008 910 92 BOMAG 605

Preassembly of bearing flange (travel

motor side)
37. Clean the flange and oil the inside (Fig. 19).
Fig. 19
38. Cool the vibration bearing down to -25 ° Celsius
and slide it into the flange (Fig. 20).
! Danger
Wear gloves.
Fig. 20
39. Press the bearing down to full contact (Fig. 21).
Fig. 21
606 BOMAG 008 910 92

40. Insert the circlip into the groove (Fig. 22).
Fig. 22
41. Assemble a new O-ring and apply a thin coat of
oil (Fig. 23).
42. Oil the cylinder roller bearing.
Fig. 23
43. Oil the bearing shell (Fig. 24).
Fig. 24
44. Slide the bearing flange onto the exciter unit (Fig.
25).
Fig. 25
008 910 92 BOMAG 607

Preassembly of travel gear

45. Clamp the flange in a vice (Fig. 26).
46. Push the travel gear into the flange and tighten
screws with washers crosswise.
Fig. 26
47. Assemble screw fitting, pipe elbow and magnetic
plug (Fig. 27).
Fig. 27
608 BOMAG 008 910 92

Assembly
Assembling the bearing flange (vibration mo-
tor side)
48. Clean the inner tube in the drum (Fig. 28).
49. Screw in two guide bolts to assist the installation
of the bearing flange.
Fig. 28
50. Slide the bearing flange over the guide bolts (Fig.
29).
Fig. 29
51. Install the screws with LOCTITE 243 (Fig. 30).
52. Remove the guide bolts.
Fig. 30
53. Tighten the screws crosswise (Fig. 31).
Fig. 31
008 910 92 BOMAG 609

Installing the exciter unit

54. Clean the inner tube in the drum (Fig. 32).
55. Check the dowel pin, replace if necessary.
i Note
Install the dowel pin with LOCTITE 243 .
Fig. 32
56. Oil the bearing shell (Fig. 33).
Fig. 33
57. Attach the lifting tackle to the exciter unit (Fig. 34).
!Danger
Hold the exciter unit in horizontal position.
Take care that the exciter unit does not slip
out of the flange.
i Note
Observe the centring by the dowel pin.
Fig. 34
58. Install the fastening screws with LOCTITE 542
(Fig. 35).
Fig. 35
610 BOMAG 008 910 92

59. Tighten the screws crosswise (Fig. 36).
Fig. 36
Checking the end float
60. Turn the eye bolt into the bore in the exciter shaft
(Fig. 37).
61. Push the exciter shaft into the bearing housing
against the end stop.
62. Unscrew the screw.
Fig. 37
63. Measure the distance from the exciter shaft to the
front face of the bearing housing (Fig. 38).
Fig. 38
64. Turn the eye bolt into the bore in the exciter shaft
(Fig. 39).
65. Pull the exciter shaft out against the stop.
66. Unscrew the screw.
Fig. 39
008 910 92 BOMAG 611

67. Measure the distance from the exciter shaft to the

front face of the bearing housing (Fig. 40).
i Note
Subtract the second measurement from the first
measurement to calculate the end float.
Nominal value:
min. + 0,5 mm
Fig. 40
68. Assemble the screw fitting and the magnetic plug
with seal ring. (Fig. 41).
Fig. 41
69. Assemble the pipe elbow with magnetic plug and
sealing ring (Fig. 42).
Fig. 42
70. Spray the inner tube in the drum with a corrosion
protection wax (Fig. 43).
Fig. 43
612 BOMAG 008 910 92

Installing the travel gear
71. Turn in two guide bolts (Fig. 44).
Fig. 44
72. Attach the lifting tackle to the travel gear and slide
it over the guide bolts (Fig. 45).
! Danger
Fig. 45
73. Turn in the fastening screws with washers (Fig.
46).
74. Unscrew the guide bolts.
75. Tighten the screws crosswise.
Fig. 46
Mounting the bearing flange (travel motor
side)
Fig. 47
008 910 92 BOMAG 613

77. Attach the lifting tackle to the bearing flange and

slide it over the guide bolts (Fig. 48).
!Danger
i Note
Check the rubber buffers, replace if necessary.
Fig. 48
78. Turn the guide bolts back out (Fig. 49).
79. Screw in all fastening screws and tighten them
crosswise.
80. Take off the travel gear cover (arrow).
Fig. 49
Installing the travel motor
81. Attach a new O-ring to the travel motor flange and
apply a thin coat of oil (Fig. 50).
Fig. 50
82. Install the travel motor (Fig. 51).
Fig. 51
614 BOMAG 008 910 92

83. Tighten the fastening screws (Fig. 52).
Fig. 52
Assembling the bearing flange (vibration mo-
tor side)
84. Check the dowel pin, replace if necessary (Fig.
53).
i Note
Install the dowel pin with LOCTITE 243 .
Fig. 53
85. Screw in two guide bolts to assist the installation
of the travel bearing flange (Fig. 54).
86. Attach the lifting tackle to the travel bearing
flange and slide it over the guide bolts.
!Danger
Fig. 54
87. Assemble the screws with LOCTITE 542 and re-
move the bearing bolts (Fig. 55).
88. Tighten the screws crosswise.
Fig. 55
008 910 92 BOMAG 615

Assemble the bearing race.

89. Assemble a new O-ring and apply a thin coat of
oil (Fig. 56).
Fig. 56
90. Attach the bearing race and tighten the screws
crosswise (Fig. 57).
Fig. 57
Installing the intermediate shaft
91. Install the intermediate shaft with the elastic cou-
pling element (Fig. 58).
i Note
Check the elastic coupling element, replace if
necessary.
Fig. 58
Installing the bearing cover
Fig. 59
616 BOMAG 008 910 92

93. Press the new radial seal into the bearing cover
and lubricate with grease (Fig. 60).
Fig. 60
94. Attach the lifting tackle to the bearing cover and
slide it over the guide bolts (Fig. 61).
! Danger
i Note
Check the rubber buffers, replace if necessary.
Fig. 61
95. Turn in the fastening screws with washers (Fig.
62).
96. Remove the guide bolts.
Fig. 62
97. Tighten the fastening screws crosswise (Fig. 63).
Fig. 63
008 910 92 BOMAG 617

Installing the vibration motor

98. Clean hub bore and shaft (Fig. 64).
99. Slightly loosen clamping screws (2).
100. Push hub (1) onto the shaft of the vibration motor.
101. Tighten the clamping screws with 35 Nm.
Fig. 64
102. Attach a new O-ring to the vibration motor flange
and apply a thin coat of oil (Fig. 65).
Fig. 65
103. Rotate the coupling hub to match the coupling el-
ements (Fig. 66).
Fig. 66
104. Install the vibration motor (Fig. 67).
105. Tighten the fastening nuts.
Fig. 67
618 BOMAG 008 910 92

Filling with oil
106. Fill oil into the exciter shaft tube (Fig. 68).
For quality and quantity of oil see chapter on

fuels, lubricants and filling capacities in these
operating instructions.
Fig. 68
107. Change the oil in the drum drive gear. (Fig. 69).
For quality and quantity of oil see chapter on

fuels, lubricants and filling capacities in these
operating instructions.
Fig. 69
008 910 92 BOMAG 619

620 BOMAG 008 910 92

18 Oscillating articulated joint
008 910 92 BOMAG 621

18.1 Repair overview oscillating articulated joint
18.1 Repair overview oscillating articulat-

ed joint
622 BOMAG 008 910 92

Repair overview oscillating articulated joint 18.1
008 910 92 BOMAG 623

18.1 Repair overview oscillating articulated joint
1 Crab walk cylinder 3 Cross member

2 Steering cylinder
624 BOMAG 008 910 92

Removing - disassembling the oscillating articulated joint 18.2
18.2 Removing - disassembling the oscil-
lating articulated joint
108. Disconnect the main battery switch (Fig. 1).
! Caution
Do not start the engine during repair work on
the articulated joint!
! Danger
Do not work in the articulation area of the roll-
er while the engine is running.
Fig. 1
109. Open the maintenance cover (Fig. 2) to gain ac-
cess to the water pump.
Fig. 2
110. Drain the water tank
111. Loosen hose connections 3 and 4 (Fig. 3) and
drain off all water.
112. Disconnect plugs (1 and 2) from water sprinkling
pumps, pressure switch and float switch.
Fig. 3
008 910 92 BOMAG 625

18.2 Removing - disassembling the oscillating articulated joint
113. Disconnect the water hose in the area of the ar-

ticulated joint (Fig. 4).
Fig. 4
114. Remove the left and right hand sraps 1 (Fig. 5).
115. Remove protective frame (2).
Fig. 5
116. Loosen the hose clamps 1 (Fig. 6) and remove

the top water tank.
117. Remove the protective frame (3) and disassem-
ble the bottom water tank (4)+.
Fig. 6
626 BOMAG 008 910 92

118. Mark connecting lines 1 and 2 (Fig. 7) for steering
cylinders and disconnect. Close the hydraulic
connections with plugs.
! Caution
mentally!
Fig. 7
119. Mark connecting lines 1 and 2 (Fig. 8) for crab
walk cylinders and disconnect. Close the hydrau-
lic connections with plugs.
! Caution
mentally!
Fig. 8
120. Mark connecting lines 1 and 2 (Fig. 9) for steering
cylinders and disconnect. Close the hydraulic
connections with plugs.
! Caution
mentally!
121. Remove the holding plate (3).
122. Unscrew screws (5) and disassemble holder (6)
with proximity switch.
123. Disconnect plug (4) from the proximity switch..
Fig. 9
124. Mark and disconnect all hydraulic hoses (Fig. 10).
Close the hydraulic connections with plugs.
! Caution
mentally!
Fig. 10
008 910 92 BOMAG 627

125. Disconnect the plug of the rear frame wiring har-

ness (Fig. 11) from terminal strip X1 in the central
electrics.
i Note
Plug
X1:71 - 74, X1:125-126, X1:127-131, X132-133,
X1:145-148, X1:185-186.
126. Carefully lay the wiring harness down in the rear

frame.
Fig. 11
127. Remove the battery box (Fig. 12).
Fig. 12
128. Remove the battery (Fig. 13).
! Caution
When removing the battery disconnect the
minus pole first and the plus pole after.
Follow the rules for handling batteries (see
technical manual "Basic Electrics").
Fig. 13
129. Attach the lifting tackle to the rear frame (Fig. 14).
130. Support the front frame safely and block the front
wheel with wedges against rolling.
! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
Fig. 14
628 BOMAG 008 910 92

131. Unscrew the screws 1 (Fig. 15) from both steer-
ing cylinders.
132. Remove the axle holder (2).
133. Attach the lifting tackle to the steering cylinder.
! Danger
134. Knock out bearing bolt (3).
135. Remove the steering cylinder (4).
Fig. 15
136. Unscrew the screws 1 (Fig. 16) from the crab
walk cylinder.
137. Remove the axle holder (2).
138. Attach the lifting tackle to the crab walk cylinder.
139. Knock out bearing bolt (3).
! Danger
140. Remove the crab walk cylinder (4).
Fig. 16
141. Unscrew nut 1 (Fig. 17).
Fig. 17
142. Pull hexagon screw 1 (Fig. 18) down and out.
Fig. 18
008 910 92 BOMAG 629

143. Unscrew fastening screws 1 (Fig. 19).

144. Remove top cover (2).
i Note
The cover hides Belleville springs and shims.
Fig. 19
145. Unscrew the screws with washers 1 (Fig. 20)
from the bottom cover.
146. Remove the bottom cover.
Fig. 20
147. Use a tap (M24) 1 (Fig. 21) to cut a thread into top
and bottom joint bolts (2).
Fig. 21
148. Turn a screw (M24) 1 (Fig. 22) into the joint bolt
(2) in the front frame.
! Danger
Make sure that front and rear frames are prop-
erly secured against rolling and tipping over.
149. Pull the bottom joint bolt out of the console.
150. Pull the top joint bolt (2) out of the console.
Fig. 22
630 BOMAG 008 910 92

151. Attach the lifting tackle to the cross-member (Fig.
23).
152. Separate the front frame from the rear frame.
Fig. 23
153. On the rear frame unscrew the screws (Fig. 24)
from the top and bottom covers.
154. Remove the top cover.
i Note
The top cover hides Belleville springs and shims.
155. Remove the bottom cover.
Fig. 24
156. Use a tap (M24) 1 (Fig. 25) to cut a thread into top
and bottom joint bolts on the rear frame (2).
Fig. 25
157. Turn a screw (M24) 1 (Fig. 26) into the joint bolt
(2).
158. Pull the bottom joint bolt out of the console.
! Danger
159. Pull the top joint bolt (2) out of the console.
Fig. 26
008 910 92 BOMAG 631

160. Separate the cross member from the rear frame

(Fig. 27).
Fig. 27
161. Lay the cross member to the side (Fig. 28).
Fig. 28
162. Check the pivot bearings (Fig. 29) on console and
cross member, replace if necessary.
Fig. 29
163. Check the pivot bearings (Fig. 30) on the front
frame, replace if necessary.
Fig. 30
632 BOMAG 008 910 92

164. Attach the lifting tackle to console 3 (Fig. 31).
! Danger
165. Unscrew the screws (1), remove both stops (2)
and lift off the cosole with the live ring connection
(3).
Fig. 31
166. Unscrew the screws 1 (Fig. 32) and separate the
live ring connection (2) from the console (3).
Fig. 32
167. Use forcing screws 1 (Fig. 33) to press the pivot
bearings (3) off the joint bolts.
Fig. 33
008 910 92 BOMAG 633

18.3 Assembling the oscillating articulated joint
18.3 Assembling the oscillating articulated

joint
1. Spray the mating surfaces with sliding lacquer
OKS 571 to ease assembly (Fig. 1).
! Caution
Do not use any grease.
Attach the inner bearing race in straight posi-
tion.
2. Assemble backing disc (2).
3. Press the inner bearing race (1) over the joint bolt
(3).
Fig. 1
4. Assemble live ring 2 (Fig. 2) and console (3) with
screws (1) and washers.
5. Tighten the fastening screws cross-wise.
Fig. 2
6. Attach the lifting tackle to the console with live
ring (Fig. 3) and position the assembly on the rear
frame.
Fig. 3
634 BOMAG 008 910 92

Assembling the oscillating articulated joint 18.3
7. Fasten the console with live ring 3 (Fig. 4) and
both end stops (2) to the rear frame using screws
(1) and washers.
i Note
Mind the correct position of the grease nipples.
8. Tighten the fastening screws cross-wise.
Fig. 4
9. Change the seal ring in the upper area of the front
frame (Fig. 5).
Fig. 5
10. Change the seal ring in the lower area of the front
frame (Fig. 6).
Fig. 6
11. Clean the receiving bores for the joint bolts (Fig.
7).
Fig. 7
008 910 92 BOMAG 635

12. Attach the lifting tackle to the cross-member (Fig.

8).
! Danger
Fig. 8
13. Insert the cross member (Fig. 9) into the front
frame.
Fig. 9
OKS 571 or cover with grease to ease assembly
(Fig. 10).
15. Insert the upper joint bolt.
16. Insert the lower joint bolt.
Fig. 10
17. Press upper and lower joint bolts in together (Fig.
11).
! Caution
Avoid skewing of the joint bolts.
Fig. 11
636 BOMAG 008 910 92

18. Spray the upper outer rocker bearing race with
sliding agent OKS 571 (Fig. 12).
! Caution
Ensure straight installation of the outer bear-
ing race.
19. Attach the outer bearing race and knock it in.
i Note
Allow the bearing to protrude for about 5-10 mm
Fig. 12 and pull it completely in later when assembling
the cover.
20. Spray the lower outer rocker bearing race with
sliding agent OKS 571 (Fig. 13).
! Caution
Ensure straight installation of the outer bear-
ing race.
21. Attach the outer bearing race and knock it in.
i Note
Allow the bearing to protrude for about 5- 10 mm
the cover.
22. Attach the lower cover and tighten the screws
crosswise (Fig. 14).
Fig. 14
008 910 92 BOMAG 637

Determining the shim thickness

23. Install screw 1 (Fig. 15) from underneath through
the joint bolts of the cross member.
Fig. 15
24. Insert backing disc 1 (Fig. 16) and Belleville
springs (2) into the upper cover.
i Note
Lay the Belleville springs into the cover with the
curvature pointing down .
Fig. 16
25. Assemble nut 1 (Fig. 17) and washer and tighten
with 90 Nm.
! Caution
Check the measurement with an axial preload
of 40kN. Tightening torque = 90Nm.
26. Measure the gap (measurement „Y“) between
cover and frame.
i Note
Shim thickness "S" = 3.2 mm - "Y"
Fig. 17 27. Remove the cover again.
28. Insert shims 2 (Fig. 18) of appropriate thickness
and backing disc (1) into the cover.
Fig. 18
638 BOMAG 008 910 92

29. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 19).
Fig. 19
30. Assemble cover 2 (Fig. 20) with Belleville springs,
shims and backing disc.
31. Turn in screws (1) and tighten crosswise.
Fig. 20
32. Insert screw 1 (Fig. 21) from underneath.
33. Assemble the washer, turn on the nut and tighten
with 120 Nm.
Fig. 21
34. If previously disassembled, press the rocker
bearing (Fig. 22) fully into the frame with a press-
ing mandrel.
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease!
Fig. 22
008 910 92 BOMAG 639

35. Replace both seal rings in the console (Fig. 23).
Fig. 23
36. Join the cross member with the rear frame (Fig.
24).
! Danger

Fig. 24
OKS 571 or cover with grease to ease assembly
(Fig. 25).
38. Insert the upper joint bolt.
39. Insert the lower joint bolt.
Fig. 25
40. Press upper and lower joint bolts in together (Fig.
26).
! Caution
Avoid skewing of the joint bolts.
Fig. 26
640 BOMAG 008 910 92

41. Spray the upper and lower outer rocker bearing
race with sliding agent OKS 571 (Fig. 27).
! Caution
Keep straight when assembling.
42. Knock upper (1) and lower outer races in with a
plastic hammer.
i Note
Allow the bearing to protrude for about 5-10 mm
the cover.
43. Attach the lower cover (Fig. 28) and tighten the
screws crosswise.
Fig. 28
Determining the shim thickness
44. Insert backing disc 1 (Fig. 29) and Belleville
springs (2) into the upper cover.
i Note
Lay the Belleville springs into the cover with the
curvature pointing down .
Fig. 29
45. Assemble the cover and tighten screw 1 (Fig. 30)
with 90 Nm.
! Caution
Check the measurement with an axial preload
of 40kN. Tightening torque = 90Nm.
46. Measure the gap (measurement „Y“) between
cover and frame.
i Note
Shim thickness "S" = 3.2 mm - "Y"
Fig. 30 47. Remove the cover again.
008 910 92 BOMAG 641

48. Insert shims 2 (Fig. 31) of appropriate thickness

and backing disc (1) into the cover.
Fig. 31
49. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 32).
Fig. 32
50. Assemble the cover (Fig. 33) with Belleville
springs, shims and backing disc.
51. Turn in the screws and tighten crosswise.
Fig. 33
52. Turn in screw 1 (Fig. 34).
53. Assemble the washer, turn on the nut and tighten
with 120 Nm.
Fig. 34
642 BOMAG 008 910 92

54. If previously disassembled, press the rocker
bearing (Fig. 35) fully into the console with a
pressing mandrel.
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease!
55. Install and connect the crab walk cylinder.
Fig. 35
! Danger
56. Install and connect both steering cylinders.
! Danger
57. Reconnect all hydraulic lines, rout and fasten

them properly.
58. Assemble the water hoses.
59. Install the battery.
! Caution
Connect the plus pole first and the minus pole
after.
Follow the rules for handling batteries (see
technical manual "Basic Electrics").
60. Install the battery box.
61. Grease the articulated joint (Fig. 36).
Fig. 36
008 910 92 BOMAG 643

62. Mount bracket 3 (Fig. 37) and adjust the contact

pin (1) for the proximity switch (2) to a < 4mm
switching gap.
Fig. 37
63. Reconnect all wiring harness plugs (Fig. 38).
! Caution
Ensure correct routing of the wiring harness-
es. Ensure sufficient length compensation
when steering the machine. Avoid chafing.
Fig. 38
64. Install and fill the water tanks.
65. Connect and wire the water sprinkling pumps
(Fig. 39).
! Caution
Check the water sprinkling system for func-
tion and leak tightness before putting the ma-
chine back into service.
Fig. 39
66. Check the hydraulic oil level (Fig. 40).
! Caution
Check the hydraulic system for function and
leak tightness before putting the machine
back into service.
i Note
To bleed the steering cylinders run the engine
with idle speed and operate the steering several
times to left and right. Extend and retract the crab
walk cylinder several times. Then check the hy-
Fig. 40 draulic oil level once again.
644 BOMAG 008 910 92

19 Vibration valve Y54/Y55
008 910 92 BOMAG 645

19.1 Vibration control valve, repair overview
1 not used 11 not used

2 Magnetic coil 12 not used
3 Pressure control valve 13 Fitting
4 Flushing valve 14 Fitting
5 Nozzle 15 Fitting
6 Measuring connection 16 not used
7 Pressure relief valve 17 not used
8 not used 18 not used
9 Fitting 19 not used
10 Fitting 20 Fitting
646 BOMAG 008 910 92

Vibration control valve, repair overview 19.1
008 910 92 BOMAG 647

19.1 Vibration control valve, repair overview
648 BOMAG 008 910 92

20 Suppliers documentation
008 910 92 BOMAG 649

650 BOMAG 008 910 92
20.1 Travel pump
008 910 92 BOMAG 651

20.1 Travel pump
Bild 41
652 BOMAG 008 910 92

Travel pump
Electric Drives Linear Motion and
20.1
and Controls Hydraulics Assembly Technologies Pneumatics Service
Verstellpumpe A4VG 40–56 RDE 92 003-11-R/12.05
Variable Pump A4VG 40–56

Baureihe / Series 32 R1
Reparaturanleitung / Repair Manual
Baugruppen / Assembly Groups
008 910 92 BOMAG 653

2/36
20.1
Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 40–56 RDE 92 003-11-R/12.05
Travel pump
Vermeidung von Gefahren Avoiding Dangers

Für einen sicheren Betrieb und um Schäden bei der Reparatur To ensure safe operations and avoid damages during repairs,
zu vermeiden, lesen Sie diese Reparaturanleitung sorgfältig read this complete repair manual carefully and attentively.
und aufmerksam durch!
Für Personen- oder Maschinenschäden, die durch Nichtbe- Bosch Rexroth AG accepts no responsibility for personal
achtung dieser Reparaturanleitung entstehen, verfällt jegliche injuries or damages to the machine that arise from disregarding
Gewährleistung von Bosch Rexroth AG. this repair manual.
1 Zu dieser Anleitung 1 About this Manual

Diese Anleitung unterstützt Sie bei der Reparatur, den Ein- This manual supports you in the repair, adjustment and recom-
stellungen und der Wiederinbetriebnahme von Rexroth A4VG missioning of Rexroth A4VG variable pumps, sizes 40–56. The
Verstellpumpen, NG 40–56. Diese Anleitung umfasst die manual is structured as follows:
folgenden Kapitel:
x „Sicherheit“ auf Seite 7 x “Safety” on page 7
Hier erhalten Sie grundsätzliche Hinweise zum sicheren This chapter provides you with basic hints and tips regarding
Umgang mit Verstellpumpen und zu deren Betrieb. working with and operating variable pumps.
Lesen Sie dieses Kapitel bevor Sie anfangen zu arbeiten. Read this chapter before you start working.
x „Produktbeschreibung“ auf Seite 11 x “Product Description” on page 11
Hier erfahren Sie, wie Sie den Typ einer Verstellpumpe This chapter explains how you identify the variable pump.
feststellen. Ferner finden Sie hier eine Übersicht über die Addtionally, it provides you an overview of the how the vari-
Funktionsweise und Informationen zur bestimmungsgemäßen able pump and information regarding the correct usage.
Verwendung der Verstellpumpe. Read this chapter to refresh your knowledge of the variable
Lesen Sie dieses Kapitel, um Ihr Grundwissen über die pumps.
Verstellpumpe aufzufrischen.
x „Austausch externer Baugruppen“ auf Seite 15 x “Exchanging External Assembly Groups” on page 15
Dieses Kapitel erklärt Ihnen, wie Sie Baugruppen einer Ver- Rexroth provides various replacement parts for repairs. This
stellpumpe austauschen. section provides you an overview of the available spare parts
subassemblies.
x „Überprüfungen“ auf Seite 29 x “Checking” on page 29
Dieses Kapitel erklärt Ihnen, wie Sie die Einstellungen an Read this chapter to be able to check the settings on a
einer Verstellpumpe überprüfen. variable pump.
654 BOMAG 008 910 92

RDE 92 003-11-R/12.05
Travel pump Reparaturanleitung/Repair Manual A4VG 40–56
20.13/36
Bosch Rexroth AG
1.1 Inhaltsverzeichnis 1.1 Contents
1. Zu dieser Anleitung 2 1. About this Manual 2

1.1 Inhaltsverzeichnis 3 1.1 Contents 3
1.2 Gültigkeitsbereich dieser Anleitung 4 1.2 Validity of this Manual 4
1.3 Wichtige Unterlagen 5 1.3 Important Documents 5
1.4 Gefahrenkennzeichnungen und Pictogramme 6 1.4 Danger Labels and Pictograms 6
2. Sicherheit 7 2. Safety 7
2.1 Grundlegende Sicherheitshinweise 7 2.1 Basic Safety Information 7
2.2 Anforderungen an das Personal 10 2.2 Requirements on the Personnel 10
3. Produktbeschreibung 11 3. Product Description 11
3.1 Typschild 11 3.1 Type Plate 11
3.2 Funktionsbeschreibung 11 3.2 Functional Description 11
3.3 Technische Daten 14 3.3 Technical Data 14
4. Austausch externer Baugruppen 15 4. Exchanging External Assembly Groups 15
4.1 Wellendichtring austauschen 16 4.1 Exchanging the Shaft Seal 16
4.2 Dichtungen austauschen 18 4.2 Exchanging Seals 18
4.3 Hilfspumpe austauschen 24 4.3 Exchanging the Backing Pump 24
4.4 Steuergerät austauschen 26 4.4 Exchanging the Controller 26
5. Überprüfungen 29 5. Checking 29
5.1 Niederdruck (Speisedruck) überprüfen 30 5.1 Checking Low Pressure (Charge Pressure) 30
5.2 Hochdruck überprüfen 30 5.2 Checking High Pressure 30
5.3 Mechanische Nulllage überprüfen 31 5.3 Checking the Mechanical Zero Stroke 31
5.4 Hydraulische Nulllage überprüfen 32 5.4 Checking the Hydraulic Zero Stroke 32
008 910 92 BOMAG 655

4/36
20.1
Travel pump
1.2 Gültigkeitsbereich dieser 1.2 Validity of this Manual

Anleitung
Diese Reparaturanleitung gilt für die Axialkolben-Verstellpumpe This manual is valid for the Bosch Rexroth axial piston variable
A4VG NG 40–56 der Bosch Rexroth AG. Informationen zu pump A4VG NG 40–56. Refer to the system manufacturer for
zugelassenen Druckflüssigkeiten entnehmen Sie den Angaben information about the allowed hydraulic fluids.
des Anlagenherstellers.
Diese Reparaturanleitung richtet sich an: This repair manual is directed at:
x Anlagenbetreiber, x the system operator
x den autorisierten Fachbetrieb bzw. Händler, x authorized dealers
x den Anlagenhersteller. x the system manufacturer
Für den Anlagenhersteller sind zusätzlich auch die jeweilige For the system manufacturer, the installation drawing, the
Einbauzeichnung, das technische Datenblatt, die Betriebsan- catalog sheet, the manual, and the confirmation of order from
leitung und die Auftragsbestätigung der Bosch Rexroth AG the Bosch Rexroth AG are also obligatory.
verbindlich.
656 BOMAG 008 910 92

RDE 92 003-11-R/12.05
Travel pump Reparaturanleitung/Repair Manual A4VG 40–56 Bosch Rexroth AG
20.15/36
1.3 Wichtige Unterlagen 1.3 Important Documents

Bevor Sie mit den in dieser Anleitung beschriebenen Arbeiten Before you start any of the procedures described in this manu-
anfangen, stellen Sie sicher, dass Sie folgende Unterlagen al, make sure you have the following documents:
griffbereit haben:
x Auftragsbestätigung x Confirmation of order
Die Auftragsbestätigung enthält die voreingestellten techni- The confirmation of order contains the values set during the
schen Daten. Die Axialkolbenmaschine darf nur unter den in commissioning by Rexroth. Before you can recommission the
der Auftragsbestätigung angegebenen Werten und Bedin- axial piston unit after a repair, you have to restore the values
gungen betrieben werden. originally set by Rexroth.
x Einbauzeichnung x Installation drawing
Die Einbauzeichnung der Axialkolbenmaschine enthält die The installation drawing of the axial piston unit contains the
Außenabmessungen, sämtliche Anschlüsse und den Schalt- sizes of all connections.
plan.
x Technisches Datenblatt x Technical data sheet
Das technische Datenblatt RD 92 003 enthält u.a. die zuläs- The technical data sheet RE 92 003 contains the maximum
sigen technischen Daten für die Axialkolbenmaschine. allowed performance data.
x Gesamtschaltplan der Maschine bzw. Anlage x Hydraulic diagramWiring diagram
Der Hydraulikschaltplan und der elektrische Schaltplan der The hydraulic diagram and the wiring diagram of the unit
Maschine bzw. Anlage enthalten die Informationen zu den or system contain the information related to the respective
hydraulischen bzw. elektrischen Anschlüssen. Diese Daten machine.You need this data to work with the axial piston as
brauchen Sie, um mit der Axialkolbenmaschine als Teil der part of the machine or system. You can get this information
Maschine bzw. Anlage zu arbeiten. Die Unterlagen erhalten from the unit or system manufacturer.
Sie vom Maschinen- bzw. Anlagenhersteller.
x RD 90 300-B: Allgemeine Betriebsanleitung für Axialkol- x RE 90 300-B: General Manual for Axial Piston Units
benmaschinen The general manual supports you during the installation,
Die allgemeine Betriebsanleitung unterstützt Sie bei Installa- initiation, and operation of Rexroth axial piston units.
tion, Inbetriebnahme und Betrieb von Rexroth-Axialkolbenma-
schinen.
x Produktspezifische Betriebsanleitung x Product Specific Manual
Die produktspezifische Betriebsanleitung enthält spezielle, The product-specific manual contains information specially
für die Axialkolbenmaschine gültige Informationen. Informie- designed for the axial piston unit. Get in touch with Rexroth
ren Sie sich bei Rexroth, ob es zu Ihrer Axialkolbenmaschine to find out if there is any product-specific information on your
eine produktspezifische Betriebsanleitung gibt. specific axial piston unit.
Folgende Rexroth-Druckschriften geben Ihnen weitere Informa- The following Rexroth publications provide additional informati-
tionen zu Installation und Betrieb der Axialkolbenmaschine: on to the installation and operation of axial piston units:
x RD 90 220: Druckflüssigkeiten auf Mineralölbasis x RE 90 220: Mineral-oil Based Pressure Fluids
Beschreibt die Anforderungen an eine Druckflüssigkeit auf This publication describes the requirements on a hydraulic
Mineralölbasis für den Betrieb mit Rexroth-Axialkolbenma- fluid for operation in an axial piston unit and supports you in
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- the selection of a hydraulic fluid for your installation.
keit für Ihre Anlage.
x RD 90 221: Umweltfreundliche Druckflüssigkeiten HEES, x RE 90 221: Environmentally Acceptable Hydraulic Fluids
HEPG, HETG für Axialkolbenmaschinen HEES, HEPG, HETG for Axial Piston Units
Beschreibt die Anforderungen an eine umweltfreundliche Describes the demands on environmentally compatible, rea-
Druckflüssigkeit für den Betrieb mit Rexroth-Axialkolbenma- dily biodegradeable hydraulic fluids HEPG, HEES that can
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- be used in Rexroth axial piston units and supports you by the
keit für Ihre Anlage. choice of a hydraulic fluid for your system.
x RD 90 223: Axialkolbenmaschinen für den Betrieb mit x RE 90 223: Axial Piston Units for Use with HF Fluids
HF-Druckflüssigkeiten Provides additional information for the use of Rexroth axial
Enthält zusätzliche Informationen zum Einsatz von Rexroth- piston units with HF hydraulic fluids.
Axialkolbenmaschinen mit HF-Druckflüssigkeiten.
x RD 90 300-03-B: Hinweise zum Einsatz von hydrauli- x RE 90 300-03-B: Instructions on the Use of Hydrostatic
schen Antrieben bei tiefen Temperaturen Drives at Low Temperatures
Enthält zusätzliche Informationen zum Einsatz von Rexroth- Provides additional information for the use of Rexroth axial
Axialkolbenmaschinen bei tiefen Temperaturen. piston units for low temperatures.
008 910 92 BOMAG 657

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20.1
Travel pump
1.4 Gefahrenkennzeichnungen 1.4 Danger Labels and Pictograms

und Piktogramme
Diese Anleitung unterscheidet zwischen Kategorien von Gefah- This manual differentiates between the following categories of
ren gemäß ISO Guide 37: danger according to ISO Guide 37:
! GEFAHR ! DANGER
Weist auf hohes Risiko und die Gefahr von Tod oder schwe- Indicates high risk, mortal danger and serious injuries.
ren Verletzungen hin.
! WARNUNG ! WARNING
Weist auf mittleres Risiko und die Gefahr von Verletzungen Indicates middle risk, injuries or serious material damage.
und schweren Sachschäden hin.
! VORSICHT ! CAUTION
Weist auf geringes Risiko und Sachschäden hin. Indicates low risk or material damage.
Hinweis Note
Kennzeichnet Informationen, die zum besseren Verständnis Indicates information that contributes to a better understan-
der Maschinenabläufe beitragen oder weist auf einen beson- ding of the machine processes or indicates important informa-
deren bzw. wichtigen Sachverhalt hin. tion.
Tipp Tip
Kennzeichnet Informationen, die zum effizienteren Arbeiten Indicates information that contributes to more efficient work.
beitragen.
658 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.17/36
2 Sicherheit 2 Safety
Lesen Sie dieses Kapitel sorgfältig durch, bevor Sie mit Arbei- Read through this chapter carefully before you start any work
ten an der Verstellpumpe beginnen. on the variable pump.
Die Rexroth-Verstellpumpen sind im Sinne der Maschinenricht- The Rexroth variable pump are in the sense of the machine gui-
linie 98/37/EG Komponenten, die zum Einbau in eine Anlage deline 98/37/EG components of a larger machine or system.
bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung be- The safety guidelines in this manual only cover the variable
ziehen sich nur auf die Verstellpumpe. Beachten Sie zusätzlich pump. You must additionally follow the system manufacturer’s
die Sicherheitsrichtlinien des Anlagenherstellers. safety guidelines.
Informieren Sie sich an Hand der allgemeinen Betriebsanlei- Read the general manual for axial piston units to get more infor-
tung für Axialkolbenmaschinen über die bestimmungsgemäße mation on the designated use and the operator‘s obligation to
Verwendung und die Sorgfaltspflicht des Betreibers und exercise dilligence.
Bedieners.
2.1 Grundlegende 2.1 Basic Safety Information

Sicherheitshinweise
Befolgen Sie die folgenden Sicherheitshinweise und die des Pay exact attention to the following safety information and that
Anlagenherstellers genau, um Verletzungen und Gesundheits- of the system manufacturer to eliminate injuries and health
schäden sowie Sach- und Umweltschäden auszuschließen. damages as well as damages to material or the environment.
! GEFAHR ! DANGER
Lebensgefahr Danger to Life

Das Arbeiten an nicht stillgelegten Maschinen bzw. Anlagen Working on systems that have not been shut down is life-thre-
stellt eine Gefahr für Leib und Leben dar. atening.
Die in diesem Dokument beschriebenen Arbeiten dürfen nur The work described in this document can only be carried out
an stillgelegten Maschinen bzw. Anlagen vorgenommen on a shut down system. Before you start any of the tasks:
werden. Bevor Sie mit den Arbeiten beginnen:
x Stellen Sie sicher, dass der Antriebsmotor nicht eingeschal- x Make sure that the engine / motor cannot be switched on.
tet werden kann.
x Stellen Sie sicher, dass sämtliche kraftübertragenden Kom- x Make sure that all components and connections that carry
ponenten und Anschlüsse (elektrisch, pneumatisch, hydrau- energy (electrical, pneumatic, hydraulic) have been shut
lisch) gemäß den Herstellerangaben ausgeschaltet sind und down according to the manufacturer’s instructions and
nicht eingeschaltet werden können. Falls möglich, entfernen cannot be switched on. If possible, disable the main fuse.
Sie die Hauptsicherung der Maschine bzw. Anlage.
x Stellen Sie sicher, dass die Maschine bzw. Anlage komplett x Make sure that the system is completely unloaded. Follow
hydraulisch entlastet ist (drucklos). Folgen Sie hierzu den the instructions of the the system manufacturer.
Angaben des Maschinen- bzw. Anlagenherstellers.
! WARNUNG ! WARNING
Verletzungsgefahr Danger of injuries

Um Verletzungen zu vermeiden, beachten Sie bitte folgende To avoid injuries, pay attention to the following regarding
Empfehlungen betreffend Sicherheitskleidung: safety clothing.
x Tragen Sie bei Arbeiten an Maschine bzw. Anlage Sicher- x When working on the system, wear steel-toed safety shoes.
heitsschuhe mit Stahlkappen.
x Tragen Sie bei Arbeiten mit gefährlichen Stoffen (beispiels- x When working with dangerous substances (for example,
weise Druckflüssigkeiten) Schutzhandschuhe und Schutz- certain hydraulic fluids), wear protective gloves and protec-
brille. tive glasses.
008 910 92 BOMAG 659

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8/36 Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 40–56 RDE 92 003-11-R/12.05
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! GEFAHR ! DANGER
Vergiftungs- und Verletzungsgefahr Danger of poisoing or injuries

Der Kontakt mit Drückflüssigkeiten ruft Gesundheitsschäden Contact with hydraulic fluids can cause health damage (eye
hervor (z.B. Augenverletzungen, Haut- und Gewebeschädi- injuries, skin damage, poisoning due to inhalation).
gungen, Vergiftungen beim Einatmen).
x Überprüfen Sie vor jeder Inbetriebnahme die Leitungen auf x Always check the hydraulic lines for wear and damage prior
Verschleiß bzw. Beschädigungen. to putting the unit into operation.
x Tragen Sie dabei Schutzhandschuhe und Schutzbrille. x Always wear protective gloves and safety glasses.
x Wenn dennoch Druckflüssigkeit in die Augen gelangt oder x Should pressure fluid come into contact with your eyes or
in die Haut eindringt, konsultieren Sie unmittelbar einen skin: Get medical help immediately!
Arzt.
x Beachten Sie beim Umgang mit Druckflüssigkeiten unbe- x When handling hydraulic fluids, pay exact attention to the
dingt die Sicherheitsangaben des Druckflüssigkeitsherstel- manaufacturer’s safety instructions.
lers.
! WARNUNG ! WARNING
Verbrennungsgefahr Danger of burns

Die Axialkolbenmaschine erwärmt sich während des Betriebs. The variable pump heats up during operation. The unit’s sole-
Auch die Magnete an der Axialkolbenmaschine werden im noids get hot during operation. Touching the variable pump or
laufenden Betrieb heiß. Bei Berührung der Axialkolbenma- solenoids can lead to severe injuries.
schine oder der Magnete können schwere Brandverletzungen
entstehen.
x Lassen Sie die Axialkolbenmaschine vor jedem Kontakt x Let the variable pump cool down prior to any contact.
abkühlen.
x Schützen Sie sich mit hitzebeständigen Handschuhen und x Protect yourself from burns by wearing safety gloves and
Schutzkleidung. protective clothing.
! GEFAHR ! DANGER
Vergiftungs- und Verletzungsgefahr Danger of poisoning

Beim Suchen nach Leckstellen kann entweichende Druckflüs- When looking for leaks, escaping hydraulic fluid can break
sigkeit in die Haut eindringen und schwerste Vergiftungen und into the skin and cause serious poisoning.
Verletzungen hervorrufen.
x Suchen Sie nur bei abgestellter und druckloser Maschine x Always use a piece of cardboard or paper to look for leaks.
nach Leckstellen.
! WARNUNG ! WARNING
Verletzungs- und Beschädigungsgefahr Danger of injuries or damage

Durch falsch angeschlossene Komponenten können erhebli- Incorrectly connected components can considerably impair
che Fehlfunktionen entstehen. the functionality of a hydraulic system.
x Achten Sie auf korrekte Verrohrung gemäß Schaltplan. x Make sure that the hydraulic lines are connected properly.
x Führen Sie komponentenorientierte Funktionstests durch. x Check the correct functioning of all components.
660 BOMAG 008 910 92

RDE 92 003-11-R/12.05
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! GEFAHR ! DANGER
Feuergefahr Danger of fire

Hydraulische Druckflüssigkeit ist brennbar. Hydraulic fluid is inflammable.
x Halten Sie offenes Feuer von der Verstellpumpe fern. x Keep open fires away from the variable pump.
! WARNUNG ! WARNING
Gehörschäden Danger of hearing loss

Die Geräuschemission von Axialkolbenmaschinen ist u.a. von The noise emission produced by axial piston units depends
Drehzahl, Betriebsdruck und Einbauverhältnissen abhängig. on speed, operating pressure, and installation. During normal
Es ist damit zu rechnen, dass der Schalldruckpegel bei nor- application conditions, over 70 dBA can be anticipated. This
malen Einsatzbedingungen über 70 dBA steigt. Dies kann zu can lead to hearing damage.
Gehörschäden führen.
x Schützen Sie sich stets mit Gehörschutz bei Arbeiten in x Always wear hearing protection when working in the vicinity
der Nähe der Axialkolbenmaschine während des laufenden of the variable pump during operation.
Betriebs.
! WARNUNG ! WARNING
Umweltschäden Risk of damage to the environment

Druckflüssigkeiten sind wassergefährdende Flüssigkeiten. Hydraulic fluid leakage leads to contamination of the ground
Das Austreten von Druckflüssigkeiten kann zu Grundwasser- and ground water.
vergiftung und Bodenverseuchung führen.
x Bringen Sie unter der Axialkolbenmaschine eine Auffang- x A basin for catching any hydraulic fluid must be placed
wanne an. under the variable pump.
x Beseitigen Sie Leckstellen unverzüglich. x Leaks must be cleaned up immediately.
x Es sind stets die nationalen Gesetze und Vorschriften zu x In Europe, hydraulic systems are considered “Systems
beachten. In Deutschland sind hydraulische Maschinen bzw. using water-threatening substances” in the sense of the
Anlagen „Anlagen zum Umgang mit wassergefährdenden Water Management Law (WHG).Therefore, pay special
Stoffen im Sinne des Wasserhaushaltsgesetzes (WHG)“. attention to §1 and §19 WHG( §19g, 19i, 19l). Additionally
Beachten Sie in diesem Zusammenhang besonders §1 und pay attention to any national regulations and norms.
§19 WHG (§19g, 19i, 19l).
x Weitere Informationen zum richtigen Umgang mit Rexroth- x For further information regarding the correct use of Bosch
Hydraulikprodukten finden Sie in unseren Druckschriften Rexroth hydraulic products, see the publications RE 90 220
„Allgemeine Produktinformationen für Hydraulikprodukte“, “Mineral-oil Based Pressure Fluids” and RE 90 221 “En-
RD 90 220 und „Umweltschonende, biologisch schnell vironmentally Acceptable Hydraulic Fluids HEES, HEPG,
abbaubare Druckflüssigkeiten HEPG, HEES für Axialkol- HETG for Axial Piston Units“, RD 90 221.
benmaschinen“, RD 90 221.
008 910 92 BOMAG 661

20.1
10/36Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 40–56 RDE 92 003-11-R/12.05
Travel pump
2.2 Anforderungen an das Personal 2.2 Requirements on the Personnel

Diese Reparaturanleitung richtet sich an Fachkräfte mit This repair manual is directed at qualified personnel with
Hydraulik-Fachwissen, die an einer Service-Schulung bei specialized hydraulics know-how who have taken part at a
Rexroth teilgenommen haben. service training at Rexroth.
Als Fachkraft gilt, wer aufgrund seiner fachlichen Ausbildung Qualified personnel is defined as persons who have sufficient
und Erfahrung ausreichende Kenntnisse hat, sowie mit den knowledge on the basis of specialized training and experience,
einschlägigen Bestimmungen so weit vertraut ist, dass er and are familiar with the relevant regulations, so that they are
able to
x die ihm übertragenene Arbeiten beurteilen kann, x judge the delegated tasks,
x mögliche Gefahren erkennen kann, x recognize possible dangers,
x die notwendigen Maßnahmen zur Beseitigung von Gefahren x take the necessary measures for the elimination of dangers,
ergreifen kann,
x Kenntnisse über die möglichen Gesundheitsgefahren von x judge the possible health risks from hydraulic fluids,
Druckflüssigkeiten hat
x und die erforderlichen Reparatur- und Montagekenntnisse x and have the required repair and installation know-how.
hat.
Hydraulik-Fachwissen bedeutet, das Personal muss, Specialized hydraulics know-how means that these persons
must:
x in der Lage sein, die Hydraulikpläne zu lesen und vollständig x be able to read and completely understand hydraulic plans,
zu verstehen,
x insbesondere die Zusammenhänge bezüglich der eingebau- x especially understand the connections regarding the in-
ten Sicherheitseinrichtungen vollständig verstehen stalled safety equipment,
x und Kenntnisse über Funktion und Aufbau von hydraulischen x and are familiar with the function and structure of hydraulic
Bauteilen haben. components.
662 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.111/36
Bosch Rexroth AG
3 Produktbeschreibung 3 Product Description

Dieses Kapitel gibt Ihnen einen allgemeinen Überblick über die This chapter provides a general overview of the functionality of
Funktionalität der Rexroth A4VG Verstellpumpe. the A4VG variable pump.
Machen Sie sich mit den Inhalten dieses Kapitels vertraut, You should be familiar with the contents of this chapter before
bevor Sie mit Arbeiten an einer Verstellpumpe beginnen. starting any work on the variable pump.
3.1 Typschild 3.1 Type Plate

Die Verstellpumpe ist am Typschild zu identifizieren: The variable pump can be identified on its type plate:
1 3FYSPUI
D-89275 Elchingen
2 TYP: A4VG56DA2D2/32R-NZC02F003SP 7
3 MNR: R90XXXXXXX
7202 8
4 SN: 12345678
5 FD: 03W28 Rotation:
-1 9
6 n = XXXX min P = XXX kW
Made in Germany 10
Folgende Informationen finden Sie auf dem Typschild: The following information can be found on the type plate:
1 Hersteller 1 Manufacturer
2 Typschlüssel 2 Ordering code
3 Materialnummer der Axialkolbenmaschine 3 Material number of the axial piston unit
4 Seriennummer 4 Serial number
5 Fertigungsdatum 5 Date of manufacturing
6 Drehzahl 6 Speed
7 interne Werksbezeichnung 7 Internal manufacturing code
8 Drehrichtung (bei Blick auf die Welle; hier: rechts) 8 Direction of rotation (when facing the shaft; here: clockwi-
9 vorgesehener Platz für Prüfstempel se)
10 Leistung 9 Designated space for certification stamp
Stellen Sie sicher, dass Typ und Nenngröße der zu reparieren- 10 Power
den Verstellpumpe mit dieser Anleitung übereinstimmen. Ensure that the variable pump to be repaired is of the type and
size covered by this manual.
3.2 Funktionsbeschreibung 3.2 Functional Description

Damit Sie in der Lage sind, Probleme an der Verstellpumpe To make sure that you are able to identify problems with a vari-
zu identifizieren und gezielt Reparaturen durchzuführen, sind able pump and to carry out specific repairs, familiarity with how
Kenntnisse der Funktionsweise und des Aufbaus erforderlich. the unit functions and its assembly are required. This section
Dieser Abschnitt gibt Ihnen eine grobe Übersicht. provides you with a rough overview.
Die A4VG Verstellpumpe ist eine Axialkolben-Verstellpum- The variable displacement axial piston pump type A4VG in
pe in Schrägscheibenbauart für hydrostatische Antriebe im swashplate design is designed for closed circuit hydrostatic
geschlossenen Kreislauf. Der Volumenstrom ist proportional zu drives. The flow is proportional to the input drive speed and
der Antriebsdrehzahl und dem Verdrängungsvolumen. Durch displacement. By adjusting the swashplate, it is possible to
die Verstellung der Schrägscheibe ist eine stufenlose Volumen- infinitely vary the flow.
stromänderung möglich.
008 910 92 BOMAG 663

20.1
Travel pump
3.2.1 Schnittzeichnung 3.2.1 Sectional Drawing

Die folgenden Schnittzeichnungen zeigen das Zusammenspiel The following drawings show the interrelation of the compon-
der Komponenten der A4VG Verstellpumpe. ents of the A4VG variable pump.
Seitenansicht / Side View Steuergerät (siehe unten) /

Control Device (see below)
Schwenkwiege /
Cradle
Antriebswelle /
Drive Shaft
Anschlussplatte
mit Hilfspumpe /
Port Plate with
Auxiliary Pump
Wellendichtring /
Shaft Seal Ring
Triebwerk /
Rotary Group
Draufsicht Verstellungen/
Top View with Controllers
Steuergerät
HWD Control Device DAD
Antriebswelle
Antriebswelle Drive Shaft
Drive Shaft
Verstellkolben
Control Piston
EPD HDD
Antriebswelle
Drive Shaft
Antriebswelle
Drive Shaft
Steuergerät
Control Device
664 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.113/36
Bosch Rexroth AG
Ansicht Anschlussplatte /
View Port Plate
HWD / EPD / HDD
DAD
008 910 92 BOMAG 665

20.1
Travel pump
3.3 Technische Daten 3.3 Technical Data

Die technischen Daten der Verstellpumpe finden Sie in der Auf- You can find the technical data for the variable pump in the
tragbestätigung. Ergänzend dazu ist das jeweilige technische Confirmation of Order. This is supplemented by the unit‘s data
Datenblatt. Für die A4VG Verstellpumpe gilt das technische sheet. For the A4VG variable pump, the valid data sheet is
Datenblatt RD 92 003. RE 92 003.
666 BOMAG 008 910 92

RDE 92 003-11-R/12.05
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4 Austausch externer 4 Exchanging External
Baugruppen Assembly Groups
Dieses Kapitel beschreibt den Austausch von extern zugängli- This chapter describes the replacement of the externally acces-
chen Baugruppen der Verstellpumpe A4VG. sible assembly groups of the variable pump A4VG.
Der Austausch folgender Baugruppen wird beschrieben: The exchange of the following assembly groups is described:
x Wellendichtring x Shaft seal
x Dichtungen x Seals
x Hilfspumpe x Auxiliary pump
x Steuergerät x Control device
Hinweis Note
Alle in nachfolgenden Zeichnungen dargestellten Steuergerä- All the following illustrations are only examples and do not
te sind nur stellvertretend und müssen nicht der Konfiguration have to completely correspond with the configrations of your
Ihrer Axialkolbenmaschine entsprechen. axial piston unit.
! WARNUNG ! WARNING
Gefahr von Verschleiß und Funktionsstörungen Danger of wear and malfunction

Die Sauberkeit der Druckflüssigkeit und die Lebensdauer der The durability of the hydraulic unit depends to a great extent
Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept. Dirt in the hydraulic fluid can
Verschmutzung der Druckflüssigkeit führt zu Verschleiß und lead to malfunctions. Especially hard foreign matter in the
Funktionsstörungen. Insbesondere harte Fremdkörper in den hydraulic conduits, for example, welding beads and cuttings,
Hydraulikleitungen, wie z.B. Schweißperlen und Metallspäne, can damage the axial piston unit.
können die Axialkolbenmaschine beschädigen.
Beachten Sie daher unbedingt folgende Hinweise: Therefore you should observe the following instructions:
x Achten Sie auf äußerste Sauberkeit. Die Axialkolbenmaschi- x Make sure everything is kept extremely clean. The axial pis-
ne muss schmutzfrei eingebaut werden. Verunreinigungen ton unit must be installed in a dirt-free environment. Conta-
in der Druckflüssigkeit können die Funktion und Lebensdau- mination of the hydraulic fluid can lead to considerable wear
er der Axialkolbenmaschine erheblich beeinträchtigen. and malfunctions of the axial piston unit.
x Achten Sie besonders bei der Installation darauf, dass x Espacially during the istallation, you should make sure that
Anschlüsse, Hydraulikleitungen und Anbauteile (z.B. Mess- ports, hydraulic conduits, and mounting components (for
geräte) sauber sind. Reinigen Sie diese gründlich, bevor example, gauges) are clean. Clean these thoroughly before
Sie Anschlüsse öffnen. Stellen Sie sicher, dass auch beim you open connections. After that, when sealing the ports,
nachfolgenden Verschließen der Anschlüsse keine Verunrei- make sure that contaminating elements cannot enter the
nigungen eindringen. system.
x Verwenden Sie für die Beseitigung von Schmiermitteln und x When removing grease and other dirt you should use ap-
anderen starken Verschmutzungen geeignete flüssige Reini- propriate liquid cleaning agents. Cleaning agents must not
gungsmittel. Es darf kein Reinigungsmittel in das Hydraulik- enter the hydraulic system.
system eindringen.
x Verwenden Sie zur Reinigung keine Putzwolle oder fasern- x Do not use cotton waste or rags which lose threads.
de Putzlappen.
x Verwenden Sie als Dichtungsmittel keinesfalls Hanf oder x Never use hemp or putty as a sealant.
Kitt.
008 910 92 BOMAG 667

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20.1
Travel pump
4.1 Wellendichtring austauschen 4.1 Exchanging the Shaft Seal

Dieser Abschnitt erklärt, wie Sie den Wellendichtring austau- This section explains how you can replace the shaft seal.
schen.
Voraussetzungen: Keine Requirements: None
Benötigtes Sonderwerkzeug: Required Special Tools:
x Montagehülse x Mounting sleeve
Die Materialnummern sind je nach Pumpenmodell verschie- The material number depends on the pump model.
den:
– A4VG40: Mat.-Nr. R909877507 – A4VG40: Mat. no. R909877507
– A4VG56: Mat.-Nr. R909877508 – A4VG56: Mat. no. R909877508
Beispiel/Example HW
b
a
a: Sicherungsring Circlip
b: Wellendichtring Shaft Seal
c: Triebwelle Drive Shaft
Um den Wellendichtring auszutauschen: To exchange the shaft seal:

1 Kleben Sie die Triebwelle (c) ab, um Beschädigungen am 1 Mask the drive shaft (c) for protection against damage of the
Wellendichtring (b) zu vermeiden. shaft seal (b).
2 Entfernen Sie den Sicherungsring (a). 2 Remove the safety ring (a).
668 BOMAG 008 910 92

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3 Drehen Sie Blechschrauben in die mit Gummi gefüllten 3 Screw the tapping screw into the rubber lined holes of the
Löcher des Wellendichtrings (b) und ziehen Sie den Wellen- shaft seal (b), and use pliers to pull the shaft seal out.
dichtring mit einer Zange heraus.
4 Fetten Sie den Wellendichtring zwischen Dicht- und Staub- 4 Grease the shaft seal between the seal and dust lip to avoid
lippe leicht ein, um Trockenlauf zu vermeiden. a dry run.
5 Pressen Sie den Wellendichtring mit Hilfe der Montagehülse 5 Using the mounting sleeve (special tool), press the shaft seal
(Sonderwerkzeug) auf Anschlag ein. until it is in stop position.
6 Führen Sie den Sicherungsring so ein, dass er in die dafür 6 Place the safety ring so that it locks into place in the respec-
vorgesehene Nut einrastet. tive slot.
7 Entfernen Sie die Abklebung an der Triebwelle. 7 Remove the mask on the drive shaft.
008 910 92 BOMAG 669

20.1
18/36 Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 40–56 RDE 92 003-11-R/12.05
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4.2 Dichtungen austauschen 4.2 Exchanging Seals

Die Baugruppe „Dichtungssatz komplett“ enthält Dichtungen The assembly group "complete seal set" contains seals for the
für folgende Komponenten: following components:
x Stellkolbendeckel x Positioning piston covers
x Ventile x Valves
x Druckabschneidung x Pressure cut-off
x Hilfspumpe (siehe „Hilfspumpe austauschen“) x Auxiliary pump (refer to "Exchanging the Auxiliary Pump")
x Steuerung (siehe „Steuergerät austauschen“) x Controller (refer to "Exchanging the Control Device")
Voraussetzungen: Keine Requirements: none
Benötigtes Sonderwerkzeug: Required Special Tools:
x Hülse zum Aufziehen von O-Ring und Stützring, x Sleeve to screw off the o-ring,
Mat.-Nr.: R909454005 Mat. no.: R909454005
Dichtung an den Stellkolbendeckeln austauschen Exchanging the valve positioning piston covers
Die beiden Seiten des Stellkolbens sind mit zwei unterschiedli- Both sides of the positioning piston have their own different
chen Deckeln abgedeckt. Die nötigen Schritte zum Austausch covers. The required steps to exchange the covers are threre-
der Deckeldichtungen unterscheiden sich daher. fore different.
a
c
d
c c b
a: Linker Deckel Left cover

b: Rechter Deckel Right cover e
c: O-Ring O-ring
d: Stellschraube Adjustment screw
e: Kontermutter Counter nut
f: Befestigungsschrauben Fastening screw
Um die Dichtung an den Stellkolbendeckeln auszutauschen: To exchange the valves of the positioning pistons:
1 Entfernen Sie die Befestigungsschrauben (f) des linken 1 Remove the fastening screw (f) of the left cover (a).
Deckels (a).
2 Verdrehen Sie den Deckel (a) und lösen Sie ihn vorsichtig 2 Twist the cover (a) and carefully loosen it by tapping it with a
mit leichten Hammerschlägen (Gummihammer). (rubber) hammer.
670 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.119/36
3 Entfernen Sie den alten O-Ring (c). Kontrollieren Sie die 3 Remove the old o-ring (c). Check the slot (h) and the
Nut (h) und das Gehäuse (g) auf Verschleiß und Verunreini- housing (g) for wear and dirt.
gungen.
c
h g
4 Setzen Sie einen neuen O-Ring ein und schrauben Sie den 4 Install a new o-ring and screw the cover shut.
linken Deckel fest.
5 Markieren Sie die Lage des rechten Deckels (b), damit Sie 5 Mark the position of the right cover (b) so that you can set it
ihn nach dem Abdichten wieder lagerichtig aufsetzen kön- back to its original position after sealing.
nen.
Messen und notieren Sie das Maß X der Kontermutter (e) für Measure and write down the dimension X of the counter
die spätere Montage. nut (e). You need this for the subsequent assembly.
Entfernen Sie die Kontermutter (e). Halten Sie dazu die Remove the counter nut (e). To do so, grip the positioning
Stellschraube (d) fest. screw (d).
b
X
d
6 Drücken Sie den Deckel durch Eindrehen der Stellschraube 6 Press the cover off by screwing in the set screw.
ab.
7 Entfernen Sie die beiden O-Ringe (c). Kontrollieren Sie die 7 Remove the two o-rings (c). Check the slots (i) and housing
Nuten (i) und das Gehäuse (j) auf Verschleiß und Verunreini- (j) for wear and dirt.
gungen.
c
i j
008 910 92 BOMAG 671

20.1
Travel pump
8 Kleben Sie das Gewinde ab, um Beschädigungen des O- 8 Mask the screw thread to avoid damaging the o-ring, and
Rings zu vermeiden, und schieben Sie den kleinen O-Ring push the smaller o-ring up to the designated slot.
bis zur vorgesehenen Nut auf.
9 Setzen Sie den großen O-Ring ein, entfernen Sie die Abkle- 9 Insert the larger o-ring, remove the masking and screw the
bung und schrauben Sie den Deckel fest. cover back on.
10 Schrauben Sie die Kontermutter (e) per Hand ein. Blockie- 10 Screw in the counter nut (e) manually. Block the adjusting
ren Sie die Stellschraube (d) während Sie die Kontermutter- screw (d) while you tighten the counter nut.
festziehen.
Kontrollieren Sie das Maß X nach der Montage. Check the dimension X after assembly.
b
X
e d
Hinweis Note
Nach dem Einbau im Gerät bzw. Prüfstand muss die korrekte After the installation of the unit or the test rig, the correct
mechanische Nulllagen-Einstellung erfolgen, siehe „Überprü- mechnical zero stroke must be adjusted, refer to "Checking",
fungen“ auf Seite 29. page 29.
672 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.121/36
Ventildichtungen austauschen Exchanging the valve seals
Hinweis Note
Möglicherweise sind nicht alle in den Zeichnungen gezeigten It is possible that the valves displayed in these illustrations are
Ventile an Ihrer Einheit vorhanden. not all present in your unit.
Hochdruckventil mit Bypass /

High-pressure valve with bypass
Hochdruckventil ohne Bypass / function
High-pressure valve without
bypass function
Niederdruckventil
Low-pressure valve
Um die Ventildichtungen auszutauschen: To exchange the valve seals:

1 Schrauben Sie die Niederdruckventile heraus. 1 Unscrew the low pressure valves.
2 Kleben Sie die Gewinde der Niederdruckventile ab, um 2 Mask the screw thread to avoid damage to the o-ring.
Beschädigungen der O-Ringe zu vermeiden.
3 Setzen Sie die neuen O-Ringe ein, entfernen Sie die Abkle- 3 Insert the new o-ring, remove the masking from the screw
bungen an den Gewinden und schrauben Sie die Nieder- thread, and screw the low pressure valves back in.
druckventile wieder ein.
Ziehen Sie sie mit einem Drehmoment von 70 Nm fest. Tighten them with a torque of 70 Nm.
4 Schrauben Sie das Hochdruck-Ventil heraus. 4 Unscrew the high-pressure valve.
Es gibt zwei Ausführungen des Ventils: mit und ohne There are two types of this valve: with or without bypass
Bypass-Funktion. function.
ohne Bypass-Funktion / mit Bypass-Funktion /

without bypass function with bypass function
008 910 92 BOMAG 673

20.1
Travel pump
5 Entfernen Sie O-Ring und Stützring. 5 Remove the o-ring and support ring.
6 Schieben Sie den neuen O-Ring und den Stützring mit dem 6 Push the new o-ring and the support ring back with an auxili-
Hilfswerkzeug (Hülse, siehe „Anhang“) auf. ary tool (sleeve, refer to "Appendix").
Der Stützring muss ersetzt werden, wenn er Verschleißspu- The support ring must be replaced when it shows wear or
ren oder Bechädigungen aufweist. damage.
Hülse
Sleeve
7 Bauen Sie das Hochdruck-Ventil ein und ziehen Sie es mit 7 Install the high-pressure valve and tighten it with a torque of
einem Drehmoment von 160 Nm fest. 160 Nm.
Dichtung der Druckabschneidung austauschen Exchanging the seals of the pressure cut-off
Um die Dichtung der Druckabschneidung auszutauschen: To exchange the seal of the pressure cut-off:
1 Notieren Sie das Einstellmaß X der Dichtmutter für die späte- 1 Write down the sealing nut's setting dimension X for the
re Montage. subsequent assembly.
2 Bauen Sie die Dichtmutter (a) und die Verschlussschraube 2 Extract the sealing nut (a) and the locking screw (b).
(b) aus.
Entfernen Sie den O-Ring (c). Remove the o-ring (c).
a
b 9
3 Setzen Sie einen neuen O-RIng (c) ein. 3 Install a new o-ring (c).
4 Setzen Sie die Verschlussschraube (b) ein und ziehen Sie 4 Install the locking screw (b) and tighten it with a torque of 35
sie mit einem Drehmoment von 35 Nm fest. Nm.
5 Bauen Sie eine neue Dichtmutter (a) ein und stellen Sie das 5 Install the new sealing nut (a) and adjust to the setting
notierte Einstellmaß X ein. measure X that you wrote down previously.
Ziehen Sie die Dichtmutter mit 25 Nm fest. Tighten it with a torque of 25 Nm.
674 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.123/36
Bosch Rexroth AG
Dichtung des Regelventils austauschen Exchanging the control valve
b
b a
a: Regelventil Control valve

b: O-Ring O-ring
Um die Dichtung am Regelventil auszutauschen: To exchange the control valve:

1 Schrauben Sie das Regelventil (a) aus. 1 Unscrew the control valve (a).
2 Kleben Sie das Gewinde zur Vermeidung von Beschädigun- 2 Mask the screw thread to avoid damaging the o-ring.
gen des O-Rings ab.
3 Schieben Sie den neuen O-Ring auf. 3 Slide the new o-ring on.
4 Entfernen Sie die Abklebung und schrauben Sie das Regel- 4 Remove the masking and screw the control valve back on.
ventil ein.
Ziehen Sie sie mit einem Drehmoment von 50 Nm fest. Tighten them with a torque of 50 Nm.
008 910 92 BOMAG 675

20.1
Travel pump
4.3 Hilfspumpe austauschen 4.3 Exchanging the Auxiliary Pump

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of an auxiliary pump
einer Hilfspumpe als auch für den Austausch eines O-Rings. as well as to the exchange of an o-ring.
Voraussetzungen: Keine Requirements: none
Benötigtes Sonderwerkzeug: Keines Required Special Tools: none
Um die Hilfspumpe auszutauschen: To exchange the auxiliary pump:
1 Markieren Sie die Lage des Deckels (a), damit Sie ihn nach 1 Mark the position of the cover (a), so that you can replace it
dem Abdichten wieder lagerichtig aufsetzen können. in its original position after the sealing.
2 Entfernen Sie die vier Befestigungsschrauben (b). 2 Remove the four fastening screws (b).
3 Drücken Sie den Deckel wie gezeigt ab. 3 Press the cover off as illustrated.
4 Entfernen Sie die Hilfspumpe und untersuchen Sie die Teile 4 Remove the auxiliary punp and check the part for wear and
der Hilfspumpe auf Verschleiß und Verunreinigungen. dirt.
Markieren Sie vorher die Lage der Hilfspumpe, damit Sie sie Mark the position of the auxiliary pump beforehand, so that
später wieder lagerichtig einbauen können (sofern Sie die you can return it to its original position afterwards (if you
alte Hilfspumpe weiter verwenden). keep the old auxiliary pump in use).
Hinweis Note
Die Hilfspumpe kann nur komplett ausgetauscht werden. The auxiliary pump can only be exchanged as a whole.
5 Setzen Sie zwei neue O-Ringe bzw. Dichtringe (c) ein. 5 Install two new o-rings (c).
676 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.125/36
Bosch Rexroth AG
6 Setzen Sie die (neue) Hilfspumpe ein. 6 Install the (new) auxiliary pump.
Achten Sie darauf, dass die angefaste „Seite“ (d) zum De- Pay attention that the chamfered "side" (d) is assembled
ckel (a) montiert wird. facing the cover (a).
a
d
Hinweis Note
Die Hilfspumpe wird mit Haltestopfen (e) geliefert. Diese wer- The auxiliary pump is delivered with fixing plugs (e). These are
den bei der Montage auf die Anschlussplatte in die entspre- pressed into the bore of the port plate during assembly.
chenden Bohrungen eingepresst.
7 Schrauben Sie den Deckel (a) fest. Beachten Sie dabei die 7 Screw the cover (a) back on. Pay attention to the marking
vorher angebrachte Markierung. made previously.
008 910 92 BOMAG 677

20.1
Travel pump
4.4 Steuergerät austauschen 4.4 Exchanging the Control Device

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of the whole control
des ganzen Steuergeräts als auch für den Austausch eines O- device as well as to the exchange of an o-ring.
Rings am Steuergerät.
Voraussetzungen: Keine Requirements: None
Benötigtes Sonderwerkzeug: Keines Required Special Tools: None
Hinweis Note
Es gibt eine Vielzahl von Steuergeräten (siehe Abbildung). There exists a multitude of control devices (as illustrated).
Bitte beachten Sie, dass hier exemplarisch nur der Austausch Please pay attention to the fact that only the example of an
eines HW Steuergeräts gezeigt wird. HW control device is described here.
HW alt / old
DA alt / old
neu / new
HD
neu / new
EP
HW mit Nulllagenschalter alt / old
HW with zero position switch
neu / new
Polrohr
Anziehmoment 19 Nm /
Pole tube
Tightening torque 19 Nm
Anziehmoment 5+1 Nm
Steckschlüssel SW 26 /
Tightening torque 5+1 Nm
26 A/F socket spanner
678 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.127/36
Um das Steuergerät auszutauschen: To exchange the control device:
1 Entfernen Sie die fünf Befestigungsschrauben (a). 1 Remove all five fastening screws (a).
2 Drücken Sie das Steuergerät (b) wie gezeigt ab. 2 Press the control device (b) off as illustrated.
3 Entfernen Sie den O-Ring (c) und die Flachdichtung (e). 3 Remove the o-ring (c) and the seal (e). Check the sealing
Kontrollieren Sie die Dichtflächen (d) auf Beschädigungen surfaces (d) for wear and dirt.
und Verunreinigungen.
Tauschen Sie das Steuergerät bei Bedarf aus. Exchange the control device if required.
Hinweis Note
Das Steuergerät kann nur komplett ausgetauscht werden. The control device can only be exchanged as a whole.
d
e
d
4 Setzen Sie einen neuen O-Ring und eine neue Flachdich- 4 Insert the new o-ring and the new seal (e).
tung (e) ein.
5 Setzen Sie das (neue) Steuergerät ein. 5 Insert the new control device.
008 910 92 BOMAG 679

20.1
Travel pump
6 Zentrieren Sie die Dichtung (e) mit zwei Befestigungsschrau- 6 Center the seal (e) with two fastening screws (a) and install
ben (a) und bauen Sie das Steuergerät ein. the control device.
Ziehen Sie alle vier Befestigungsschrauben mit halbem Screw all four fastening screws tight with half the torque.
Drehmoment an.
a
a: Befestigungsschraube Fixing screw

b: Steuergerät Control device
e: Dichtung Seal
7 Setzen Sie die fünfte Schraube (f) ein und ziehen Sie sie mit 7 Insert the fifth screw (f) and tighten it with a torque of
einem Drehmoment von 10,4 Nm fest. 10.4 Nm.
Ziehen Sie die anderen vier Schrauben (a) nach Drehmo- Tighten the other four screws (a) crosswise and according
ment über Kreuz fest. to torque.
Hinweis Note
Nach der Montage des Steuergeräts muss die hydraulische After installing the control device, the hydraulic zero stroke
Nulllage neu eingestellt werden (gilt nicht für DA-Regelung), must be re-established. This does not apply to DA-control.
siehe „Überprüfungen“ auf Seite 29. Please refer to "Checking", page 29.
680 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.129/36
5 Überprüfungen 5 Checking
Bei der ersten Inbetriebnahme nach einer Reparatur müssen When starting up for the first time after a repair, you must
Sie die ursprünglichen Einstellungen der Verstellpumpe kontrol- check the original settings of the variable pump. This chapter
lieren. Dieses Kapitel erklärt folgende Überprüfungen: describes the following checkings:
• Niederdruck • Low pressure
• Hochdruck • High pressure
• Mechanische Nulllage • Mechanical zero stroke
• Hydraulische Nulllage • Hydraulic zero stroke
Hinweis Note
Führen Sie alle Überprüfungen bei Betriebstemperatur durch. Carry out checkings at operating temperature.
Hinweis Note
Wenn die überprüften Werte von den ursprünglichen Einstel- If the checked values differ from the original settings, please
lungen abweichen, setzen Sie sich bezüglich der Einstellung contact Rexroth in terms of adjusting the settings.
bitte mit dem Rexroth-Service in Verbindung.
! WARNUNG ! WARNING

Arbeiten an der Verstellpumpe bei Betriebstemperatur sind Working on the variable pump at operating temperature is
gefährlich. dangerous.
x Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ x Pay exact attention to the safety advice (refer to "Safety",
auf Seite 7). page 7).
! WARNUNG ! WARNING
Gefahr von Verschleiß und Funktionsstörungen Danger of wear and malfunction

Die Sauberkeit der Druckflüssigkeit und die Lebensdauer der The durability of the hydraulic unit depends to a great extent
Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept.
x Achten Sie bei Überprüfungen darauf, dass Messanschlüs- x When checking settings, you should make sure that gauge
se, Schläuche und Messgeräte sauber sind. Reinigen Sie ports, hydraulic conduits, and und gauges are clean. Clean
diese gründlich bevor Sie die Messpunkte öffnen und mit these thoroughly before you open gauge ports and begin
den Einstellarbeiten beginnen. adjusting settings.
x Stellen Sie sicher, dass auch beim nachfolgenden Verschlie- x After that, when sealing the ports, make sure that contami-
ßen der Messpunkte keine Verunreinigungen eindringen. nating elements cannot enter the system.
008 910 92 BOMAG 681

30/36
20.1
Travel pump
5.1 Niederdruck (Speisedruck) überprüfen 5.1 Checking Low Pressure (Charge Pressure)
Dieser Abschnitt erklärt, wie Sie ND-Ventile überprüfen. This section describes how to check the low pressure valves.
Um den Niederdruck zu überprüfen: To check the low pressure:
1 Schließen Sie wie gezeigt ein Manometer an Anschluss G 1 Connect a manometer to connection G as displayed.
an.
2 Überprüfen Sie den Niederdruck (G). 2 Check the low pressure (G):
Hinweis Note
Die genauen Einstelldaten entnehmen Sie dem Technischen Refer to the catalog sheet RE 92 003 and your specification
Datenblatt RD 92 003 und Ihrer Spezifikation. for the detailed setting data.
5.2 Hochdruck überprüfen 5.2 Checking the High Pressure

Die Begrenzung des Hochdrucks erfolgt über die Druckab- The limitation of the operating pressure is performed by a high
schneidung. Zusätzlich ist ein Hochdruckbegrenzungsventil pressure relief valve. Additionally, a high pressure relief valve
(Sicherheitsventil) überlagert. Der Druckwert der Druckab- (safety valve) is in superposition. The pressure value of the
schneidung liegt ca. 10 % unter dem Wert des Hochdruckbe- pressure cut-off is 10 % below that of the high pressure relief
grenzungsventils. valve.
Es kann also nur der Druckwert der Druckabschneidung über- Therefore, only the pressure value of the pressure cut-off can
prüft werden. be measured.
Hinweis Note
Die genauen Einstelldaten entnehmen Sie Ihrer Spezifikation. Refer to your specification for the detailed setting data.
682 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.131/36
5.3 Mechanische Nulllage überprüfen 5.3 Checking the Mechanical Zero Stroke
Dieser Abschnitt erklärt, wie Sie die mechanische Nulllage bei This section describes how to check the mechanical zero stro-
HW-, HD-, EP- und DA-Steuergeräten überprüfen. ke for HW-, HD-, EP-, and DA-controllers.
HW HD EP DA
! WARNUNG ! WARNING

Die im Folgenden beschriebenen Arbeiten an der Verstellpum- The following procedures carried out on the variable pump are
pe sind gefährlich. dangerous.
x Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ x Please pay attention to the safety advice (refer to "Safety",
auf Seite 7). page 7).
x Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage x Block the machinery or unit before you carry out the installa-
bevor Sie die Einstellarbeiten durchführen. tion.
mind. / at least
Nennweite 6 / Nominal Width 6
MA
Messbereich/
Metering range
0 ... 600 bar
MB
Um die mechanische Nulllage zu überprüfen: To check the mechanical zero stroke:

1 Verbinden Sie beide Stellkammern über einen Schlauch mit 1 Connect the two position chambers with a hose (with at
mindestens Nennweite NW6. least nominal width NW6).
Dadurch stellen Sie sicher, dass ein Restsignal aus dem Thus, you ensure that a residual signal from the controller
Steuergerät keine Auswirkung auf die Einstellung der me- has no influence on the setting of the hydraulic zero stroke.
chanischen Nullage hat.
2 Schließen Sie an die Messanschlüsse MA und M B Manome- 2 Connect manometers to the measuring ports MA and M B.
ter an.
3 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 3 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked.
008 910 92 BOMAG 683

20.1
Travel pump
5.4 Hydraulische Nulllage überprüfen 5.4 Checking the Hydraulic Zero Stroke
Dieser Abschnitt erklärt, wie Sie die hydraulische Nulllage bei This section describes how to check the hydraulic zero stroke
HW-, HD- und EP-Steuergeräten überprüfen. for HW-, HD-, and EP-controllers.
! WARNUNG ! WARNING

Die folgenden Arbeiten an der Verstellpumpe sind gefährlich. The following procedures carried out on the variable pump are
dangerous.
x Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“
auf Seite 7). x Pay attention to the safety advice (refer to "Safety",
page 7).
x Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage x Block the machinery or unload the unit before you procede
bevor Sie die Einstellarbeiten durchführen. with the installation.
HW HD EP
Messbereich/
Metering range
X1 0 ... 60 bar
X2
Um die hydraulische Nulllage zu überprüfen: To check the hydraulic zero stroke:

1 Schließen Sie an die Anschlüsse X1 und X2 Manometer an. 1 Connect manometers to the ports X1 und X2.
2 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 2 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked
Hinweis Note
Verdrehen Sie die Exzenterjustierung (a) am Steuergerät nicht Never turn the eccentric calibration (a) of the controller over
über ±90°. ±90 degrees.
684 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.133/36
Bosch Rexroth AG
008 910 92 BOMAG 685

20.1
RDE 92 003-11-R/12.05 Reparaturanleitung/Repair Manual A4VG 40–56 Bosch Rexroth AG
Travel pump 34/36
686 BOMAG 008 910 92

RDE 92 003-11-R/12.05
20.135/36
Bosch Rexroth AG
008 910 92 BOMAG 687

20.1 Travel pump
Bosch Rexroth AG
Hydraulics
Produktsegment
Axialkolbenmaschinen
Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
© This document, as well as the data, © Alle Rechte bei Bosch Rexroth AG,
specifications and other information auch für den Fall von Schutzrechtsan-
set forth in it, are the exclusive proper- meldungen. Jede Verfügungsbefugnis,
ty of Bosch Rexroth AG. It may not be wie Kopier- und Weitergaberecht,
reproduced or given to third parties bei uns.
without its consent.
Die angegebenen Daten dienen
The data specified above only serve to allein der Produktbeschreibung.
describe the product. No statements Eine 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
information given does not release werden. Die Angaben entbinden
the user from the obligation of own den Verwender nicht von eigenen
judgment and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are
zu beachten, dass unsere Produkte
subject to a natural process of wear
einem natürlichen Verschleiß- und
and aging.
Alterungsprozess unterliegen.
Subject to change. Änderungen vorbehalten.
Printed in Germany
RDE 92 003-11-R/12.05
688 BOMAG 008 910 92

20.2 Vibration pump
008 910 92 BOMAG 689

20.2 Vibration pump
690 BOMAG 008 910 92

Vibration pump 20.2
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
008 910 92 BOMAG 691

20.2 Bosch Rexroth AG | Mobile Hydraulics
2 A10VG | RDE 92 750-01-R/03.03
Vibration 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
692 BOMAG 008 910 92

RDE 92 750-01-R/03.03
Vibration pump | A10VG Mobile Hydraulics | Bosch Rexroth AG 20.23
Schnittbild
Sectional view
mit Druckabschneidung
with pressure cut-off
HW
ohne Druckabschneidung
without pressure cut-off
HDD EPD
008 910 92 BOMAG 693

4 A10VG | RDE 92 750-01-R/03.03
Vibration pump
Schnittbild
Sectional view
DA
694 BOMAG 008 910 92

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.
008 910 92 BOMAG 695

6 A10VG | RDE 92 750-01-R/03.03
Vibration 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
696 BOMAG 008 910 92

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
008 910 92 BOMAG 697

8 A10VG | RDE 92 750-01-R/03.03
Vibration 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
698 BOMAG 008 910 92

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.
008 910 92 BOMAG 699

10 A10VG | RDE 92 750-01-R/03.03
Vibration 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.
700 BOMAG 008 910 92

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.
008 910 92 BOMAG 701

12 A10VG | RDE 92 750-01-R/03.03
Vibration 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.
702 BOMAG 008 910 92

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.
008 910 92 BOMAG 703

14 A10VG | RDE 92 750-01-R/03.03
Vibration 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).
704 BOMAG 008 910 92

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".
008 910 92 BOMAG 705

16 A10VG | RDE 92 750-01-R/03.03
Vibration 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).
706 BOMAG 008 910 92

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
* 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).
008 910 92 BOMAG 707

18 A10VG | RDE 92 750-01-R/03.03
Vibration 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
Polrohr
Anziehmoment 19 Nm
Pole tube
708 BOMAG 008 910 92

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
008 910 92 BOMAG 709

20 A10VG | RDE 92 750-01-R/03.03
Vibration pump
Ansteuergeräte
Control units
Ansteuergerät HD neu
HD - control unit new
Ansteuergerät EP neu
EP - control unit new
710 BOMAG 008 910 92

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!
008 910 92 BOMAG 711

22 A10VG | RDE 92 750-01-R/03.03
Vibration 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
* *
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
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
712 BOMAG 008 910 92

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
008 910 92 BOMAG 713

24 A10VG | RDE 92 750-01-R/03.03
Vibration 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
714 BOMAG 008 910 92

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.
008 910 92 BOMAG 715

26 A10VG | RDE 92 750-01-R/03.03
Vibration 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.
716 BOMAG 008 910 92

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.
008 910 92 BOMAG 717

28 A10VG | RDE 92 750-01-R/03.03
Vibration 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).
718 BOMAG 008 910 92

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.
008 910 92 BOMAG 719

30 A10VG | RDE 92 750-01-R/03.03
Vibration 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).
720 BOMAG 008 910 92

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.
008 910 92 BOMAG 721

32 A10VG | RDE 92 750-01-R/03.03
Vibration 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.
722 BOMAG 008 910 92

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.
008 910 92 BOMAG 723

34 A10VG | RDE 92 750-01-R/03.03
Vibration 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.
724 BOMAG 008 910 92

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
008 910 92 BOMAG 725

36 A10VG | RDE 92 750-01-R/03.03
Vibration 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.
726 BOMAG 008 910 92

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.
008 910 92 BOMAG 727

38 A10VG | RDE 92 750-01-R/03.03
Vibration 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.
728 BOMAG 008 910 92

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.
008 910 92 BOMAG 729

40 A10VG | RDE 92 750-01-R/03.03
Vibration 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.
730 BOMAG 008 910 92

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.
008 910 92 BOMAG 731

42 A10VG | RDE 92 750-01-R/03.03
Vibration 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
732 BOMAG 008 910 92

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
008 910 92 BOMAG 733

44 A10VG | RDE 92 750-01-R/03.03
Vibration 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

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
734 BOMAG 008 910 92

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
008 910 92 BOMAG 735

46 A10VG | RDE 92 750-01-R/03.03
Vibration 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.
736 BOMAG 008 910 92

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!
008 910 92 BOMAG 737

48 A10VG | RDE 92 750-01-R/03.03
Vibration 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"
*
738 BOMAG 008 910 92

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
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.
008 910 92 BOMAG 739

50 A10VG | RDE 92 750-01-R/03.03
Vibration 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°.
740 BOMAG 008 910 92

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.
008 910 92 BOMAG 741

52 A10VG | RDE 92 750-01-R/03.03
Vibration 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.
742 BOMAG 008 910 92

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.
008 910 92 BOMAG 743

54 A10VG | RDE 92 750-01-R/03.03
Vibration 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!
744 BOMAG 008 910 92

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!
008 910 92 BOMAG 745

20.2 Vibration pump
Brueninghaus Hydromatik GmbH

Werk Elchingen
Glockeraustraße 2
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm@boschrexroth.de
© 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
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
746 BOMAG 008 910 92

20.3 Travel motor
008 910 92 BOMAG 747

20.3 Travel motor
This repair manual describes the fixed displacement motor A2FM/E; the repair procedures are identical
with the ones for the fixed displacement motor A2FE32, which differs only by a different housing design.
748 BOMAG 008 910 92

Travel motor 20.3
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
RDE 91 001-03-R/05.03
Konstantmotor A2FM/E ersetzt / replaces 04.00
Fixed Displacement Motor A2FM/E

Baureihe / Series 61
Reparaturanleitung / Repair Instructions
008 910 92 BOMAG 749

2 A2F | RDE 91 001-03-R/05.03
Travel motor
Hinweis / Inhalt
Notice / Contents
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.
INHALT Seite/ CONTENTS

Page
A2F A2F
Schnittbild 3-6 Sectional view

Allgemeine Reparaturhinweise 7 General repair instructions
Dichtsätze und Baugruppen 8-9 Seal kits and sub-assemblies
Triebwelle abdichten 10 Sealing of the drive shaft
Anschlußplatte abdichten 11-14 Sealing of the cover plate
Triebwerk ausbauen 15-16 Removal the rotary group
Überprüfungshinweise 17-18 Inspection guidelines
Triebwerk einbauen 19-21 Installing rotary group
Anziehdrehmomente 22-24 Tightening torques
Sicherheitsbestimmungen 25 Safety regulations
750 BOMAG 008 910 92

RDE 91 001-03-R/05.03
Travel motor | A2F Mobile Hydraulics | Bosch Rexroth AG 20.33
Schnittbild
Sectional view
A2FM Pos.B
Pos.D
Pos.A
Meßpunkte: Measuring points:

Siehe Serviceinfo See service information
008 910 92 BOMAG 751

4 A2F | RDE 91 001-03-R/05.03
Travel motor
Schnittbild
Sectional view
A2FM mit Spülventil /

A2FM with flushing valve
752 BOMAG 008 910 92

RDE 91 001-03-R/05.03
Schnittbild
Sectional view
A2FE
008 910 92 BOMAG 753

6 A2F | RDE 91 001-03-R/05.03
Travel motor
Schnittbild
Sectional view
A2FE
754 BOMAG 008 910 92

RDE 91 001-03-R/05.03
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 bzw. entlüften.
Before start-up fill up hydraulic aggregates with

hydraulic oil respectively deaerate.
008 910 92 BOMAG 755

8 A2F | RDE 91 001-03-R/05.03
Travel motor

Dichtsatz
Seal kit
Triebwerk, mechanischer Teil /

Rotary group, mechanical part
Triebwerk, mechanischer Teil;

muß abgestimmt werden Pos. "A".
(siehe Serviceinfo)
Rotary group, mechanical part;

has to be adjusted to item "A".
(see service info)
Lagersatz, komplett abgestimmt.

Pos. B (Stützscheibe und Sicherungsring
nicht tauschbar)
zusätzliche Abstimmung Pos. "A".
(siehe Serviceinfo)
Bearing set, matched

Item B (support disc and circlip are
not exchangeable)
Additional adjustment item "A".
(see service info)
756 BOMAG 008 910 92

RDE 91 001-03-R/05.03
Triebwerk, hydraulischer Teil /

Rotary group, hydraulic part
Triebwerk, hydraulischer Teil;

Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)
Rotary group, hydraulic part;

Adjustment of the hydraulic part Pos. "D".
(see service info)
Triebwerk komplett; - fertig vorabgestimmt -

Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)
Complete rotary group, - pre-adjusted -

Adjustment of the hydraulic part Pos. "D".
(see service info)
Spülventil
Flushing valve
Ventil
Valve
008 910 92 BOMAG 757

10 A2F | RDE 91 001-03-R/05.03
Travel motor
Bei nicht verzahnten Triebwellen: Paßfeder abneh-

men. Triebwelle abkleben,
For non-splined shafts: remove key.

Protect the drive shaft (e.g. tape).
Sicherungsring ausbauen, Verschlußring abdrücken
Remove circlip, prise off cover.
Sichtkontrolle
Wellendichtring (1), Verschlußring (2),
Triebwelle (3), Gehäuse (4), O-Ring (5).
Visual check
Shaft seal (1), cover (2), drive shaft (3),
housing (4), O-ring (5).
758 BOMAG 008 910 92

RDE 91 001-03-R/05.03
11
Wellendichtring demontieren.
Remove shaft seal.
Neuen Wellendichtring lagerichtig mit

passender Büchse einpressen.
Press in the new shaft seal,ensuring that

it is correctly orientated, using a suitable bush.
Neuen O-Ring einlegen, auf bündiges Anliegen

achten. O-Ring sowie Dicht- und Staublippe des
Wellendichtringes einfetten. (siehe Serviceinfo)
Fit new O-ring, ensure that it is correctly located.

Grease the O-ring as well as the seal and dust lips
of the shaft seal. (see service information)
Sicherungsring einbauen.
Sitzkontrolle des Sicherungsringes in der Nut.
Fit circlip.
Check to ensure that the circlip is correctly located
within the groove.
008 910 92 BOMAG 759

12 A2F | RDE 91 001-03-R/05.03
Travel motor
Anschlußplatte abdichten
Sealing of the cover plate
Lage der Anschlußplatte zum Gehäuse kenn-

zeichnen (Pfeil), Befestigungsschrauben lösen.
Mark the position of the cover plate with regard

to the housing (arrow), loosen the fixing screws.
Anschlußplatte um Verdrillstift schwenken (1)

und abheben (2).
Swing the connection plate about the locating

pin (1) and lift off (2).
760 BOMAG 008 910 92

RDE 91 001-03-R/05.03
13
Auf Montagestellung des Verdrillstiftes achten

(Pfeile).
Take the assembly position of the locating

pin (arrow) into account.
Pumpe, Drehrichtung rechts.

Saugseite / (Blick auf sphärische Fläche.)
Suction side Druckseite /
Pressure side Pump, clockwise rotation.
(viewed on spherical surface.)
Saugseite /
Druckseite / Pumpe, Drehrichtung links.
Suction side
Pressure side (Blick auf sphärische Fläche.)
Pump, anti-clockwise rotation.

(viewed on spherical surface.)
Motor, beide Drehrichtungen.

(Blick auf sphärische Fläche.)
Motor, bi-directional.
(Viewed on spherical surface.)
008 910 92 BOMAG 761

14 A2F | RDE 91 001-03-R/05.03
Travel motor
Sichtkontrolle
O-Ring (1), Einstich (2), Platte (3).
Visual check
O-ring (1), Groove (2), Plate (3).
Neuen O-Ring einlegen, zuvor leicht einfetten.
Lightly grease and fit O-ring.
Anschlußplatte aufsetzen, auf Kennzeichnung und

Lage des Verdrillstiftes achten.
Place the cover plate onto the housing taking into

account the location mark and position of the
locating pin.
Befestigungsschrauben mit Drehmomenten-

schlüssel anziehen.
Tighten fixing screws using a torque wrench.
762 BOMAG 008 910 92

RDE 91 001-03-R/05.03
15
Triebwerk ausbauen
Removal the rotary group
Lagersatz / Bearing set
Demontage der Anschlußplatte.

Steuerplatte abheben.
Zylinder am Mittelzapfen mit Schraube befestigen.
Removal of the connection plate.

Lift off the control plate.
Secure the cylinder to the centre pin using a screw.
Gewindestift,Zylinderschraube /
Threaded pin,socket head screw
NG / Size (mm)
10; 12; 16 M3 x 35
23; 28; 32 M5 x 45
45 M5 x 50
56; 63 M5 x 55
80; 90 M5 x 60
107; 125; 131 M6 x 70
160; 180 M6 x 85
008 910 92 BOMAG 763

16 A2F | RDE 91 001-03-R/05.03
Travel motor
Triebwerk ausbauen
Removal the rotary group
Verschlußring, O-Ring und Paßscheibe ausbauen.
Remove the cover, O-ring and shim.
Triebwerk mit Vorrichtung ausbauen.
Withdraw the rotary group using an extractor.
Befestigungsschraube ausbauen.
Zylinder abheben.
Remove the fixing screw.

Lift off the cylinder.
Rückzugplatte demontieren, Schrauben sind

eingeklebt.
Komplettes Triebwerk bei ca. 120o C im Ölbad
erwärmen. Danach Befestigungsschrauben lösen!
Disassemble the retaining plate, screws are locked

with an adhesive.
Heat up the complete rotary group in an oil bath
to approx 120o C, then remove the fixing screws.
764 BOMAG 008 910 92

RDE 91 001-03-R/05.03
17
Inspection guidelines
Triebwelle
4 4 1. kein Passungsrost, nicht ausgeschlagen.
1 2
3 2. keine Einlaufspuren, riefenfrei.
3. Kalotten riefenfrei und keine Pittings.
4. Keine Laufspuren (Lagerdreher)
3
Drive shaft
1. No wear, or fretting
2. No traces of wear, free of scratches.
3. Cups free of wear and no pitting.
4. No traces of wear, (bearing rotation).
1
1. Axiales Kolbenspiel
1. Axial play of piston.
Alt / Old
Kolben
Riefenfrei, keine Pittings.
Piston
Neu / New
Free of scratches, no pitting.
1 2
Mittelzapfen
1. Riefenfrei, ohne Pittings.
2. Riefenfrei.
Center pin
1. Free of scratches, no pittings.
2. Free of scratches.
Rückzugplatte
Riefenfrei, keine Ausbrüche.
Retaining plate
Free of scratches, no wear.
008 910 92 BOMAG 765

18 A2F | RDE 91 001-03-R/05.03
Travel motor
Inspection guidelines
Zylinder/Steuerplatte
1. Bohrungen riefenfrei, nicht ausgelaufen.
2. Gleichmäßiges Tragbild, riß- und riefenfrei.
Cylinder / control plate

1. Bores unscratched, and no traces of wear.
2. Even load distribution, free of cracks and
grooves.
Gehäuse
Im Lagerbereich riefenfrei und keine
Einlaufspuren.
Housing
No traces of wear in the bearing area.
Nur kompletten Kolbensatz austauschen.
Only exchange the pistons as a complete set.
Zylinder und Steuerplatte nur gemeinsam

austauschen.
Only replace the cylinder and control plate as a pair.
766 BOMAG 008 910 92

RDE 91 001-03-R/05.03
19
Triebwerk einbauen
Installing rotary group
Triebwelle mit Lager vormontiert verwenden.
Use a pre-assembled drive shaft with bearings.
S Abstimmung Pos. A / Adjustment item A
A = A* + S
S = Nennmaß - Sicherungsring /Safety ring
A A*
Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.
Fit retaining plate complete with pistons and

centre pin.
Uses screws with a Precote coating.
Druckfeder (1) und Abstimmscheibe (2) einbauen.
Fit the compression spring (1) and shim(2).
Zylinder in Neutralposition befestigen.
Fix the cylinder in the neutral position.
008 910 92 BOMAG 767

20 A2F | RDE 91 001-03-R/05.03
Travel motor
Triebwerk einbauen
Triebwerk max. ausschwenken.
Swivel the rotary group to max.
Neuer Radialwellendichtring montiert?
Is the new shaft seal fitted?
Gehäuse auf ca. 80o C erwärmen.
Heat the housing to approx. 80o C.
Heißes Gehäuse bis zum Anschlag aufsetzen.
Push on the hot housing until the stop is reached.
Neue Montagestellung.
New assembly position.
768 BOMAG 008 910 92

RDE 91 001-03-R/05.03
21
Triebwerk einbauen
Paßscheibe, O-Ring einlegen. Verschlußring

montieren.
O-Ring, Zwischenraum Wellendichtring einfetten
(siehe Serviceinfo).
Fit the shim and O-ring. Then fit the cover.

Grease the O-ring as well as the seal and dust
lipsof the shaft seal.
Triebwerk gegen Verschlußring ziehen.

Kontrolle: Verschlußring spielfrei.
Pull the rotary group against the cover.

Check: to see that the cover is free of play.
Befestigungsschraube ausbauen.
Steuerplatte lagerichtig aufsetzen.
Fertigmontage
Abstimmung Pos. D - siehe Serviceinfo
Remove fixing screw. Fit the control plate into its

correct location.
Final assembly
For adjustment of Pos. D - see service info
Abstimmung Pos. D / Adjustment item D

Pos. D
Anschlüsse mit Staubschutz abdichten.

Korrosionsschutz (innen/außen). Fertig!
Seal connections to protect against dust.

Corrosion proctection (internal/external).
Assembly complete.
008 910 92 BOMAG 769

22 A2F | RDE 91 001-03-R/05.03
Travel motor

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.

Gewinde / Thread 8.8 10.9 12.9
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
770 BOMAG 008 910 92

RDE 91 001-03-R/05.03
23

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

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
008 910 92 BOMAG 771

24 A2F | RDE 91 001-03-R/05.03
Travel motor

7. Linsenschrauben 7. Oval head screw

mit Innen-TORX, Gewindevorbeschichtung mit "precote" with inner TORX, thread precoated with "precote"
Standard / Standard precote 80 - Rot / Red
precote 86 - Blau / Blue

Variante / Variant
*
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20
siehe Stückliste / as to parts list
* mit Unterkopfbeschichtung - farblos

* with head bottom coating - colorless

Gewinde / Thread 10.9
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7
772 BOMAG 008 910 92

RDE 91 001-03-R/05.03
25
Safety regulations
Allgemein General advice
● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.
Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck-Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. heavy injuries.
Daher sofort einen Arzt aufsuchen, da anderenfalls Therefore immediately consult a doctor as otherwise
schwere Infektionen entstehen können! heavy infections can be caused.
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr 2. When searching leakages use appropriate auxiliary devices
geeignete Hilfsmittel verwenden! because of the danger of accidents.
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt 3. Before working at the hydraulic equipment, lower pressure
drucklos machen und angebaute Geräte absenken! to zero and lower working arms of the rnachine.
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor 4. When working at the hydraulic equipment, absolutely stop
abstellen und Traktor gegen Wegrollen sichern motor and secure tractor against rolling away
(Feststellbremse, Unterlegkeil)! (parking brake, shim)!
5. Beim Anschließen von Hydraulikzylindern und -motoren ist 5. When connecting hydraulic cylinders and motor pay
auf vorgeschriebenen Anschluß der Hydraulikschläuche attention to correct connection of hydraulic flexible hoses.
zu achten! 6. In case of exchanging the ports, the tunctions are vice versa
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen (f. ex. lift-up/lower) - danger of accidents!
(z.B. Heben/Senken) - Unfallgefahr! 7. Check hydraulic flexible hoses regularly and replace them in
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und case of dammage or wear! The new hose pipes must comply
bei Beschädigung und Alterung austauschen! Die with the technical requirements of the machine manufacturer!
Austausch schlauchleitungen müssen den technischen
Anforderungen des Geräteherstellers entsprechen! Orderly disposal or recycling of oil, fuel and
filters!
Öle, Kraftstoffe und Filter ordnungsgemäß
entsorgen!
008 910 92 BOMAG 773

26 A2F | RDE 91 001-03-R/05.03
Travel motor
774 BOMAG 008 910 92

RDE 91 001-03-R/05.03
27
008 910 92 BOMAG 775

20.3 Travel motor
Bosch Rexroth AG
Mobile Hydraulics
Produktbereich Axialkolbenmaschinen
Werk / Plant Elchingen
Glockeraustraße 2
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm-ak@boschrexroth.de
© 2003 by Bosch Rexroth AG, © 2003 by Bosch Rexroth AG,

Mobile Hydraulics, 89275 Elchingen Mobile Hydraulics, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Bosch Rexroth AG reproduziert oder
any form or by any means, without the unter Verwendung elektronischer
prior written authorization of Bosch Systeme gespeichert, verarbeitet,
Rexroth AG. In the event of vervielfältigt oder verbreitet werden.
contravention of the above provisions, Zuwiderhandlungen verpflichten zu
the contravening party is obliged to Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are zu beachten, dass unsere Produkte
subject to a natural process of wear einem natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.
Printed in Germany
RDE 91 001-03-R/05.03
776 BOMAG 008 910 92

20.4 Drum reduction gear
008 910 92 BOMAG 777

778 BOMAG 008 910 92

Drum reduction gear 20.4
008 910 92 BOMAG 779

780 BOMAG 008 910 92

008 910 92 BOMAG 781

782 BOMAG 008 910 92

008 910 92 BOMAG 783

784 BOMAG 008 910 92

008 910 92 BOMAG 785

786 BOMAG 008 910 92

008 910 92 BOMAG 787

788 BOMAG 008 910 92

008 910 92 BOMAG 789

790 BOMAG 008 910 92

008 910 92 BOMAG 791

792 BOMAG 008 910 92

008 910 92 BOMAG 793

794 BOMAG 008 910 92

008 910 92 BOMAG 795

796 BOMAG 008 910 92

008 910 92 BOMAG 797

798 BOMAG 008 910 92

008 910 92 BOMAG 799

800 BOMAG 008 910 92

008 910 92 BOMAG 801

802 BOMAG 008 910 92

008 910 92 BOMAG 803

804 BOMAG 008 910 92

008 910 92 BOMAG 805

806 BOMAG 008 910 92

008 910 92 BOMAG 807

808 BOMAG 008 910 92

008 910 92 BOMAG 809

810 BOMAG 008 910 92

008 910 92 BOMAG 811

812 BOMAG 008 910 92

008 910 92 BOMAG 813

814 BOMAG 008 910 92

008 910 92 BOMAG 815

816 BOMAG 008 910 92

008 910 92 BOMAG 817

818 BOMAG 008 910 92

008 910 92 BOMAG 819

820 BOMAG 008 910 92

008 910 92 BOMAG 821

822 BOMAG 008 910 92

008 910 92 BOMAG 823

824 BOMAG 008 910 92

008 910 92 BOMAG 825

826 BOMAG 008 910 92

008 910 92 BOMAG 827

828 BOMAG 008 910 92

20.5 Vibration motor
008 910 92 BOMAG 829

830 BOMAG 008 910 92

Vibration motor 20.5
008 910 92 BOMAG 831

832 BOMAG 008 910 92

008 910 92 BOMAG 833

834 BOMAG 008 910 92

008 910 92 BOMAG 835

836 BOMAG 008 910 92

008 910 92 BOMAG 837

838 BOMAG 008 910 92

008 910 92 BOMAG 839

840 BOMAG 008 910 92

008 910 92 BOMAG 841

842 BOMAG 008 910 92

008 910 92 BOMAG 843

844 BOMAG 008 910 92

008 910 92 BOMAG 845

846 BOMAG 008 910 92

008 910 92 BOMAG 847

848 BOMAG 008 910 92

008 910 92 BOMAG 849

850 BOMAG 008 910 92

20.6 Wheel drive
008 910 92 BOMAG 851

20.6 Wheel drive
852 BOMAG 008 910 92

Wheel drive 20.6
Hydraulikmotoren
MS
Hydraulic motors
Reparaturen
Repairs
02 05 08 11 18
MS
MSE
Störungsbeseitigung
Trouble Shooting
Wartungsarbeiten
Maintenance
Reparaturen
Repairs
5767
Ersatzteile
Spare Parts
5763 5765
0549 5766 0545
5764
0550 0547
Ref : 800378128J POCLAIN HYDRAULICS Industrie

B.P. 106
REPAR MS2-18 D/GB 60411 VERBERIE CEDEX - FRANCE POCLAIN HYDRAULICS
Tel.: 33 3 44 40 77 77
Rev : A - Avr - 00 Fax: 33 3 44 40 77 99
www.poclain-hydraulics.com Certifié ISO 9001
008 910 92 BOMAG 853

20.6 Wheel drive
POCLAIN HYDRAULICS
Dieses Dokument richtet sich an die Hersteller von Maschinen und Sy- This document is provided to machine manufacturers integrating PO-
stemen, die Produkte von POCLAIN-HYDRAULICS einbauen, deren CLAIN-HYDRAULICS products.. It suggests processes that manufac-
Artikelnummer auf der Titelseite genannt sind. Es beschreibt die Instal- turers may utilize to repair products after the warranty period.
lationsangaben und den Inbetriebnahmevorgang, damit ihre optimale
Funktionsweise gewährleistet wird.
Es wird empfohlen, daß sämtliche Arbeiten von Monteuren mit einer an- It is recommended that all operations be performed by technicians
gemessene Ausbildung durchgeführt werden. Sie müssen die Informa- trained accordingly. The technicians should read and understand the
tionen in diesem Dokument gelesen und verstanden haben und vom information given in this document and be authorized by the machine
Hersteller der Maschine bevollmächtigt sein. manufacturer.
Selbstverständlich müssen die Monteure die Richtlinien zur Sicherheit It is essential that the technicians comply with safety instructions to pre-
und zur Unfallverhütung beachten. vent injury.
Dieses Dokument enthält wichtige Hinweise zur Sicherheit. Sie werden This document includes major safety warnings announced in this way:
auf folgende Weise gekennzeichnet:
! Sicherheitshinweis. ! Safety warning.
Additionally, this document includes instructions essential to product

Dieses Dokument enthält weiterhin wesentliche Anweisungen zum Be-
function as well as those providing general information. Both are an-
trieb des Produkts sowie allgemeine Informationen. Sie werden auf fol-
nounced similar to the following examples:
gende Weise gekennzeichnet:
Wesentliche Anweisung. Essential instruction.
General information.
Allgemeine Information.
POCLAIN HYDRAULICS kann nicht für Vorfälle haftbar gemacht wer- POCLAIN HYDRAULICS designs products that are integrated by its
den, die auf die Anwendung der in diesem Dokument empfohlenen Ver- customers in the machines they design.
fahren zurückgehen.
POCLAIN HYDRAULICS ist nicht verantwortlich für die Konstruktion Subsequently POCLAIN HYDRAULICS disclaims liability for conse-
und die Betriebsbedingungen der Maschinen und Systeme, die mit PH- quences of improper integration of its products and of improper set-up
Produkten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS we- of adjustable devices. In the same way, POCLAIN HYDRAULICS may
der für die Folgen eines falschen Einbaus der Produkte noch für ein fal- not be liable for incomplete or improper operating and maintenance in-
sches Parametrieren einstellbarer Werte, noch für ungültige oder unvoll- structions provided to the end user by the machine manufacturer nor for
ständige Gebrauchs- und Wartungsanweisungen, die den Endverbrau- failures resulting from operations performed by any person using these
chern von den Maschinenherstellern zur Verfügung gestellt worden sind, suggested procedures.
verantwortlich. A re-certification of the machine may be required for every change in
Jegliche Änderung einstellbarer Parameter der PH Produkte kann eine set-up of adjustable devices.
Neuzulassung der Maschinen erforderlich machen.
Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HY- In order to offer the best quality service, POCLAIN HYDRAULICS rec-
DRAULICS seinen Kunden, jede Anwendung von POCLAIN HY- ommends to its customers to have applications approved by POCLAIN
DRAULICS prüfen und freigeben zu lassen. HYDRAULICS.
Das Öffnen der Produkte führt zum Garantieverlust. Verwenden Sie nur Opening of products voids the warranty contract.
Original-Ersatzteile von POCLAIN HYDRAULICS. Die Montage von Use only POCLAIN HYDRAULICS genuine spare parts. Using parts
Teilen anderen Ursprungs könnte den Betrieb des Bauteils und des Sy- from different sources could reduce the performance of the product and
stems sowie die Sicherheit beeinträchtigen. pose a safety hazard..
Stets um die Verbesserung seiner Erzeugnisse bemüht, behält sich In accordance with its policy of continuous improvement, POCLAIN
POCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankündigung HYDRAULICS reserves the right to modify the specifications of all
alle Änderungen vorzunehmen, die als nützlich für die in diesem Doku- products described herein without prior notice.
ment beschriebenen Produkte bewertet werden.
Dieses Dokument enthält Abschnitte auf deutsch und kursiv gedruckte Ab- This document contains sections written in German and sections
schnitte, die Übersetzung in englischer Sprache darstellen. printed in italics composing the English translation of the French sec-
Im Zweifelsfall ist die französische Version ausschlaggebend. tions. The French sections will be the reference in case of dispute.
Die Maße sind in metrischen Einheiten angegeben. Die Entsprechungen All measures are expressed in metric units. Converted values to other
in anderen Meßsystemen (vor allem angelsächsisch) werden zur Unter- systems (notably US and UK) are given for reference only.
richtung angegeben.
Die Abbildungen haben unverbindlichen Charakter. The illustrations for information only.
© POCLAIN HYDRAULICS Industrie 1998. © POCLAIN HYDRAULICS Industrie 1998.

Die Handelsmarke POCLAIN HYDRAULICS ist das Eigentum von PO- The trademark POCLAIN HYDRAULICS is the property of POCLAIN
CLAIN HYDRAULICS SA. HYDRAULICS S.A.
Dieses Dokument ist das Eigentum von POCLAIN HYDRAULICS Indu- This document is the property of POCLAIN HYDRAULICS Industrie.
strie. Es ist streng vertraulich. Es darf ohne unseres vorheriges schriftli- It is strictly confidential. It must not be used, duplicated, copied or dis-
ches Einverständnis weder gesamt noch teilweise verwendet, vervielfäl- closed to a third party in full or in part without our prior written consent.
tigt, kopiert oder an Dritte weitergegeben werden. FACOM is FACOM SA registered trademark.
FACOM ist ein eingetragenes Warenzeichen der FACOM SA. LOCTITE is LOCTITE SA registered trademark.
LOCTITE ist ein eingetragenes Warenzeichen der LOCTITE SA. AUTO-TOP is AGIP SPA registered trademark.
AUTO-TOP ist ein eingetragenes Warenzeichen der AGIP SPA.
2 REPAR MS2-18 D/GB 800378128J
854 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Inhaltsverzeichnis Contents
INHALTSVERZEICHNIS ............................................. 3 CONTENTS................................................................. 3
SICHERHEIT UND QUALITÄT ................................... 4 SAFETY AND QUALITY ............................................. 4

VOR DEN W ARTUNGSARBEITEN ....................................... 4 BEFORE SERVICING ........................................................ 4
W ÄHREND DER W ARTUNGSARBEITEN............................... 4 DURING SERVICING ......................................................... 4
NACH DEN W ARTUNGSARBEITEN ..................................... 4 AFTER SERVICING ........................................................... 4
IDENTIFIZIERUNG DES BAUTEILS ....................................... 5 IDENTIFICATION OF THE COMPONENT................................. 5
STÖRUNGSBESEITIGUNG........................................ 6 TROUBLE SHOOTING ............................................... 7
WARTUNGSARBEITEN.............................................. 8 MAINTENANCE .......................................................... 8

AUSTAUSCHEN DES MOTORS........................................... 8 REPLACING THE MOTOR .................................................. 8
Ausbau..................................................................... 8 Removal................................................................... 8
Einbau...................................................................... 8 Installation................................................................ 8
MECHANISCHE BREMSLÖSUNG ........................................ 9 MECHANICAL BRAKE RELEASE .......................................... 9
KONTROLLE DER STATISCHE HALTEBREMSE. ................... 10 CHECKING THE PARKING BRAKE EFFICIENCY..................... 10
REPARATUREN. ...................................................... 11 REPAIRS. ................................................................. 11
AUSWECHSELN DER BREMSKOLBENDICHTUNG................. 11 REPLACEMENT OF THE O-RING OF THE BRAKE PISTON....... 11
Demontage ............................................................ 11 Disassembly........................................................... 11
Wiedereinbau......................................................... 13 Reassembly. .......................................................... 13
AUSWECHSELN DES LAGERTEILES (070)......................... 16 REPLACEMENT OF THE BEARING SUPPORT (070).............. 16
Wiedereinbau......................................................... 18 Reassembly ........................................................... 18
AUSWECHSELN DER BREMSBACKEN ............................... 20 REPLACING THE BRAKE SHOES....................................... 20
AUSWECHSELN DES NOCKENRINGS (026)....................... 27 REPLACEMENT OF THE CAM (026) .................................. 27
AUSWECHSELN DES KOMPLETTEN ZYLINDERBLOCKS (010) 28 REPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)28
AUSWECHSELN DES VERTEILERS (047). ......................... 29 REPLACEMENT OF THE VALVING (047). ........................... 29
AUSWECHSELN DER DECKELDICHTUNG (045).................. 32 REPLACEMENT OF THE O-RING (045) OF THE END COVER . 32
AUSWECHSELN DES DREHZAHLSENSORS (OPTION).......... 34
REPLACING THE SENSOR (OPTIONAL) .............................. 34
Demontage ............................................................ 34
Disassembly........................................................... 34
Wiedereinbau......................................................... 35
Reassembly ........................................................... 35
WERKZEUG-LISTE .................................................. 36
TOOLING INVENTORY............................................. 36
Standard Werkzeug................................................ 36
Standard tools ........................................................ 36
Spezialwerkzeuge .................................................. 37
Special tools........................................................... 37
ANZIEHDREHMOMENTE NM ± 10%........................... 38
TIGHTENING TORQUES IN [LBF.FT] ± 10% .......... 38
ERSATZTEILE.......................................................... 39
SPARE PARTS LIST ................................................ 39
MOTOREN MIT KONSTANTEM HUBVOLUMEN MS, MSE 02-
SINGLE DISPLACEMENT MOTORS MS, MSE 02-05-08-11-
05-08-11-18. .............................................................. 42
18. ............................................................................. 42
MOTOREN MIT UMSCHALTBAREM HUBVOLUMEN MS, MSE
DUAL DISPLACEMENT MOTORS MS, MSE 02-05-08-11-18.44
02-05-08-11-18. ......................................................... 44
800378128J REPAR MS2-18 D/GB 3
008 910 92 BOMAG 855

20.6 Wheel drive
POCLAIN HYDRAULICS
Sicherheit und Qualität Safety and Quality
Vor den Wartungsarbeiten Before servicing
• Alle notwendigen Sicherheitsvorkehrungen treffen • Be extremely careful to prevent personal injury and
(Menschen und Material) und die geltenden Sicher- to avoid damage to material. Comply with all safety
heitsvorschriften beachten. regulations.
• Parkbremse betätigen und Maschine mit Keilen • Apply the parking brake and prevent the machine
festsetzen. from rolling with tire blocks.
• Energieerzeugung (Motor) des Hydrauliksystems • Stop the hydraulic system power source (engine)
abstellen und die Stromversorgung ausschalten. and disconnect the battery.
• Gegebenenfalls eine Sicherheitszone einrichten. • If necessary, block off the safety area.
• Die Außenflächen der Bauteile reinigen, um • Wash dirt and grease from exterior of the compo-
Schmutz und Fett restlos zu entfernen. nents.
• Warten, bis das Hydrauliksystem vollständig abge- • Await the complete cooling down and depressuriza-
kühlt und druckentlastet ist (die Speicher entlasten). tion of the hydraulic system (accumulators must be
purged).
Das heiße oder unter Druck stehende Öl Hot or pressurized hydraulic fluid may
! kann zu schweren Verbrennungen mit
Entzündung führen.
! cause serious burns & infections to the
human body.
Bei einem Unfall einen Arzt hinzuziehen. Consult a physician in case of accident.
Während der Wartungsarbeiten During servicing

• Bestimmte Bauteile sind sehr schwer. Sie müssen • Some hydraulic components are very heavy. Se-
bei der Abnahme vom Rahmen mit einer angemessen cure them with a lifting device of adequate capacity
ausgelegten Hebevorrichtung gehalten werden. when removing from the machine frame.
• Die Sauberkeit ist wesentlich beim Betrieb der Hy- • Cleanliness is essential to functioning of the hy-
draulikbauteile. Die meisten Teile können mit einem draulic components. Most of the parts may be cleaned
sauberen Lösungsmittel gereinigt werden. with a clean solvent.
• Während der Handhabung alle empfindlichen Ober- • During handling, protect all sensitive surfaces from
flächen gegen Stöße schützen (Zentrierungen, gleitende shocks (piloting and interface surfaces, thrust & bear-
Teile, Auflagen, Dichtungs- und Lagerauflagen usw.). ings surfaces, seal races, etc...)
• Diese Flächen vor dem Wiederzusammenbau reinigen. • Clean up these surfaces before reassembling.
• Systematisch die demontierten Dichtungen beim • Always install new O-rings, seals & gaskets dis-
Wiederzusammenbau durch neue ersetzen. Wir emp- carding the old ones. We recommend lubricating all
fehlen, vor der Montage alle Dichtungen zu fetten. seals prior to assembly.
• Alle gleitenden Flächen durch Aufbringen eines Films • Lubricate all surfaces which have relative motion
sauberer Hydraulikflüssigkeit ölen, der eine korrekte between parts by coating them with a film of clean hy-
Schmierung beim ersten Neustart gewährleistet. draulic fluid to assure lubrication at first start.
• Niemals die Hydraulikflüssigkeit, die sich bei hohen • Never heat hydraulic fluid, as it may flame at high
Temperaturen entzünden kann, erwärmen. Einige Lö- temperature. Some solvents are also flammable.
sungsmittel sind ebenfalls entzündlich.
Während der Arbeiten nicht rauchen. Do not smoke during servicing.
Nach den Wartungsarbeiten After servicing

Die Bauteile wieder einbauen und das Hydrauliksystem Reinstall the components and restart the hydraulic
gemäß den Anweisungen in den folgenden Dokumen- system according to instructions defined in the following
ten wieder in Betrieb nehmen: documents:
• INSTALLATION MS D/GB (ref: 800078173V) • INSTALLATION MS F/GB (ref. 677777844K)
• INSTALLATION CIRCUITS D/GB (ref. 677777853U) • INSTALLATION CIRCUITS F/GB (ref. 677777831V)
Die Einstellung der Sicherheitsventile
! nicht erhöhen. ! Do not overset relief valves.
4 REPAR MS2-18 D/GB 800378128J
856 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Identifizierung des Bauteils Identification of the component
MS18-2-D11-F19-2A10-K000
B D
000143896J
C 40712
001
0349
A : Handelsbezeichnung: A: Commercial description:

Ex : MSE18-2-D11-F19-2A10-K000 E.g : MSE18-2-D11-F19-2A10-K000
B : Code : Artikelnr.: B: Code: Part number.

Ex : 000143896J E.g : 000143896J
C : Serie : Herstellungsnummer C: Series: Manufacturing batch number.

Ex : 001 E.g : 001
D : Num : Chronologische Ordnungsnummer D: Num: Chronological serial number.

Ex : 40712 E.g : 40712
Bei sämtlichen Ersatzteilbestellungen The part number and the chronological

müssen die Artikelnummer und die chro- serial number must be specified to order
nologische Ordnungsnummer angege- spare parts.
ben werden.
800378128J REPAR MS2-18 D/GB 5
008 910 92 BOMAG 857

20.6 Wheel drive
POCLAIN HYDRAULICS
Störungsbeseitigung
BECHÄDIGUNG → ABRIEB → ERKENNUNG DURCH FILTER → VORBEUGUNG……
Störung Ursachen Abhilfe

Regelmäßiges Lagerteil verschlissen Lagerteil ersetzen
Ohne Brummen
Last Lockere Befestigungen Mit entsprechendem Drehmo-
LAUTE Vibrationen
und / oder Anschlüsse ment anziehen
GERÄUSCHE DES
MOTORS Speise- und Austauschdruck-
Klappern Speisedruck zu niedrig
Unter ventil kontrollieren.
Last Zylinderblock und Ölverteiler
Kavitation Interne Lecks zu groß ersetzen
Der Motor wird nicht ver- Den Antrieb der Pumpe und ih-
sorgt re Versorgung überprüfen
Kein Druckanstieg im Hochdruck-Begrenzungsventile
MOTOR DREHT SICH Kreis kontrollieren (Regler)
NICHT Zylinderblock und Ölverteiler
Interne Lecks zu groß
ersetzen
Die Bremse bleibt angezo- Den Steuerkreis der Bremse
gen kontrollieren
Die Antriebsdrehzahl und den

Der Fördermenge der
Zustand der Pumpe kontrollie-
Pumpe ist unzureichend
ren
DER MOTOR DREHT
SICH NICHT MIT Den Zustand des Zylinder-
NORMALER LAST- Interne Lecks zu groß blocks und des Ölverteilers
DREHZAHL überprüfen
Der Betriebsdruck ist zu Den Zustand des Sicherheits-
niedrig ventils kontrollieren (Regler)
Die Fördermenge der Steuerdruck und Fördermenge

DER MOTOR DREHT Pumpe schwankt der Pumpe kontrollieren
SICH UNREGEL- Den Zustand des Zylinder-
MÄSSIG Interne Lecks zu groß blocks und des Ölverteilers
überprüfen.
Gehäusedruck zu groß Den Leckagekreis und den Zu-

stand des Filters überprüfen
Dichtungen beschädigt Die Dichtungen ersetzen
ÄUSSERE ÖLUN-
DICHTIGKEITEN Das Anziehmoment der Monta-
geschrauben, der Entlüftungs-
Fehlerhafte Montage
schrauben und der Anschlüsse
kontrollieren
6 REPAR MS2-18 D/GB 800378128J
858 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Trouble shooting
DAMAGE → IRON PARTICLES → DETECTION BY FILTERS → PREVENTION……
Troubles Causes Remedies

Regular rum- Worm bearing support Replace the bearing support
Without bling
load Mountings and/or hydraulic
Vibrations Tighten to torque
piping becoming loose
NOISY MOTOR
Check the setting and condi-
Clattering Boost pressure too low
tion of counter-pressure valve
Under load Replace the cylinders- block
Cavitation Excessive internal leaks and distribution valve assem-
bly
Check pump drive and pump

No supply to the motor
inlet
The circuit does not reach Check condition of safety
THE MOTOR DOES working pressure valve (regulator)
NOT REVOLVE Replace the cylinders block
Excessive internal leaks and distribution valve assem-
bly
The brake stays engaged Check the brake pilot circuit
Check drive speed and condi-

Pump flow is too low
tion of the pump
THE MOTOR DOES
Check condition of cylinders-
NOT REVOLVE AT
Excessive internal leaks block and distribution valve
ITS NORMAL SPEED
assembly
UNDER LOAD
Working pressure is too Check safety valve setting
low pressure (regulator)
Irregular flow Check the pump flow

THE MOTOR RE-
VOLVES IRREGU- Check condition of cylinders-
LARLY Excessive leaks block and distribution valve
assembly
Too high casing pressure Check the leakage circuit and

filter condition
EXTERNAL OIL Seals damaged Replace seals
LEAKS
Check tightening of mounting
Incorrect assembling screws, bleed screws and
unions
800378128J REPAR MS2-18 D/GB 7
008 910 92 BOMAG 859

20.6 Wheel drive
POCLAIN HYDRAULICS
Wartungsarbeiten Maintenance
Austauschen des Motors Replacing the motor
Ausbau Removal
• Druck im Arbeitskreis abbauen. • Release the pressure in the supply circuit.
• Leckageleitung am Tank abschrauben, um ein • Disconnect the drain line at the tank level to avoid
Leerlaufen zu verhindern. its siphoning.
• Die Rohre oder Schläuche, die am Motor ange- • Disconnect and plug the pipes or hoses which are
schlossen sind, abklemmen. connected to the motor.
• Drehzahlsensor abklemmen. • Disconnect the speed sensor.
• Die Befestigungsschrauben demontieren und den • Disconnect the mounting screws, and remove the
Motor ausbauen. motor.
• Das Motorgehäuse entleeren. • Drain the casing.
Einbau Installation
Die zum Ausbau angegebenen Arbeitsgänge in umge- Execute the removal operations in the reverse order.
kehrter Reihenfolge ausführen.
Für weitere Informationen beziehen Sie sich bitte auf Please refer to the following documentation brochures:
folgende Dokumente:
• INSTALLATION MS D/GB (ref: 800078173V) • INSTALLATION MS F/GB (ref: 677777844K)
• INSTALLATION CIRCUITS D/GB (ref: 677777853U) • INSTALLATION CIRCUITS F/GB (ref: . 677777831V)
8 REPAR MS2-18 D/GB 800378128J
860 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Mechanische Bremslösung Mechanical brake release
Bei bestimmten Reparaturfällen In certain service situations, it may

oder zum Abschleppen der Maschi- be necessary to release the motor
ne muß die integrierte Parkbremse brake.
gelöst werden.
• Stopfen (142) aus der Schutz- • Extract and release the plug 142
kappe (141) herausziehen. (142) from the brake cover (141).
6499
• Schraube im Kolben festziehen • Tighten the screw in the piston
6556
• Mutter so weit anziehen, bis die • And tighten the nut until the
Welle frei dreht. motor shaft turns freely.
6555
Entsprechendes
Bremsen Brakes Kraft N Force [lbf] Equivalent torque [lbf.ft] Mutter Nut
Drehmoment Nm
F02-F04 18000 [4.000] 42 [30.9] M12
F05-F07 20000 [4.500] 47 [34.6] M12
F08 34000 [7.600] 110 [81.1] M16
F11 45000 [10.000] 140 [103] M16
F12 45000 [10.000] 140 [103] M16
F19 45000 [10.000] 140 [103] M16
Nach Bremslösung, einen neuen Stopfen After brake release, mount a new plug
! (142) einbauen. ! (142).
800378128J REPAR MS2-18 D/GB 9
008 910 92 BOMAG 861

20.6 Wheel drive
POCLAIN HYDRAULICS
Kontrolle der statische Haltebremse. Checking the parking brake efficiency.
Bei fahrbaren Maschinen den Test auf ebenem For a rolling machine, make the test on a hori-
! Grund durchführen. ! zontal ground.
Bremssteuerdruck: mini 12 bar Pilot brake pressure : minimum 12 bar [174 PSI]
Maxi 30 bar. Maximum 30 bar [435 PSI]
• Sich vergewissern, daß der Bremsversorgungs- Make sure that the brake supply pressure is zero,
druck gleich Null ist,
• Die Bremse über die höchstgelegene Schraube • Purge the brake using the screw (112) located at
(112) entlüften, the highest level,
• Den Motor mit Maximaldruck beaufschlagen, • Supply the motor up to the setting pressure.
• Die Motorwelle darf sich nicht drehen, da andern- • The motor shaft must not turn, otherwise it is nec-
falls die Bremse ausgetauscht werden muß : essary to replace the brake :
! Mehrscheibenbremsen nicht einfahren. ! Do not run multidisc brakes in.
10 REPAR MS2-18 D/GB 800378128J
862 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Reparaturen. Repairs.
Auswechseln der Brems- Replacement of the O-ring

kolbendichtung of the brake piston.
Demontage Disassembly
• Den Motor ausbauen. • Remove the motor.
• Motor auf das Lagerteil stellen. • Place the motor on the bearing
support.
Muttern zum Schutz der

Protect the studs by
! Gewindebolzen wieder
aufsetzen
! reinstalling the nuts
• Schutzkappe (141) abnehmen • Remove and discard the brake

und beseitigen. cover.(141) 141
6500
• O-Ring (143) herausziehen und • Extract and discard the O-ring

143
beseitigen. (143).
6501
• Tellerfeder (108) zusammen- • Compress the washer (108).

drücken:
• Mit Hilfe des Dorns und Ab- • Using a mandrel and an ex-
ziehers (siehe Werkzeug Seite tractor (see tools page 36)
36) (fig 6502) (fig 6502)
• Mit Hilfe des Dorns und einer • Using a mandrel and a
Schraube Klasse 12.9 (siehe screw class 12.9 (see tools 6502
Werkzeug Seite 36) page 36)
• Mit Hilfe des Dorns und einer • Using a mandrel and a press
Presse (fig 6503). Die Kraft F (fig 6503). Respect the force F
beibehalten (siehe Schaubild (see table page 9)
Seite 9)
Einsatzrichtung des Si- Mark the mounting di-

cherungsrings markieren. rection of the snap ring.
6503
800378128J REPAR MS2-18 D/GB 11
008 910 92 BOMAG 863

20.6 Wheel drive
POCLAIN HYDRAULICS
• Sicherungsring (109) mit Hilfe • Remove the snap ring (109)
einer Zange für Innenringe heraus- using internal snap ring pliers. (see
nehmen (siehe Werkzeuge Seite tools page 36)
36)
• Extractor and pliers (fig 6504 6504 6505
• Abzieher und Zange (fig and 6505)
6504 und 6505) • Press and pliers (fig 6506
• Presse und Zange (fig 6506 and 6507)
und 6507)
6506 6507
Bei Verwendung der Pres- If you use the press do
!
se das Lagerteil nicht auf
den Gewindebolzen ab- ! not place the bearing
support on the studs.
stützen.
• Tellerfeder (108) herausziehen. • Extract the washer (108).
108
6508
• Bremskolben (107) herauszie- • Extract the brake piston (107)

hen.
6513
• O-Ring (106) beseitigen. • Discard the O-ring (106).

106
6511
12 REPAR MS2-18 D/GB 800378128J
864 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Wiedereinbau. Reassembly.
Vor dem Wiedereinbau ist unbedingt Before reassembling, it is neces-
sicherzustellen, daß alle Teile, Nuten sary to ensure that all parts, the
und Dichtungs-Auflageflächen sauber surface condition of the piston seal
sind. contact surface and the grooves are
clean.
Es dürfen keine Rost-,
! Schmutz- oder Wasser-
All traces of rust, mud,
spuren vorhanden sein
! water must be removed.
Mit Korrosionsschutzfett (siehe

Werkzeug Seite 36) einschmieren: Coat with anti-oxidizing grease (see
die Nut, die obere Fläche des tools page 36), the grooves, the top
Bremskolbens, die Tellerfeder, den of the brake piston, the spring
Sicherungsring und die Auflagefläche washer, the snap ring and the pis-
der Kolbendichtung im Bremsgehäuse. ton seal contact surface in the
brake body.
• Neuen O-Ring (106) auf den • Install a new O-ring (106) on
Kolben (107) montieren. the piston (107).
Der Ring muß fest an The ring should be tight

! den Kolben gepreßt und
nicht verdreht werden. ! on the piston and not
twisted. 106
6512
• Bremskolben (107) einsetzen. • Install the brake piston (107).
Achtung, wenn die Take care when passing 107

Dichtung über die Nut
! des Sicherungsrings ! the seal over the snap
ring groove.
geführt wird.
6509
• Tellerfeder (108) einlegen. Install the spring washer (108). 108
6513
800378128J REPAR MS2-18 D/GB 13
008 910 92 BOMAG 865

20.6 Wheel drive
POCLAIN HYDRAULICS
• Tellerfeder (108) zusammen- • Compress the spring washer
drücken: (108).
• Mit Hilfe des Dorns und Ab- • Using a mandrel and an ex-
ziehers (siehe Werkzeug Seite tractor (see tools page 36)
36) (fig 6502) (fig 6502)
• Mit Hilfe des Dorns und einer • Using a mandrel and a press
Presse (fig 6503). Die Kraft F (fig 6503). Respect the force F
einbehalten (siehe Schaubild (see table page 9) 6502
Seite 9)
Bei Verwendung der If you use the press do
!
Presse das Lagerteil
nicht auf den Gewinde- ! not place the bearing
support on the studs.
bolzen abstützen.
6503
• Sicherungsring (109) mit Hilfe • Install the snap ring (109) using
einer Zange für Innenringe gemäß internal snap ring pliers in line with
der bei der Demontage ange- the mark made during disassembly
brachten Kennzeichnung montie- . (see tools page 36)
ren: (siehe Werkzeuge Seite 36) 6504 6505
• Abzieher und Zange (fig • Extractor and pliers (fig 6504
6504 und 6505) and 6505)
• Presse und Zange (fig 6506 • Press and pliers (fig 6506
und 6507) and 6507)
6506 6507
• Neuen, mit Korrosionsschutzfett • Install a new O-ring (143)

eingeschmierten O-Ring (143) in coated with anti-oxidizing grease in 143
die Nut einsetzen (siehe Werkzeu- its groove. (see tools page 36)
ge Seite 36).
6515
• Neue Schutzkappe (141) auf • Place the new cover (141) on

141
den Anschnitt legen. the entry chamfer .
6516
14 REPAR MS2-18 D/GB 800378128J
866 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
• Schutzkappe mit Hilfe des • Click the cover into place using
Dorns einrasten lassen (siehe the right mandrel. (see tools page
Werkzeug Seite 36). 36).
Sich vergewissern, daß Make sure that the outer
!
der Außenrand des
Schutzkappe in die Nut ! edge of the cover is en-
gaged in the groove.
eingreift ist.
6517
• Neuen Stopfen (142) einsetzen. • Install a new plug (142).
Sich vergewissern, daß Make sure about the con- 142

zwischen Schutzkappe
! und Stopfenrille ein- ! tact between the cover
and the plug groove.
wandfreier Kontakt be-
steht.
6518
• Motor wieder einsetzen. • Install the motor.
800378128J REPAR MS2-18 D/GB 15
008 910 92 BOMAG 867

20.6 Wheel drive
POCLAIN HYDRAULICS
Auswechseln des Lager- Replacement of the bearing

teiles (070) support (070)
Motor herausnehmen. Remove the motor.

Motor auf der Bremse oder Ver- Place the motor on the brake or on
schlussplatte abstützen (Motor ohne the end cover (motor without
Bremse). brake).
• Position des Lagerteiles • Mark the position of the

(070) in Bezug auf Nockenring bearing support (070) in relation to 070
(026) und Verteilerdeckel (040) the cam (026) and to the valving
kennzeichnen. cover (040).
025
040
6519
• Schrauben (042) heraus- • Remove the screws (042).

nehmen.
042
6520
• Lagerteil (070) herausneh- • Remove the bearing support

men. (070).
070
6521
• Nockenring (026) heraus- • Remove the cam (026).

nehmen. 026
6524
16 REPAR MS2-18 D/GB 800378128J
868 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
• O-Ring (027) vom Verteiler- • Discard the O-ring (027)
deckel (041) entfernen. from the valving cover (041). 027
041
6525
• O-Ring (027) vom Lagerteil • Discard the O-ring (027)

(071) entfernen. from the bearing support (071) 027
071
6522
800378128J REPAR MS2-18 D/GB 17
008 910 92 BOMAG 869

20.6 Wheel drive
POCLAIN HYDRAULICS
Wiedereinbau Reassembly
Vor dem Wiedereinbau ist unbe- Before reassembling it is necessary

dingt sicherzustellen, daß die Nut to ensure that the groove is clean
sauber ist
Es dürfen keine Rost-, All traces of rust, mud,
spuren vorhanden sein.
! water must be removed
• Neuen, mit Korrosions- • Install a new O-ring (027) 027

schutzfett eingeschmierten O-Ring coated with anti-oxidizing grease
(027) in die Nut des Lagerteiles (see tools page 36) in the groove of
(071) einsetzen (siehe Werkzeuge the bearing support (071).
Seite 36) .
071
6523
• Neuen, mit Korrosions- • Install a new O-ring (027)

schutzfett eingeschmierten O-Ring coated with anti-oxidizing grease
(027) in die Nut des Verteilerdek- (see tools page 36) in the groove of
kels (041) einsetzen (siehe Werk- the valving cover (041)
zeuge Seite 36) .
041
6525
• Nockenring (026) gemäß der • Install the cam (026) in line

bei der Demontage markierten with the marks made during disas- 026
Kennzeichnung montieren. sembling.
Große Ansenkungen in The big chamfers oriented

! Richtung Lagerteil ! towards bearing support
Den Nockenring anhand von zwei Center the cam using two screws 6526
einander gegenüberliegenden (042) diametrically opposite.
Schrauben (042) zentrieren.
18 REPAR MS2-18 D/GB 800378128J
870 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
• Lagerteil montieren • Install the bearing support
Bei Wellenmotoren For shaft motors the

müssen die Anschlüsse ports must be perpen-
! quer zur Einbauachse
des Motors liegen.
! dicular to the mounting
axis of the motor. (Fig
(Abb. 6521) 6521)
6521
6527
• Befestigungsschrauben (042) • Install and tighten the mounting

einsetzen und mit dem angegebe- screws (042) to the right torque.
nen Drehmoment anziehen. (siehe (see table page 38).
Schaubild Seite 38).
042
6520
• Motor wieder einsetzen. • Install the motor.
800378128J REPAR MS2-18 D/GB 19
008 910 92 BOMAG 871

20.6 Wheel drive
POCLAIN HYDRAULICS
Auswechseln der Brems- Replacing the brake shoes.

backen
Vor der Demontage kann man die Before disassembling it is possible

Abnutzung der Bremsbeläge durch to make a visual checking of the
die Inspektionsöffnungen kontrollie- brake pads wear via the inspection
ren. ports.
2055
Das Auswechseln des The same repairs

Bremsbacken und das should be made on
Schleifen der Trommeln each motor of the same
! muß auf allen Motoren ! axle when replacing
shoes and brake
der gleichen Achse vor-
genommen werden. drums.
• Befestigungsmuttern der Felge • Loosen the wheel rim retaining

lösen. nuts.
• Maschine auf der Höhe der • Raise the machine on the side
auszubauenden Felge hochheben. of the wheel rim to be removed.
• Rad abnehmen (Reifen). • Remove the wheel rim (tyre).
• Mechanische Bremse lösen. • Release the mechanical brake.
• Trommel (096) abziehen. • Extract the drum (096).
Reibfläche der Trommel Check the friction sur-

überprüfen, die weder tiefe face condition of the
Rillen (tiefer als 0,2 mm) drum which should show
noch abnormale Abnut- no deep scratches
! zungserscheinungen auf-
! (deeper than 0,2 mm
[0.0078 in]) nor abnormal
096
weisen darf, sonst muß
sie geschliffen werden. wear. Otherwise, the
brake drum should be 6528
(Ra 1,6 bis 3,2)
replaced. (Ra 1.6 to 3.2)
20 REPAR MS2-18 D/GB 800378128J
872 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
• Rückholfeder (154.a) abbauen. • Remove the return spring
(154.a).
154.a
6529
6530
• Halterungsfedern (154.b) ab- • Remove the retention springs

bauen. (154.b). 1
154.b
2
6531
• Bremsbacken aus der Betäti- • Release the brake shoes from

gungsvorrichtung lösen. the regulating mechanism.
6532
• Rückholfedern (154.c) abbau- • Remove the return springs

en. (154.c).
154.c
6533
800378128J REPAR MS2-18 D/GB 21
008 910 92 BOMAG 873

20.6 Wheel drive
POCLAIN HYDRAULICS
• Bremsbacke (154.1) abbauen. • Remove the brake shoe (154.1)
154.1
6534
• Den mechanischen Bremshebel • Releasing the mechanical brake

vom Bremsseil lösen und Brems- control lever from its cable, remove
backe (154.2) entfernen the brake shoe (154.2)
154.2
6535
6536
22 REPAR MS2-18 D/GB 800378128J
874 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Vorrichtung entstau- Remove all dust from the

ben, sich vergewissern, whole assembly. Make
! daß der Radzylinder ! sure there are no leaks at
the wheel cylinder.
dicht ist.
Reibfläche der Trommel überprü- Check the friction surface condition

fen, die weder tiefe Rillen (tiefer als of the drum which should show no
0,2 mm) noch abnormale Abnut- deep scratches (deeper than 0.2 6549
zungserscheinungen aufweisen mm) [0.0078in] nor abnormal wear.
darf, sonst muß sie geschliffen Otherwise, the brake drum should
werden. be replaced.
• Den Bremshebel am Bremsseil • Attaching the control lever on

(098) befestigen und Bremsbacke the brake cable (098), install the
(154.2) einbauen brake shoe (154.2)
098
154.2
6536
6535
800378128J REPAR MS2-18 D/GB 23
008 910 92 BOMAG 875

20.6 Wheel drive
POCLAIN HYDRAULICS
• Rückholplatte an die Brems- • Mount the return plate on the
backe (154.2) montieren. brake shoe (154.2)
6537
6538
• Bremsbacke (154.1) einsetzen. • Install the brake shoe (154.1)
6539
• Bremsbacken auf der Betäti- • Position the brake shoes on the

gungseinrichtung positionieren. regulating mechanism.
6532
• Rückholfedern (154.c) einset- Install the return springs (154.c)

zen.
154.c
6533
24 REPAR MS2-18 D/GB 800378128J
876 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
• Bremsbacken in die Betäti- • Install the brake shoes in the
gungseinrichtung einbauen. regulating mechanism
6532
• Halterungsfedern (154.b) ein- • Install the retention springs

setzen. (154.b).
1
154.b
2 6531
• Rückholfedern (154.a) einset- • Install the return spring (154.a).

zen.
154.a
6530
• Reibungsdurchmesser D der • Measure the brake drum friction

Trommel und der eingesetzten Ba- diameter D and that of the brake
cken messen. shoes, which have been installed.
Durchmesser D diameter
6529
800378128J REPAR MS2-18 D/GB 25
008 910 92 BOMAG 877

20.6 Wheel drive
POCLAIN HYDRAULICS
• Backendurchmesser anpassen, • Adjust the brake shoes diame-
um bei Bremsen mit mechanischer ter to obtain correct clearance be- 1 5 6 .4
Einstellvorrichtung mit Hilfe des ei- tween the brake padding and the
1 5 6 .2 1 5 6 .3
nen Zahnrads (156.1), oder bei drum using the adjusting wheel
Bremsen mit automatischer Brem- (156.1) for brakes equipped with
sennachstellung mit Hilfe der zwei mechanical adjustment system or
Zahnräder (156.2 und 156.3), das two adjusting wheels (156.2 and
nötige Spiel zwischen Belag und a a
156.3) for brakes equipped with
Trommel zu erzielen. In diesem automatic clearance adjustment. In
Fall muß die Wirkung auf die Zahn- this case, the adjusting wheels 6540
räder symmetrisch (a) sein. Den should be adjusted symmetrically
Hebel (156.4) muss zu diesem (a). Release the lever slightly
Zweck freigängig sein. (156.4) to enable this operation to
take place.
Trommeldurchmesser (mm)
Bremsen Drum diameter [in] Total Spiel (mm)
Brake Total clearance [in]
nominal maximum
250 x 60 250 [9.84] 252 [9.92] 0.55 [0.02]
270 x 60 270 [10.63] 272 [10.70] 0.80 [0.03]
325 x 80 325 [12.79] 327 [12.87] 0.80 [0.03]
350 x 60 350 [13.78] 352 [13.85] 0.80 [0.03]
• Trommel aufsetzen und über- • Install the drum, check that it

prüfen, ob sie frei dreht. can turn freely.
6528
• Wenn nötig, den Radzylinder • Bleed the wheel cylinder, if

entlüften. necessary.
• Felge montieren. • Install the wheel rim.
Siehe Dokument INSTALLATION See documentation INSTALLATION
MS D/GB (ref: 800078173V) MS F/GB (ref 677777844K )
26 REPAR MS2-18 D/GB 800378128J
878 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Auswechseln des Nocken- Replacement of the cam

rings (026) (026)
Dazu die im Kapitel « Auswechseln Do operations described in chapter
des Lagerteils » unter « Demontage » "replacement of the bearing sup-
beschriebenen Arbeiten ausführen, port" section "disassembly" page 16
Seite 16
des Lagerteils » unter " Wiederein- "replacement of the bearing sup-
bau " beschriebenen Arbeiten ausfüh- port" section "reassembly" page 18.
ren, Seite 18. The angular position of the cam
Allerdings muß bei Motoren mit 2 must be respected on dual dis-
Schluckvolumen mit einem placement motors with a displace-
Schluckvolumenverhältnis über ment ratio different from 2.
oder unter 2 die Winkelposition be-
rücksichtigt werden. Example : Motor MS18 with dis-
Beispiel: Motor MS18, Schluckvolu- placement 1747-1049-698.
3
men 1747-1049-698 Small displacement : 698 cm
3
Kleines Schluckvolumen: 698 cm [42.59 cu.in] letter P
Buchstabe P 3
3
Medium displacement : 1049 cm
Mittleres Schluckvolumen: 1 049 cm [64.01 cu.in] letter M.
Buchstabe M The letter P or M must be located in
Die Buchstaben P oder M müssen the axis and towards the displace-
sich in der Achse befinden und in ment change spool, with the blind
Richtung des Schiebers für das hole towards the fixing of the cam
Wechseln des Schluckvolumens on the bearing support.
zeigen, auf der der Nockenring auf
dem Lagerteil befestigt ist.
M P
M P
MS08
MSE08
A R A R
MS18
MSE18
P M
M P
A R A
MS11
MSE11
P M 2035
800378128J REPAR MS2-18 D/GB 27
008 910 92 BOMAG 879

20.6 Wheel drive
POCLAIN HYDRAULICS
Auswechseln des komplet- Replacement of the cylin-

ten Zylinderblocks (010) ders block assembly (010)

des Lagerteils » unter « Demontage » "replacement of the bearing sup-
beschriebenen Arbeiten ausführen, port" section "disassembly" page 16
Seite 16
• Nach Demontage des Nocken- • After removing the cam, re-

rings den Zylinderblock ausbauen. move the cylinders block.
6541
• Neuen O-Ring (027) einsetzen. • Install a new O-ring (027).
6542
• Kompletten Zylinderblock (010) • Install the cylinders block as-

einsetzen. sembly (010).
6541
• Dazu die im Kapitel • Do operations described in

« Auswechseln des Lagerteils » unter chapter "replacement of the bearing
"Wiedereinbau" beschriebenen Ar- support" section "reassembly" page
beiten ausführen, Seite 18 18
28 REPAR MS2-18 D/GB 800378128J
880 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Auswechseln des Verteilers Replacement of the valving

(047). (047).

« Auswechseln des kompletten Zy- chapter "replacement of the cylin-
linderblocks (010)» unter ders bloc assembly (010)" section
« Demontage » beschriebenen Ar- "disassembly" page 28.
beiten ausführen, Seite 28.
Position des Verteilers Mark location to the

(047) in Bezug auf Ver- valving (047) in relation
! teilerdeckel (041) kenn-

zeichnen. (Motor mit 2
! to the valving cover
(041) (Dual displace-
Hubvolumen). ment motor).
• Den Verteiler (047) durch An- • Separate the valving (047) from
heben an den Ausrichtungszapfen the cover (041) by levering at the
oder am Flansch vom Verteilerdek- indexing pins or at the flange.
kel (041) abmontieren.
2031
Den Verteiler vor Staub Protect the valving from

! schützen. ! dusts.
• Federn (052) ausbauen. • Remove the springs (052).

• Dichtungen und Gegendichtun- • Remove and discard the seals
gen (048) vom Verteilerdeckel and back-up rings (048) from the
(041) herausziehen und beseitigen. cover (041).
Es dürfen keine Rost-,

All traces of rust, mud,
spuren vorhanden sein. ! water must be removed.
• Neue Dichtungen und Gegen- • Lubricate and install new seals

dichtungen (048) ölen und einset- and back-up rings (048), ensuring
zen; dabei die Gegendichtungen so the back up rings are twisted as lit-
wenig wie möglich verformen. tle as possible.
1135
• Die Federn (052) in ihr zuvor • Place the springs (052) in their
mit Fett gefülltes Gehäuse einset- housings, previously filled with
zen. grease.
• Die Dichtungsauflageflächen • Lubricate the faces of the seals
des Verteilers (047) fetten. of the valving (047).
• Den Verteiler(047) in den Ver- • Press the valving (047) into the
cover (041).
teilerdeckel (041) drücken
800378128J REPAR MS2-18 D/GB 29
008 910 92 BOMAG 881

20.6 Wheel drive
POCLAIN HYDRAULICS
Die Einbaurichtung des Respect the assembly

Verteilers (047) in bezug sense of the valving
! auf den Verteilerdeckel ! (047) in relation to the
cover (041).
(041) beachten).
Den Einsatz des Vertei-

Do not force when in-
lers (047) in den Vertei-
! lerdeckel (041) nicht
!
stalling the valving
(047) into the cover
forcieren. (041).
Montage der Verteileraus- Valving assembly type sin-

führung 1C (konstanter gle displacement motor.
Hubvolumen).
• Keine besondere Montagerich- • No particular assembly sense.
tung.
041
047 2031
Montage der Verteilerausfüh- Valving assembly type Dual

rung 2C (umschaltbarer displacement motor.
Hubvolumen).
• Den gewählten Buchstaben, der • Write the chosen letter indicate

die Drehrichtung anzeigt, gegen- the rotation sense in front of the
über dem Steuerkolben (053) an- displacement change spool (053).
ordnen.
POSITIONIERUNG DES VERTEI- VALVING POSITIONING

LERS
G/L Links G/L Left
041
R 047
L
053
6758
R A
053
3 2 2 7
30 REPAR MS2-18 D/GB 800378128J
882 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
D/R Rechts D/R Right
047
R L 041
6757
R A
053
3 2 2 8
• Falls kein Buchstabe vorhanden • If there is no letter, do the in-

ist, die Ausrichtung anhand der beim dexing according to the marks
Ausbau festgelegten Markierungen made during disassembly.
vornehmen.

« Auswechseln des kompletten Zy- chapter "replacement of the cylin-
linderblocks (010)» unter ders block" section "reassembly"
« Wiedereinbau » beschriebenen Ar- page 28.
beiten ausführen, Seite 28.
Motoren SE02 und S05 Situation of SE02 and S05 mo-

tors
SE02 Motor :
SE02 motor : G/L Links D/R Rechts
G/L Left D/R Right
6 9 5 9
6959
S05 Motor :
S05 motor
G/L Links D/R Rechts
G/L Left D/R Right
053
6 9 4 8
6948
800378128J REPAR MS2-18 D/GB 31
008 910 92 BOMAG 883

20.6 Wheel drive
POCLAIN HYDRAULICS
Auswechseln der Deckel- Replacement of the O-ring

dichtung (045) (045) of the end cover
•
• Motor auf Lagerteil stellen • Place the motor on the bearing
(Muttern sind zum Schutz der Ge- support (fitted with nuts for studs
windebolzen aufgesetzt) protection)
• Schrauben (066) herausneh- • Remove the screws (066)
066
men.
6543
• Verschlussplatte abnehmen. • Remove the end cover
6544
• O-Ring (045) entfernen. • Discard the O-ring (045)

045
057
6545
• Wenn Motor mit 2 Hubvolu- • Discard the O-ring (057) if the

men, O-Ring (057) entfernen motor has 2-displacement
6546
32 REPAR MS2-18 D/GB 800378128J
884 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
• Neuen O-Ring (045) einsetzen. Install a new O-ring (045).
6547
• Wenn Motor mit 2 Hubvolu- • Install a new O-ring (057) if the

men, neuen O-Ring (057) einset- motor has 2-displacement. If not go
zen, andernfalls zum nächsten to the next section
Schritt übergehen
6548
• Verschlussplatte montieren. • Install the end cover
6544
• Schrauben (066) einsetzen und • Install and tighten the screws

mit entsprechendem Drehmoment (066) to the right torque (see table
anziehen (siehe Schaubild Seite 38) page 38)
6543
800378128J REPAR MS2-18 D/GB 33
008 910 92 BOMAG 885

20.6 Wheel drive
POCLAIN HYDRAULICS
Auswechseln des Dreh- Replacing the sensor (op-

zahlsensors (Option) tional)
• Stecker (161.3) abziehen • Disconnect the connector

(161.3)
6550
• Schraube (165) aufschrauben • Unscrew and remove the screw

und ausbauen (165) 165
6551
• Sensor (161) mit dem Träger • Extract the sensor (161) with its
166
(166) abziehen support (166)
161
6552
34 REPAR MS2-18 D/GB 800378128J
886 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Der Dichtung (164) auf Make sure that the seal

Sauberkeit der Auflage- mounting surface (164)
! fläche dem Verteiler- ! on the valving cover
(041) is clean.
deckel (041) prüfen.
• Neuen Haltering (163) und • Install the new brake washer

neue Dichtung (164) auf den Sen- (163) and the new seal (164) on the
sor (161) mit seiner Distanzscheibe sensor (161) fitted with its adjusting
(167) schieben. sticker (167).
• Den Sensor in die Halterung • Push the sensor assembly into
(166) stecken, so daß die Dichtung the support (166) until the seal
(164) korrekt in ihrer Aufnahme (164) is in its housing.
sitzt.
6552
• Sensor (041) in die Bohrung • Push the sensor into the valving
des Verteilerdeckels bis zum Kon- cover (041) until it comes in contact
takt mit dem Zylinderblock (011) with the cylinders block (011),
schieben.
2064
Die Kerbe im Steckeranschluss des the notch of the sensor should be

Sensors muss radial zur Mitte des oriented towards the center of the
Motors (Richtung Welle) zeigen. motor. 1 5 ° m a x i
1 5 ° m a x i
6558
• Schrauben (165) einsetzen und • Install and tighten the screw

mit entsprechendem Drehmoment (165) to the right torque (see table
anziehen (siehe Schaubild Seite page 38)
38)
6551
• Stecker (161.3) wieder an- • Reconnect the connector

schließen. (161.3).
6550
800378128J REPAR MS2-18 D/GB 35
008 910 92 BOMAG 887

20.6 Wheel drive
POCLAIN HYDRAULICS
Werkzeug-Liste Tooling inventory
Standard Werkzeug Standard tools

Hollow head
• Innensechskant-Schlüssel 5 6 8 10 12 14
wrench
• Ring-/Maulschlüssel für
Hex head wrench 13 17 19 22 24
Sechskantschraube
• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 bis 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 bis 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 bis 800 N.m [120 à 600 lbf.ft]
Auto-top 2000 Anti-oxidizing Leuchtend grüne Farbe / fluores-
• Korrosionsschutzfett
origine AGIP grease cent green color
Internal snap ring

• Zange für Innenringe FACOM 499.32
pliers
• Abzieher FACOM U 20 B Extractor
6553
• Sechskantschlüssel für
Hex head wrench 13 17 19 22 24
Innensechskantschraube
• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]
36 REPAR MS2-18 D/GB 800378128J
888 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Spezialwerkzeuge Special tools
Ø A
Ø B
• Montagewerkzeug
zum Anheben der • Mandrel for reassembling the
Schutzkappe oder zum brake cover or to compress the
F
E
G
Komprimieren der Tel- spring washer.
lerfeder.
Ø C
Ø D
0759
ØA ØB ØC ØD E F G
mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch]
F02
110 [4.3] 100 [4.0] 125 [4.9] 135 [5.3]
F03
F04 M12 50 [1.96] 10 [0.39] 20 [0.78]
F05 125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25]
F07
F08
125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25] 50 [1.96] 10 [0.39] 20 [0.78]
F09
F11
50 [1.96] 20 [0.78]
F12 M16
F18 190 [7.48] 180 [7.08] 205 [8.07] 215 [8.46] 10 [0.39]
F19 70 [2.75] 30 [1.18]
F21
• Rohr zum Festsetzen

[0 .9 8 " d ia ]
Tube to immobi-
Ø 2 5
Ø 1 6
des Motors lize the motor [0 .6 2 " d ia ]
5 5
[2 .1 6 " ]
7 0 0
[2 7 .5 5 " ]
M 1 2 x 1 2 0 M 1 6 x 1 2 0
c l. 1 0 .9
H M 1 2 H M 1 6
Z 1 2 N
A = 2 0 0 A = 2 8 0 A
• Werkzeuge zur me- Tools for me-
F 0 2 F 1 1
chanischen Bremslö- chanical brake F 0 3 F 1 2
sung. release F 0 4 F 1 8
F 0 5 F 1 9 Ø 1 6 .5
F 0 7 F 2 1 [0 .6 4 ]
F 0 8
F 0 9
6 0 x 3 0 5 0 x 5
800378128J REPAR MS2-18 D/GB 37
008 910 92 BOMAG 889

20.6 Wheel drive
POCLAIN HYDRAULICS
Anziehdrehmomente Tightening torques
Nm ± 10% in [lbf.ft] ± 10%
(Gemäß Norm DIN 912) (According to the standard DIN 912)
Größe Size 8.8 10.9 12.9 8.8 10.9 12.9

M6 10 14 17 7.5 10 12.5
M8 25 35 41 18.4 26 30
M10 49 69 83 36 51 61
M12 86 120 145 63.4 88.4 107
M14 135 190 230 100 140 170
M16 210 295 355 155 218 262
M18 290 405 485 214 299 358
M20 410 580 690 302 428 509
38 REPAR MS2-18 D/GB 800378128J
890 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Ersatzteile Spare parts list

Nummer Bezeichnung Item Description
010 Kompletter Zylinderblock 010 Cylinders-block assembly
012 Kompletter Kolben Cl. 0 012 Piston Cl 0 assembly
013 Kompletter Kolben Cl. 1 013 Piston Cl 1 assembly
015 Reparatursatz 015 Repair kit
026 Kompletter Nockenring 026 Cam assembly

027 O-Ring 027 O-ring
040 Komplettes Verteilerdeckel 040 Valving cover assembly

041 Verteilerdeckel 041 Valving cover part
042 Schraube 042 Screw
043 Dichtungsring 043 Seal washer
047 Verteiler 047 Valving
048 Dichtungssatz 048 Seal kit
050 Stopfen 050 Plug
052 Feder 052 Spring
053 Umschaltkolben 053 Valve spool
054 Scheibe 054 Washer
055 Sicherungsring 055 Snap ring
056 Feder 056 Spring
059 Stift 059 Pin
065 Kompletter Verschlussplatte 065 End cover assembly

067 Dichtring 067 Sealing ring
070 Komplettes Lagerteil 070 Bearing support assembly

071 Lagerteil 071 Bearing support part
072 Innerer Lippendichtring 072 Radial lip seal
073 Rollenlager 073 Roller bearing
074 Rollenlager 074 Roller bearing
075 Scheibensatz 075 Set of shims
076 Stützring 076 Thrust ring
078 Äußerer Dichtring 078 Lip seal
079 Abweiser 079 Deflector
081 Dichtungsträger 081 Seal support
087 Passfeder 087 Key
090 Welle 090 Shaft
091 Radbolzensatz 091 Set of studs
096 Bremstrommel 096 Drum brake
098 Bremsseil 098 Brake cable
154 Komplette Bremsbacke 154 Brake shoe sub-assembly
155 Kompletter Radzylinder 155 Brake cylinder sub-assembly
156 Gegenhalter 156 Brake adjustment
800378128J REPAR MS2-18 D/GB 39
008 910 92 BOMAG 891

20.6 Wheel drive
POCLAIN HYDRAULICS
Nummer Bezeichnung Item Description
100 Komplette Bremse 100 Brake assembly
101 Bremsgehäuse 101 Brake body
107 Kolben 107 Brake piston
108 Tellerfeder 108 Spring washer
110 Welle 110 Brake shaft
111 Dichtsatz Bremswelle 111 Seal
113 Dichtungsring 113 Seal washer
135 Satz Bremslamellen 135 Brake kit
141 Schutzkappe 141 Cover
142 Stopfen 142 Plug
150 Drehzahlsensor-Vorbereitung 150 Speed sensor predisposition

160 Kompletter Sensor 160 Speed sensor assembly

161 Sensor 161 Speed sensor part
162 Mutter 162 Nut
164 Dichtung 164 Seal
Als Satz lieferbare Baugruppe Sub-assembly sold assembled
40 REPAR MS2-18 D/GB 800378128J
892 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 41
008 910 92 BOMAG 893

20.6 Wheel drive
POCLAIN HYDRAULICS
Motoren mit konstantem Hubvolumen MS, MSE 02-05-08-11-18.

Single displacement motors MS, MSE 02-05-08-11-18.
0987
42 REPAR MS2-18 D/GB 800378128J
894 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Dichtungssatz
Seal kit 0988
800378128J REPAR MS2-18 D/GB 43
008 910 92 BOMAG 895

20.6 Wheel drive
POCLAIN HYDRAULICS
Motoren mit umschaltbarem Hubvolumen MS, MSE 02-05-08-11-18.

Dual displacement motors MS, MSE 02-05-08-11-18.
0990
44 REPAR MS2-18 D/GB 800378128J
896 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
Dichtungssatz
Seal kit
0989
800378128J REPAR MS2-18 D/GB 45
008 910 92 BOMAG 897

20.6 Wheel drive
POCLAIN HYDRAULICS
46 REPAR MS2-18 D/GB 800378128J
898 BOMAG 008 910 92

Wheel drive 20.6
POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 47
008 910 92 BOMAG 899

20.6 Wheel drive
China España & Portugal

POCLAIN HYDRAULICS BEIJING rep. office POCLAIN HYDRAULICS SPAIN S.L.
Unit A0808, Hui Bin Officies Gran Via Carlos III no84 – 1o 3a
No.8 Beichendong St. 08028 BARCELONA
BEIJING 100101 ESPAÑA
CHINA Tel.: 349 3 409 54 54
Tel.: 86 10 6499 3988 Fax: 349 3 490 21 79
Fax: 86 10 6499 3979 e-mail: info-espana@poclain-hydraulics.com
e-mail: info-china@poclain-hydraulics.com
France
POCLAIN HYDRAULICS SRO POCLAIN HYDRAULICS France SAS

Kšírova 186 B.P. 106
61900 BRNO 60411 VERBERIE CEDEX
FRANCE
Tel.: 420 5 43217830 Tel.: 33 3 44 40 77 77
Fax: 420 5 43217818 Fax: 33 3 44 40 77 91
e-mail: info-ceskarepublika@poclain-hydraulics.com e-mail: info-france@poclain-hydraulics.com
Deutschland Japan
POCLAIN HYDRAULICS GMBH POCLAIN HYDRAULICS KK
Bergstrasse 106 5-4-6 Kugenumashinme
64319 PFUNGSTADT FUJISAWA 251
DEUTSCHLAND JAPAN
Tel.: 49 6157 9474 0 Tel: 81 466 50 4400
Fax: 49 6157 9474 74 Fax: 81 466 50 4422
e-mail: info-deutschland@poclain-hydraulics.com e-mail: info-japan@poclain-hydraulics.com
Italia United Kingdom

POCLAIN HYDRAULICS SRL POCLAIN HYDRAULICS LTD
Via Svizzera 4/A Nene Valley Business Park
41012 CARPI (MODENA) Oundle
ITALIA PETERBOROUGH, Cambs PE8 4HN
ENGLAND
Tel.: 390 59 64 22 44 Tel.: 44 1832 273773
Fax: 390 59 64 20 44 Fax: 44 1832 274990
e-mail: info-italia@poclain-hydraulics.com e-mail: info-uk@poclain-hydraulics.com
Nederland USA
POCLAIN HYDRAULICS BENELUX BV POCLAIN HYDRAULICS INC.
Penningweg 32C 7900 Durand Avenue
4879 AM ETTEN-LEUR P.O. BOX 801
NEDERLAND STURTEVANT, WI 53177
USA
Tel.: 31 76 5021152 Tel.: 1 262 554 6739
Fax: 31 76 5012279 Fax: 1 262 554 4860
e-mail: info-netherlands@poclain-hydraulics.com e-mail: info-america@poclain-hydraulics.com
POCLAIN HYDRAULICS INDUSTRIE S.A.S. au capital de 85 124 000 Francs

B.P. 106 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
e-mail: info@poclain-hydraulics.com
www.poclain-hydraulics.com
900 BOMAG 008 910 92

21 Circuit diagrams
008 910 92 BOMAG 901

902 BOMAG 008 910 92
21.1 Hydraulic diagram 920 100 51
008 910 92 BOMAG 903

S/N Hydraulic diagram 920 100 51
S/N 101 920 001 001 ⇔ 101 920 001 086 BW 141 AD-4
S/N 101 920 011 001 ⇔ 101 920 011 086 BW 151 AD-4
904 BOMAG 008 910 92

Hydraulic diagram 920 100 51 21.1
008 910 92 BOMAG 905

906 BOMAG 008 910 92

008 910 92 BOMAG 907

S/N 101 920 001 087 ⇔ 101 920 001 ... BW 141 AD-4
S/N 101 920 011 087 ⇔ 101 920 011 ... BW 151 AD-4
908 BOMAG 008 910 92

008 910 92 BOMAG 909

910 BOMAG 008 910 92

008 910 92 BOMAG 911

S/N 101 920 101 001 ⇔ 101 920 101 ... BW 151 AC-4
912 BOMAG 008 910 92

008 910 92 BOMAG 913

914 BOMAG 008 910 92

21.4 Wiring diagram 920 100 04
008 910 92 BOMAG 915

S/N Wiring diagram 920 100 04
S/N 101 920 001 001 ⇔ 101 920 001 047 BW 141 AD-4
S/N 101 920 201 001 ⇔ 101 920 201 003 BW 141 AD-4 AM
S/N 101 920 101 001 ⇔ 101 920 101 026 BW 151 AC-4
S/N 101 920 411 001 ⇔ 101 920 411 007 BW 151 AC-4 AM
S/N 101 920 011 001 ⇔ 101 920 011 029 BW 151 AD-4
S/N 101 920 211 001 ⇔ 101 920 211 004 BW 151 AD-4 AM
S/N 101 920 311 001 ⇔ 101 920 311 007 BW 154 AD-4
S/N 101 920 511 001 ⇔ 101 920 511 021 BW 154 AD-4 AM
S/N 101 920 111 001 ⇔ 101 920 111 007 BW 161 AC-4
S/N 101 920 021 069 ⇔ 101 920 021 184 BW 161 AD-4
S/N 101 920 041 007 ⇔ 101 920 041 016 BW 161 ADH-4
S/N 101 920 061 001 ⇔ 101 920 061 015 BW 190 AD-4
S/N 101 920 261 001 ⇔ 101 920 261 013 BW 190 AD-4 AM
S/N 101 920 031 003 ⇔ 101 920 031 047 BW 202 AD-4
S/N 101 920 051 001 ⇔ 101 920 051 005 BW 203 AD-4
S/N 101 920 251 001 ⇔ 101 920 251 004 BW 203 AD-4 AM
916 BOMAG 008 910 92

Inhaltsverzeichnis: BW 141−4 ....... BW 203−4
008 910 92
table of contents: BW 141−4 ....... BW 203−4
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 920 100 04 Stromlaufplan Circuit Diagram
002 920 100 04 Versorgung, Starten, Steckdose supply, starting unit, socket
003 920 100 04 Bremse, Sitzkontakt, Not−Aus brake, seat contact, emergency off
004 920 100 04 Überwachung, Warnsummer monitoring unit, warning buzzer
005 920 100 04 Berieselung, Kantenschneidgerät sprinkler system, edge cutter
Wiring diagram 920 100 04
006 920 100 04 Drehzahlverstellung Motor, Signalhorn motor speed, warning horn
007 920 100 04 Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) illumination, working light (StVZO)
008 920 100 04 Vibration,Fahrstufenumsch.,Rückfahrwarns., Splittstreuer vibration, warning buzzer, chip spreader, speed selection
009 920 100 04 Asphalt Manager, Evib−Meter, Temperatur Asphalt asphalt manager, Evib−meter, temperature asphalt
010 920 100 04 Drucker, BCM 05, GPS printer, BCM 05, GPS
011 920 100 04 Tachograph tachograph
012 920 100 04 Geschwindigkeitsanzeige speedometer
013 920 100 04 Heizung, Klimaanlage heating, air conditioning
014 920 100 04 Kabine cab
015 920 100 04 Kabine cab
016 920 100 04 Arbeitsscheinwerfer ROPS worklamp RORS
BOMAG
017 920 100 04 Hundegang crab walk
019 920 100 04 Elektrokasten cross−bonding box

101 920 100 04 Bauteilliste component listing
01.10.2004
001 001
Kneip Stromlaufplan 920 100 04
01.10.2004
21.4
917
circuit diagram 001
Nallin
918
X2:3−1
X2:1−1 X2:1−2
X2:2−1
21.4
F01
X2:5−1 F105
6:1 Sicherung F05
X2:6−1 F37 fuse
5:2 X2:2−2 Sicherung
fuse
X2:4−1 F93
9:2
X2:7−1 30
7:6 30 X2:3−2
30 X13:A K11
P0123
P01 2:19
S00
X89:B
X89:A
87 87a
X91:A Zündstartschalter
K30 10:1 ignition switch 15 54 58 19 17
50a
2 X1:10
X13:B X13:C
15 3:1 K11 6:1
X2:9−1
2 F00 Sicherung F119
fuse
Sicherung Battrie
fuse, battery X2:9−2 F119 F119
1 F119 2:13 2:12 6:1
X2:23−1
V01 X1:104
option 1 Meldeleuchte Ladekontrolle
BW161−4 ...202−4 F15 X2:23−2 indicator light, charge control
Sicherung X6:+ 2:14 30 X6:+
fuse 86 1 K05 2:11 X6:+ 4:7
125A H08 3:8
2 K62 R09 H52
X1:27 X6:14 87 87a
BOMAG
30 (5) 85 2 A13 6:2
K08 2
2:14 X1:101 X6:6
P00
87 (6) W D+ X14:A X14:B X1:206
B+ G02 Betriebsstundenzähler X1:29
2:6 operating hour meter
Generator
+ Batterie generator X6:−
3:13 X1:135 X1:103
battery
G01 B+ B− B+ 2
− 2:3
X51:C
50(5) 15(7) S(2)
K11
86 +
Batterietrennschalter 30 50 XS
S30 3 Y01 Y01 Y139 L(1)
switch battery disconnect 2 1 A13 12V
1 85 −
4 X91:B 1 M01 T(4) R(6) 2 31(3)
K31 10:17 B53
R19 − 1 (R)_t K08
1 M− 3:3
BW161−4 ...203−4 Starter BW161...203−4 BW141...154−4 BW161...203−4 X1:127 X1:53
starter 31 3:1
Heizflansch 4:2 Startmehrmenge Magnetventil Minusabgleich 2:5 Kontrollampe Glühüberwachung 2:14 Steckdose
heating−flange start boost fuel solenoid valve boost−fuel indicator light, glow plug
socket
Temperatursensor
temperature switch
Steuergerät Heizflansch
controll unit, heating−flange
01.10.2004
1 1
008 910 92
Kneip Versorgung, Starten, Steckdose 920 100 04

01.10.2004
Nallin supply, starting unit, socket 002
2:12 15 15 4:1
X2:11−1 X2:10−1 F25

Sicherung
Sicherung F14 fuse Sitzkontaktschalter
fuse
X2:10−2 switch, seat contact
X2:11−2
008 910 92
X1:66 F25 5:1
X23:A 1
X11:A
Initiator Bremse
proximity switch, brake A03.3
S06 8:5
B63 BR/BN 2 4
86 X23:C X23:B
X1:6 MD+ 4:1
X1:67
K22 X6:12
BL/BU SW/BK
85
X11:C X11:B
+
H20
X1:65 X6:− − X6:−
3:15 4:15
Meldeleuchte Sitzkontakt
1(15/54)
8 11 indicator light drivers seat 12 14
K22 30
7
A68 H14
3:10 15 8:3
Modul Sitzkontakt
87 87a
modul seat contact (A8) 1
V48
2
6 4 13
5
X1:8 X1:202
9 (GND)
X1:123 B20 4:10

A15
X6:9
21
X1:43
3:3
9:13
BOMAG
S01 Not−Aus−Schalter 11 21 31 X7:9
switch, emergency off S01
3:11
Not−Aus−Schalter
22 X1:205
switch, emergency off 12 22 32
X1:195
X31:1
X1:47 +
X1:136 Warnsummer H82
X1:198 warning buzzer
X6:11 −
86 1
2 V03 Y13 1 K05 Y04 1 + H01
Y04 X31:2
V02
30/40Amp
2 −
BW 141..154−4
V41 1 2
(1) 2 85
M− 2:11 X6:− X6:− 3:15
2:18 M− 4:9
BW 141..154−4 BW 161..203−4
X1:137 X1:63 X1:127 X1:118 X1:53
31 X1:137
2:20 31 4:1
Hubmagnet 2:12 3:3 Bremsventil Meldeleuchte Bremskontrolle Überwachungsmodul
shut off solenoid, engine solenoid valve, brake indicator light, brake monitoring module
01.10.2004
1 1 920 100 04
Kneip Bremse, Sitzkontakt, Not−Aus
21.4
01.10.2004
919
Nallin brake, seat contact, emergency off 003
920
3:20 15
X2:13−1
F129
X2:12−1 F04
21.4
Sicherung Sicherung Geber Wasserstand

fuse
fuse sender, water level
X2:12−2 X2:13−2
F04
9:6
Meldeleuchte Wasserrestmenge X1:57
X1:71
indicator light, water res.
X26:1
B55
Meldeleuchte 4:8 1 br
Meldeleuchte Wegfahrsperre Hydrauliköltemperatur
R14 p
indicator light,anti−theft device indicator light, hydr.oil temp. X6:20 X7:20
Meldeleuchte Motoröl
indicator light, engine oil pressure X7:+ X7:+ X7:+ 2 gn
4:17 4:15 6:8
Meldeleuchte Motorüberhitzung
H80 H79 H21 idicator ligh, engine overheating H38
X26:2
Meldeleuchte Luftfilter
indicator light, air cleaner X1:72
X7:17 X7:15 X7:7 Differenzdruck Hy.
idicator ligh, hydr.oil filter X1:44
X1:203 2:17 X6:+
X1:54 X1:19
H73 H09 H49 H15 H23 X7:2
4:8
Q
R20
P19
B55
X6:5 X6:16 X6:17 X6:15 X6:13
X1:17 X1:20 X1:21 X1:22 X1:23
Wasservorrat
R21
R22
1 H70 water gauge

Tankanzeige
V42 level gauge
(A2)
2
B20 Q P01
3:17
BOMAG
X1:97
X7:− 8:14
X1:196 X6:3
X1:197 X6:4
30 X6:2 X7:6
30 B21 1
K62 K104 X1:24 X1:34
5:10
2:7 X6:− X6:− 4:16 X6:− X6:− 7:6
X1:93 X1:91 X1:92 X1:94 X1:95 X1:96 3:16 4:19
87 87a p 2 X1:125 X1:185
87 87a
X10:2 X10:1
X1:128
X27:1
X1:199
X1:200
1 B33 B55 1 B06 1 B30 B03 1 1 B21 1
gn/gr
R03
br/br
P _t p
2 2 2 2
B124
2 p 2
X7:10 X6:10
MD+ X27:2 M− X6:10
3:20 MD+ 5:1 3:5 M− 6:11
ws/wh
X10:3 8:8
X1:127 X1:127 X1:53
3:20 31 31 5:1
Meldeleuchte Wasser im Diesel
indicator light, water in fuel
Wasserabscheider Meldeleuchte reserve Kraftstoff
Kühlmittelvorrat Motor sensor, water seperator fuel indicator light, fuel oil
indicator light, eng. coolant res.
Geber Kraftstofftank
sender, level gauge
option
01.10.2004
1 1
008 910 92
Kneip Überwachung, Warnsummer 920 100 04

01.10.2004
Nallin monitoring unit, warning buzzer 004
3:20 F25 F25 17:1
4:3 MD+ MD+ 9:1
F37 X2:18−1
2:5 Sicherung
fuse F06
008 910 92
Sicherung
X2:7−1 fuse X2:18−2
F06
F61 F37 17:1
X1:46 4 A03 Modul Vibration
fuse
modul vibration
X1:124
X2:7−2 X2:6−2
Sicherung
Schalter Berieselungspumpe 43 23 33 7
switch, water pump 13
102 X1:69 X9R:3 X9R:5
S114 0
X18:2
8,5VOLT 8:1
44 24 34 14 S82 3 3
X18:1
GND 8:3 S83
+
Intervallschalter X18:3 4 4
30 30 interval switch
X1:12
30 30
X1:14
K79 K80 Emulsionsberieselung A01 1−12 X9R:4 X9R:6
emulsion sprinkler K82 K83
5:12 5:11 5:18 5:19
X1:139 X1:140
87a 87 87 87a 87 87a 87 87a
23 13
1 0 2
S19 10
Taster Kantenschneitgerät auf
push button, edge cutter, up
Taster Kantenschneitgerät ab
push button, edge cutter,down
S108
24 14
5:8
X1:119 X1:120
13 5:8 X1:109 X1:111
15/54 A04
BOMAG
Modul Berieselung
S108
30 modul, sprinkler system
X1:145 X1:146 X1:50
87 X1:51
X17:1 X16:1 X1:173
13
+ + S108 86 86
X15:1 14 1 Y20 1
M02 M18 + X1:52 K82 K83
86 86 86
X1:117 2 Y21 2
− − M03 V14 V15 85 85
K104 K80 K79
X17:2 X16:2 − 1 Y99
85 85 85
nur AC−Version
only AC−version
X15:2
2
X1:147 X1:174 X1:118 X1:53 V29 X1:110 X1:112
X1:127 X1:127
4:20 31 31 6:1
Berieselungspumpe Emulsionspumpe 4:5 5:2 5:1 Magnetventil Kantenschneidgerät ab 5:15 5:16

sprinkler pump emulsion pump solenoid valve, edge cutter, down
Magnetventil Berieselung
solenoid valve,sprinkler system Magnetventil Kantenschneidgerät auf
solenoid valve, edge cutter, upwards
ZA Kantenschneidgerät
option edge cutter
01.10.2004
1 1 920 100 04
Kneip Berieselung, Kantenschneidgerät
21.4
01.10.2004
921
Nallin sprinkler system, edge cutter 005
922
K11 K11 7:1
2:19
21.4
2:5 F105
X2:14−1
2:19 F119 F119 14:14

F105 Sicherung Sicherung
fuse F23
fuse
X2:5−2
X2:14−2
F23
10:2
K35 30 K114 30
6:12 6:5
87a 87
87a 87
X1:42 X1:30
86 86 X1:138
K139 K35 2
3
L0R 33 11 23 85 85
S120 0 S03
Meldeleuchte Motordrehzahl Taster Signalhorn
incicator light, motor speed 4
switch warning horn
BOMAG
34 12 24
Schalter Motordrehzahl 4:19 X7:+ X7:+ 8:7
switch motor speed X1:102
X1:105
X1:106
+ H60
X1:60
2:14 A13 −
X7:5
X1:134
X1:16 X1:28
2
87 87a
AUX
86 + AW +
(A7) 2 HW
K114 V47 K139 Y120 B11
85 1 6:11 − −
30 Signalhorn
warning horn
4:15 M− M− 7:8
X1:127 X1:137
5:20 31 31 7:1
6:12 6:9 6:5
Motordrehzahl
motor speed
01.10.2004
1 1
008 910 92
Kneip Drehzahlverstellung Motor, Signalhorn 920 100 04

01.10.2004
Nallin motor speed, warning horn 006
6:20 K11 K11 8:1
Meldeleuchte Warnblinker
X2:16−1 Meldeleuchte Blinker H05 Überwachungsmodul
F08 indicatot light, indicators indicator light,hazard light monitoring module
Sicherung Brücke entfäfft X1:39
fuse H06 V07 V06 bei Anbau ZA
X2:16−2 4:20 X6:−
StVZO Beleuchtung 11 23
008 910 92
X7:1 Schalter Beleuchtung
X1:38 X6:7
H06 X6:18 X6:19 not. incl. if switch head lights
StVZO Illumination 012
2:5 30 is assembled A15 X6:1 S15
7:20 31 31 8:1
13 F07 X7:8
Sicherung 12 24
15A Schalter Blinker
fuse switch indicator option
S26 S14 S14
X2:7−2 7:11 7:9
14 Warnblinkschalter X6:8 StVZO Beleuchtung
Schalter Arbeitsbeleuchtung X1:37 S37 S37 StVZO illumination
hazard light 7:12 7:10
X1:41
X1:40
switch, working head lights X1:55 L0R 13 23

0 1 23 11 53 33 43
X1:129 S14 S37 X2:19−1 X2:20−1 X2:21−1 X2:22−1
24 12 54 34 44 14 24 F09 Sicherung Sicherung F10 Sicherung F12 Sicherung

fuse fuse fuse fuse

F11
X2:19−2 X2:20−2 X2:21−2 X2:22−2
F09 14:9
Schalter Steckdose X1:26 X1:25 F10 9:2
switch socket X1:132 X1:58 X1:59 X1:133 X1:107 X1:108

X1:100 X1:73 X1:99 X1:74
1
X5:LA X4:3 X5:R3 X4:1 X4:4 X5:LB X5:R4 X4:2 X5:R1
S117
+ + + + 56b 56b
2 X4:4
X4:3 X4:1
E08 E10 E12 E14 E16 E17
X4:2
X57:2 X57:1 X25:3 X57:4 X57:7 X57:5
entfällt bei
X57:8 X25:4 − 31 31
ZA Splittstreuer
only acc. to option
deliting chip spreader
X58:2 − X58:1 + − + X58:4 X58:7 + − + X58:5
E09 E11 E13 E15
− − −
−
BOMAG
X25:5
X1:35
X1:36
E02 E73 E04 X25:6
+ + + + + + +
X94:1 X5:R2
E11
E10
E13
E15
E12
E14
E09
E09 E11 E13 E15
X25:1
56b − − − − 7:10 7:11 7:12 − − 7:14 7:15 7:16 7:17 −
56b
56b E27 E28 56b E18 E19 49 49a
7:10 7:11 7:12 7:14 7:15 7:16 7:17
31 31 A02
X58:3
31 31
E11
E10
E13
E15
E12
E14
E09
rechts X57:3
right 31
links/left
links X5L:C X5L:C
rechts/right
left Bel. Temp. Asphalt 7:13 7:10
X25:2 illum. temp. asphalt
X5:LC X5:R5
X58:3 7:13 X94:2 Bel. Evib−Meter
illum. Evib−meter M− M− X4:5 X58:3
X1:148 6:20 7:18 7:2 7:11 M− M− 8:9
31 X1:53 X1:110 X1:127
6:20 31 7:9
Arbeitsscheinwerfer Blinkrelais Blinkleuchte VL Blinkleuchte VR Parkleuchte links Parkleuchte rechts Scheinwerfer links
Arbeitsscheinwerfer parking light lh. parking light rh.
working head light indicator relay indicator front,lh. indicator front,rh. head light LH
working head lights
Bel. Geschwindigkeitsanz. Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts Scheinwerfer rechts
ZA illum. speedometer indicator rear,lh indicator rear,rh. tail light,lh tail light,rh head light RH
Splittstreuer
option
Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts
chip spreader indicator rear,lh indicator rear,rh. tail light,lh tail light,rh
01.10.2004
1 1 920 100 04
Kneip Blinkbegrenzung, Arbeitsbeleuchtung (StVZO)
21.4
01.10.2004
923
Nallin illumination, working light (StVZO) 007
924
7:20 K11 K11 9:1
Meldeleuchte 2. Gang
Aufnehmer Fahrhebel F03 X2:15−1 indicator light, 2nd speed range
transducer travel lever Sicherung
Vibrationsschalter man./autom. Fahrstufenschalter
21.4
fuse X2:15−2 switch, vibration, man./autom. speed range selector Schalter vorne hinten Schalter Splittstreuer Schalter Splittmenge
5:13 8,5VOLT 8,5VOLT 12:1 switch front/rear switch, gravel scratter switch quantity,chip
X1:31 8:11 X1:31
8:9
B39 3 X1:31 X7:+ BW161...BW203−4 13 23 13
6:10
X93:2 13 23 + H13
M0A VBH S73
S36
2 −
S08 X7:14 14 13 23
1 L0R
24 13 X7:18
X93:1 X93:3 2 1 14 24 + H33 0
14 24 S74
S02
5:12 GND −
23 14
X1:143 X1:70 X1:144 X1:48 X1:49 4:19 X6:10 X1:7 X1:9 4:20 X7:− X7:− 9:14 X1:11 14 24
X1:1
9 (8,5V)
1 (15/54)
11 (GND) 8
1 (15/54)
14 16 12 14 11 15 X1:13 X1:15
Y31
A71
A03
Modul Vibration 8:10 Modul Vibrationsverriegelung
modul vibration, interlock
modul vibration A71
8:15
15
10 (GND)
13 6 3 5 12 13 5 4 7 8 6
A03 A03.3 A03.3 X1:2
9 (GND)
8:9 3:20 9:1 A03
10 (GND)
R 8:2
9:2
K G 11 23 8:9 A71
1 Schalter Vibration klein/groß
S35 switch, vibration low/high
V46 V45
3:20 H14 (A6) (A5) 12 24
1 2
X1:3 X1:5 V44 (4)
BOMAG
X1:64
1 2
BW161...BW203−4 8:10
A73
X1:126
Y31
9:2
X9L:2
X9R:2
Y57 X1:75 X1:186
X3:1 11:1 X1:83 X1:81
Asphalt
S12 3 S13 3 Manager X77:1 X1:89
+ V2 11:1 X1:87
X28:1 X29:1 X1:118 X1:171
H14
− V08
4 4 X1:77 X1:79 Y30 Y31 V12 V11 V18
1 1
X8:1 X9:1 1 1 Y54 1 1 1 V19 V21 1
1
X3:2
Y56 Y57 2 2 Y131
X9L:1
X9R:1
2 2 2 2 2 Y55 2 2 2 2
V49 V43 X28:2 X29:2
(4) Y66 Y67
1 X8:2 1 X9:2 X77:2
X1:118 X1:63 X1:127 X1:78 7:20 M− M−13:6
X1:84 X1:82 X1:172 X1:88 X1:90
X1:137 X1:80
7:10 31 31 9:1
Taster Vibration vorn hinten Vibration vorne an Magnetventil Hydromotor

Magnetventil kleine Amplitute front rear
switch vibration vibration, front on solenoid valve, hydraulic motor
vibration low Fahrstufenumschaltug
speed range selection Magnetventil Verstellzylinder
Vibration hinten an
Warnsummer Rückfahrwarneinrichtung Magnetventil große Amplitute vibration, rear on solenoid valve, ajustable zylinder
warning buzzer back up alarm vibration high
Vibrationsabschaltung ZA
nur AD−Version option
switch over vibration, only AD−version
01.10.2004
1 1
008 910 92
Kneip Vibration, Fahrstufenumschaltung, Rückfahrwarnsummer, Splittstreuer 920 100 04

01.10.2004
Nallin vibration, warning buzzer, chip spreader, speed selection 008
8:5 R
8:6 A03.3
2:5 F93 F93

Sicherung
008 910 92
A73
8:13 fuse
5:17 MD+
X20:9 X2:4−2
X2:53 X2:54 X20:25
X2:27−2
F10 RXD
7:17 V27 31 10:2
K11 X2:17−1 X1:59 X2:24−1 X2:25−1 X2:26−1 X20:23
8:20 CAN3+ 10:2 S01 TXD 10:2
V22 3:11 V25 V26
F101 CAN3− 10:2
Sicherung 32
X2:27−1
X20:13 R31 X20:14 B15.2 11:1
X2:17−2 fuse X20:43 X20:44 1 2 X2:24−2 X2:55 X2:25−2 X2:26−2
5
X2:52 F101 9:12 1 R32 2 X20:10 X2:57
X88:54
X88:36
X88:14
X88:4
X88:5
X88:35
X88:15
X88:41
X88:53
X88:33
X88:37
X88:56
X88:57
X88:59
X88:60
X88:32
X88:38
X88:58
CAN3+
CAN3−
X88:28
Messtechnik Rechner
A83
measurement calc. unit
X88:27 X88:26
X88:1
X88:3
X88:6
X88:9
X88:7
X88:31
X88:30
X88:65
X88:66
X88:67
X88:55
X88:23
X88:29
X88:68
X88:47
X88:46
R21 F04 F101

1 2 4:20 F04 12:1 9:4 F101 10:1
R20 X2:56
AGND
1 2 X20:20 X20:38 X20:35
+ X1:45
BOMAG
X20:1 X20:2 X20:36 X7:11
B106 −
X20:29
X20:30
X20:27
X20:31
X76:D X76:F _t
X20:34
X20:33
X1:121 X1:151 X20:11 X20:15
X76:A X20:3
X76:B X20:7
X20:17
X20:18
H04
1
CAN+
CAN−
CAN−
CAN+
+ 8:15 X7:− X7:− 13:5
P34 + R30
X80:1
X79:1
X79:4
X79:3
X80:3
+
X80:4
X78:1
X78:2
15
P28 B85 B84 X107:1 X108:1
P33 _t 2
30
weiß/white
CAN2+ P16 − − G Y140 1 Y141 1
rot/reed
F1 F2
X20:5 X76:G CAN2− X20:39 B97
X80:2 X79:2 2 2
X20:6 X76:H − schw/black
GND − − X78:3 X107:2 X108:2
X1:152
X76:C X76:E option X20:19 X20:24 X20:28 X20:32
AGND
X20:4 X20:8 X1:122 X20:40 X20:37 10:2 X2:51 X20:12 X20:16
8:20 31 31 10:1
_J
Display option Evib−Meter Temperatursensor Aufnehmer Verstellmotor Aufnehmer Beschleunigung links Prop−Ventil Erreger auf
Evib−meter
display temperature switch transducer, motor trancducer, acceleration,left solenoid valve exciter up
Diagnose Temperaturanzeige Aufnehmer Beschleunigung rechts Prop−Ventil Erreger ab
diagnostics
temperature gauge, coolant trancducer, acceleration, right solenoid valve exciter down
Meldeleuchte Betriebsstörung
indicator light, breakdown
01.10.2004
1 1 920 100 04
Kneip Asphalt Manager, Evib−Meter, Temperatur Asphalt
21.4
01.10.2004
925
Nallin asphalt manager, Evib−meter, temperature asphalt 009
926
2:6 K30 K30 14:1
F101
21.4
9:15
9:9 CAN3−
9:9 CAN3+
9:19 RXD
TXD
9:19
X103:F X103:E
X100:F X100:E Schalter GPS

option TM2
Switch, GPS
1
CAN3+ CAN3− S166
X101:2 X101:1 X74:7 X74:2 X75:1
5
ST2:4
ST2:3
GPS Antenne
ST1:3 A77 A76 GPS antenna
X103:K
6:19 F23 Spannungsregler Druckerkontroller
X105:1−32
ST1:4 Voltage regulator printer controller
X20:22 X100:K X101:4 1
F150 A93
32 A87 Sicherung
2
BOMAG
USB−CAN Schnittst. fuse
USB−CAN Interface BCM
X106:1−20
20
ST2:5
ST2:6
ST1:1
ST1:2
ST2:1
ST2:2
X101:3 P11
X101:5 X102:1 X102:2 Drucker
3 printer A92
P15 5
S153
4
GPS Receiver
X75:2 GPS receiver
BCM 05 A94
X100:L X100:I BCM05 BCM 05
Papiervorschub
X103:L X103:I paper formfeed
2:4 K31 K31 11:1
X20:26
GPS
9:15 AGND
GPS Antenne
GPS antenna
31 31 12:1
9:20
ZA
option
01.10.2004
1 1
008 910 92
Kneip Drucker, BCM 05, GPS 920 100 04

01.10.2004
Nallin printer, BCM 05, GPS 010
9:20 B15.2 B15.2 12:1
BW161 AD−4 11:7 X67:B X67:B 15:5

BW141 AD−4
V2 BW161 ADH−4 BW141 AD−4 AM
008 910 92
8:7 V2 11:10 BW190 AD−4 11:6 V2 BW151 AD−4
Y57 BW202 AD−4 BW151 AD−4 AM
8:7 Y57 11:10 BW203 AD−4 11:6 Y57 BW151 AC−4
X1:188 X1:187 X1:189 BW161 AD−4 AM X1:188 X1:187 X1:189
BW190 AD−4 AM
X68:B X68:A X68:C BW202 AD−4 AM X68:B X68:A X68:C
BW203 AD−4 AM
2 3 BW144 AD−4 2 3
BW154 AD−4 1 11:7 X67:A X67:A 15:5
4 BW144 AD−4 AM A51
A51 BW154 AD−4 AM
5 1 5 4
Tachomodul Tachomodul
module, tachograph module, tachograph
5 4 4:1 1:3 2:1 1:2
A16 A16
2 1 6 3 7.8.9
1:1
5:5
5:4
5:3
5:2
5:1
3:4
3:3
3:2
3:1
6:1
B3
B4
11:4 11:4 X67:B 11:10
11:4 11:4 X67:A 11:17
B3
B4
BOMAG
B4 B3 A2 A3 A1
A3 B1
A2 B2
P09
P09 C3 A1 B3
A5 B4
Anzeige
indicator
A6 C3
A5 A6 1
G02 15:9 Anzeige R33
indicator
10:20 K31 2 K31 13:1
Platine Frequenzanzeige Platine Frequenzanzeige

circuit board, fequency indicator circuit board,frequenzy meter
1.10.2004
1 1 920 100 04
Kneip Tachograph
21.4
1.10.2004
927
Nallin tachograph 011
928
F04 F04
9:8 17:1
21.4
Lernmodus
to learn
Anzeigetest
diagnose
Lern Test
15/54
15/54
11:20 B15.2 IN A05
8:3 8,5VOLT OUT+ 1

OUT−
X2:58 X1:32 + X1:33
FM1
Multifuse P04
−
X2:59
X2:59 ZA
option
X1:194 X1:193 X1:192 X1:194 Geschwindigkeitsanzeige
speedometer
X24:4 X24:3 X24:1 X24:4
BOMAG
BW161 AD−4 BW141 AD−4 BW141 AD−4 AM BW151 AC−4
BW161 ADH−4 BW151 AD−4 BW144 AD−4 AM BW161 AC−4 X32:1 X32:2
X30:1
X30:3
X30:2
BW190 AD−4 BW151 AD−4 AM
BW203 AD−4 BW144 AD−4
BW161 AD−4 AM BW154 AD−4
BR/BN
SW/BK
SW/BK
BR/BN
WS/white
SW/BK
BR/BN
BW190 AD−4 AM
BW202 AD−4 AM
BW203 AD−4 AM
B15 B15 B15 B15
X30:4 X32:3
BL/BU
Sauer Schönbuch Bosch Rexroth Poclain
BL/BU
BL/BU
X24:2
X1:191
10:20 31 31 13:12
Aufnehmer Geschwindigkeit
transducer speed
01.10.2004
1 1
008 910 92
Kneip Geschwindigkeitsanzeige 920 100 04

01.10.2004
Nallin speedometer 012
F31 14:1
D
F31 F40
Box 1 G 14:2
4 F42 H F F15 14:1
008 910 92
B Box 1
F40 F15
0123 S44 Schalter Kabinenlüfter 7 F42 15:5
BOX 1 BOX 1
switch, cabin ventilator Schalter Kabinenheizung
8 switch, cab heating 6
3
L M H C
4 2 A72:2 5
14:15
low
mid
high
A72
Steuergerät S28
control unit 1
6 11 12 6 2 1 3
ZA
X65:3
X65:2
30 option
X65:4
K85 X63:7 X63:4 X63:6 X53:6

14:18
X52:1 15 1 4 7 6
87 87a 1
Diagnose
B103 X49:1 diagnostics
Thermofühler Klimaanlage _t
temperature sensor 2 1
X52:2
_t B131
X40:1
X50:1 P18
X40:3
X40:2
2
Thermofühler Heizung E30
X43:1 temperature sensor, heating Heizung
4 X49:2 heater timer
B104 P
Überwachung Kühlmitteldruck LP HP
3
monitoring coolant pressure
BOMAG
X43:3 X43:4 5 8 10
X53:3
X53:5
X1:207
X1:18 X43:2
X45:3
X42:3
X45:2
X42:2
X45:4
X42:4
ge rt or ge rt or X56:1 X54:1
X55:1
X21:1 Y15 1 E30 13:18 13:14 E30
M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
17:5 8:11 M− Magnetventil Heizung 12:20 31 31 17:1
solenoid valve, heating unit
X56:2
X40:4 X55:2
11:20 K31 K31 14:1
Kabinenlüfter
cab ventilator Kraftstoffpumpe
fuel pump heating unit
Klimakompressor
air conditioning compr.
ZA ZA
option option
01.10.2004
1 1 920 100 04
Kneip Heizung, Klimaanlage
21.4
01.10.2004
929
Nallin heating, air conditioning 013
930
K30 X91:A
10:20 K30 16:1
F40 7:16 F09 X51:B F09

13:19 16:7
21.4
X65:1 30 X51:A
6:10 F119
K32
14:17 X63:8
A72:2
87 13:11
13:19 F31 F31 15:1

13:19 F15 F15 15:1
E
F110
Box 1
F113 F114 S147 13 X63:5
5 20A
30 30 14 S26 13
K 127 K 128 F115 F116
20A 20A
14:12 14:13
87 87a 87 87a 14 1
X66:1 K 129 30 K 130 30 S53
14:14 14:16
87 87a 87 87a
30 5
K118
14:20
X73:B
87 87a
X72:B
X64:2
A88 A89
X75:B
X74:B
BOMAG
A90 A91
X73:A
X72:A
86 86
K 127 K 128
+ +
X69:1
X70:1
X71:1
X39:1
X75:A
X74:A
E23 E25
E23 + + E25 − − 85 85
86 86
+ + K 129 K 130 86 K32 86 K85 86 K118
+ +
− −
E28 E27 E28 E27
− − 85
− − 85 85 85 85
X69:2
X70:2
X71:2
X39:2
13:19 K31 K31 15:1
Arbeitsscheinwerfer vorne Arbeitsscheinwerfer vorne
working lights, front working lights, front
Arbeitsscheinwerfer hinten Arbeitsscheinwerfer hinten 14:7 14:9 14:10 14:11 14:4 13:2 14:4
working lights, rear working lights, rear
Xenon Schalter Arbeitsscheinwerfer

Schalter Arbeitsscheinwerfer
switch, worklamp switch, worklamp
01.10.2004
1 1
008 910 92
Kneip Kabine 920 100 04

01.10.2004
Nallin cab 014
14:12 F31
Wischer vorne Wischer hinten
windscreen wiper, front windscreen wiper, rear
14:12 F15
A B C
008 910 92
13:11 F42 F27 F28
F41
Box 1 X67:A X67:A Box 1 Box 1
11:20 X67:A
1 option Tachograph 2 3
X67:B
11:14 X67:B
S20 S21
0 1 2 7 2 0 1 2 7 2
01 S163 5
01
30
K141 1
5 4 5 4
X67:B 15:19
87 87a
X67:B X67:A
1 +
X63:1
X62:1
X63:2
X62:2
S45
X64:5
X64:3
X64:6
X64:8
S38 A12 Radio
radio
1
5 15 30 E71 1
X64:4 S158 + R80
B51 31 B51 2
2
X48:1 option X61:C X61:A
X64:7
max. 13A
BOMAG
+
E32 X67:C
X46:31b
X46:53
X44:31b
X44:53
X46:53a
X44:53a
E70 I 15
K141
− − G02 31
11:13
X67:C X46 +
53
53a
31b
53
53a
31b
3 min
+
XS option X44
+ X67:C
53a
Tachograph
Abfallverzögert
12V
E29 M04 M06 M05 M07
53a
31b 53
31
− 2,5A
− 31 − 31 −
31b 53
31
X61:2 X61:2
15:16 15:14
X48:2 X64:1 X44:31 X46:31 X61:B
14:20 K31 K31 16:1

Kennleuchte Steckdose Nachtbeleuchtung
rotary beacon socket night lamp Wascher vorn Heizung Heckscheibe
washer motor,front heating rear screen
Kabinenleuchte Wischermotor vorn Wischermotor hinten 15:18
cabin inside light wiper motor front wiper motor rear
Wascher hinten
washer motor,rear Kontrolleuchte
indicator
01.10.2004
1 1 920 100 04
Kneip Kabine
21.4
01.10.2004
931
Nallin cab 015
932
14:20 K30
21.4
switch, worklamp
14:20 F09
13 A
13 S53
S147 F108
1
14
14
A B 30
13 K135
F113 F114 S26
16:14
1 2,5qmm 2 87 87a
30 C D 14
K127 30
K128
16:7 F115 F116
16:9
87 87a 87 87a 3 4
K129 30 30
K130
16:10 16:11
87 87a
87 87a
2,5qmm
BOMAG
86
+ + K127 86 K128 + +
E23 E25 E23 E25
− − − −
85 85 86 86 86
K135
+ + K129 K130 + +
E28 E27 E28 E27
− − 85 85 85 − −
15:20 K31

working head lights, front
Arbeitsscheinwerfer hinten
working head lights, rear
16:3 16:4 16:5 16:7 16:16 Arbeitsscheinwerfer hinten Arbeitsscheinwerfer hinten

working head lights, rear working head lights, rear
XENON ZA zur Zeit in Entwicklung

option is in development at the moment
01.10.2004
1 1
008 910 92
Kneip Arbeitsscheinwerfer ROPS 920 100 04

01.10.2004
Nallin worklamp RORS 016
5:20 F25
5:17 F06
F04
12:20
008 910 92
Taster Hundegang
push button, crab walk
X1:131 X9L:3 X9L:5
S115 3 3
S116
X12:A
4
4
K138 30 K03 30
BR/BN
B10 17:16 17:18
87 87a 87 87a
BL/BU
SW/BK
X12:B X12:C X9L:4 X9L:6
X1:113 X1:115 X1:141 X1:142

X1:130
BOMAG
X1:56
X7:13
86 86
+ 1 Y19 Y18 1 K138 K03
H02
2 2
−
V16 V17 85 85
13:5 X7:−
X1:127 X1:114 X1:116 X1:127
13:15 31 31 18:1
Meldeleuchte Hundegang Magnetventil Hundegang 17:11 17:13

indicator light, grab walk solenoid valve, crab walk
Näherungsinitiator Knickgelenk
proximity switch, articulated joint
ZA
option
01.10.2004
1 1 920 100 04
Kneip Hundegang
21.4
01.10.2004
933
Nallin crab walk 017
934
A05 P16
21.4
X7:1−20
9 8 7 6 5 4 3 2 1
201918 1716151413 121110
X6:1−20
A15
Zentralstecker Sammelanzeige (Ansicht von hinten)
mainplug monitoring module (view from backside)
A83
Messtechnik Rechner
BOMAG
8 16 26 40
5 6 7 13 14 15 22 23 24 25 31 32 33 34 38 39
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 9 10 11 12 17 18 19 20 21 27 28 29 30 35 36 37
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
X20
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
X88:1−68
blau blau
(Buchse) blue blue
blau
blue
blau
blue
Asphalt Manager X20:1−40

asphalt manager
01.10.2004
1 1
008 910 92
Kneip Elektrokasten 920 100 04

cross−bonding box 019
AC−Maschine
V48
V47
2 2
008 910 92
V46
V45
2 2
V44 A04 A71 A03 A68
2
V43
1 1 1 1 1 1
2
3 4 5 6 7 8
V42 K11 K05 K114 K03 K22 K35 K62 K79 K80 K82 K83 K138 K139 K104
1
2
2
V41
1
2
1
ZA
option
X2:1−26 asphalt
manager
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
V22
V01
V25
V26
V27
51 52 53 54 55 56 57 5859 X2
X13:A−C
60 61
X14:A−B
X89:A−B
BOMAG
R09
F07
F61
F11
F01
F10
F12
F14
F05
F93
F37
F03
F06
F09
F25
F23
F08
F04
F119
F101
F105
F129
ZA
option
A02
X1:1−208
76
V49
78 80 82 84 86 88 90 110 112 114 116 118 127 137 147 148 168 174 191 X1
75 77 79 81 82 83 100 101 102 103 104 105 106 107 108 109 111 113 115 117 119 120 121 122 123 124 125 126 128 129 130 131 132 133 134 135 136 138 139 140 141 142 143 144 145 146 151 152 165 166 167 173 185186 192 193194 198 199 200 204 205 206 208
85 87 89 91 92 93 94 95 96 97 98 99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 149 150 161 162 163 164 171 172 183 183 187 188 189 190 195 196 197 201 202 203 207
blau blau blau blau blau

blue blue blue blue blue
blau
blue
blue
blau
blau
blue
blau
blau
blau
blue
blue
blau
blue
blue
blau
blue
01.10.2004
1 1 920 100 04
Kneip Elektrokasten
21.4
935
Name Bl. Pf. Benennung title TYP
21.4 A01
A02
A02
005
007
020
11
8
1
Intervallschalter
Blinkrelais
Blinkrelais
intervall switch
indicator relay
indicator relay
Wiring diagram4/6X21
920 100 04
WATT
A03 005 10 Modul Vibration modul, vibration

A04 005 5 Modul Berieselung modul, sprinkler system
A05 012 16 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer
A12 015 9 Radio Radio
A13 002 13 Steuergeraet Heizung Control unit, heating
A15 003 20 Ueberwachungsmodul monitoring module
Kneip
30.11. 4

A16 011 5 Elektronik Tachograph Electronic system, tachograph
A51 011 2 Platine Frequenzanzeige Circuit board,frequenzy meter
A66 018 9 Elektronik Steuereinheit Electronic control unit
A67 018 15 Eingabeeinheit Keyboard
A68 003 13 Modul Sitzkontakt Modul seat contact
A71 008 12 Modul Vibrationsverriegelung Modul vibration,interlock
A72 013 7 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A76 010 10 Druckerkontroller Printer controller
A77 010 7 Spannungsregler Voltage regulator
A83 009 7 Elektronik Messtechnik electronic measurement−equipment TYP 18633
A83 019 16 Elektronik Messtechnik electronic measurement−equipment
A87 010 14 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
A88 014 8 Vorschaltgerät, Xenon Licht ballast system, Xenon−light
A92 010 18 GPS Receiver GPS receiver
A93 010 19 GPS Antenne GPS antenna
B03 004 13 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B06 004 10 Druckschalter Motoroel Pressure switch, engine oil
component listing
B10 017 6 Naeherungsinitiator Knickgelenk Proximity switch, articulated joint MAX 0,3A
B11 006 18 Signalhorn Warning horn
Bauteilliste
B15 012 6 Aufnehmer Geschwindigkeit Transducer, speed

B20 004 6 Temperaturschalter Hydraulikoel Temperature switch, hydraulic oil 97−92_GC
B21 004 13 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B30 004 11 Temperaturschalter Motoroel Temperature switch, engine oil 110_GC
B33 004 4 Sensor Wassertankrestmenge Sensor, water tank residual quantity
B39 008 3 Aufnehmer Fahrhebel Transducer, travel lever 4−20 mA
B51 015 9 Lautsprecher Radio Speaker radio
B53 002 12 Temperaturgeber Kuehlmittel Temperature switch, collant (R)_t
B55 004 7 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B63 003 8 Naeherungsinitiator Bremse Proximity switch, brake Max. 300mA
B84 009 13 Aufnehmer Beschleunigung, links Trancducer, acceleration, left
B85 009 12 Aufnehmer Beschleunigung, rechts Trancducer, acceleration, right
B97 009 10 Aufnehmer Verstellmotor Sensor, ajustable motor
B103 013 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning 4_GC
B104 013 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B106 009 7 Temperatursensor Asphalt Transducer, temperature asphalt
B124 004 15 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 013 9 Temperaturschalter Heizung Temperature switch, heating 110_GC
E02 007 5 Beleuchtung Temperaturanzeige Illumination, temperature gauge

E04 007 7 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E08 007 9 Blinkleuchte vorne links Indicator, front, lh. 21W
E09 007 9 Blinkleuchte hinten links Indicator, rear, lh. 21W
E10 007 11 Blinkleuchte vorne rechts Indicator, front, rh. 21W
E11 007 12 Blinkleuchte hinten rechts Indicator, rear, rh. 21W
E12 007 15 Parkleuchte links Parking light, lh. 5W
E13 007 13 Schlussleuchte links Tail light, lh. 5W
E14 007 16 Parkleuchte rechts Parking light, rh. 5W
E15 007 17 Schlussleuchte rechts Tail light, rh. 5W
1

E16 007 19 Scheinwerfer links Head light, lh. 55 WATT
E17 007 20 Scheinwerfer rechts Head light, rh. 55 WATT
E18 007 4 Arbeitsscheinwerfer links Working head light, lh. 55W
E19 007 5 Arbeitsscheinwerfer rechts Working head light, rh. 55 WATT
11
E23 014 2 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E23 014 7 Arbeitsscheinwerfer vorne links Working head light, front, lh. 3,5A
E23 016 17 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55 WATT
920 100 04
E25 014 3 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E25 014 9 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 3,5A
E25 016 18 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55 WATT
E27 007 1 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55 WATT
101
E27 014 4 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E27 014 11 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 3,5A
936 E27 016 6 Arbeitsscheinwerfer hinten links BOMAG
Working head light, rear, lh. 3,5A 008 910 92
E27
E28
016
E28 007
014
19
2
2
Arbeitsscheinwerfer hinten links
Arbeitsscheinwerfer hinten rechts
Working head light, rear, lh.
Working head light, rear, rh.
55 WATT
55 WATT
55W
21.4
E28 014 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 3,5A
E28 016 16 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55 WATT
E29 015 7 Innenleuchte Kabine Inside light, cabin 21W
E30 013 13 Heizgeraet Heating unit
E32 015 3 Kennleuchte Warning light 55W
E70 015 6 Nachtleuchte Night lamp 5W
E71 015 18 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E73 007 6 Beleuchtung, Evib−Meter Illumination, Evib−meter
F00 002 1 Hauptsicherung Batterie Fuse, main, battery 125A

Kneip
30.11. 4
F01 002 11 Hauptsicherung Fuse, main 30A

F03 008 4 Sicherung Vibration Fuse, vibration 10A
F04 004 16 Sicherung Instrumente Fuse, gauges 5A
F05 002 20 Sicherung Steckdose Fuse, socket 15A
F06 005 7 Sicherung Berieselung Fuse, sprinkler system 10A
F07 007 8 Sicherung Warnblinker Fuse, hazard light 15A
F08 007 4 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 007 14 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 007 17 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 007 19 Sicherung Scheinwerfer links Fuse, head light, lh. 10A
F12 007 20 Sicherung Scheinwerfer rechts Fuse, head light, rh. 10A
F14 003 3 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 10A
F15 002 5 Sicherung Heizgeraet Fuse, heating unit 125A
F23 006 18 Sicherung Signalhorn Fuse, warning horn 10A
F25 003 11 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 5A
F27 015 13 Sicherung Wischer u. Wascher vorne Fuse, windscr. wiper and washer, fr. 15A
F28 015 15 Sicherung Wischer u. Wascher hinten Fuse, windscr. wiper and washer, re. 25A
F31 013 1 Sicherung Kabinenluefter Fuse, cabin ventilator 25A
F37 005 2 Sicherung Berieselungspumpe Fuse, sprinkler pump 25A
F40 013 14 Sicherung Kabinenheizung Fuse, heating unit cab 20A
F41 015 3 Sicherung Rundumkennleuchte Fuse, rotary beacon 15A
F42 013 9 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
F93 009 14 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 10A
FM1 012 5 Platinensicherung Multifuse 0,2A
F101 009 2 Sicherung Variomatic (Potential 15) fuse, variomatic (pot. 15) 10A
F105 006 12 Sicherung Motordrehzahl Fuse, motor speed 20A
component listing
F108 016 16 Sicherung Scheinwerfer mitte Fuse, head lights middle 25A
F110 014 4 Sicherung Scheinwerfer aussen Fuse, head lights outside 25A
Bauteilliste
F113 014 7 Sicherung Xenon Arbeitsscheinwerfer 1 Fuse, xenon worklamp 1 20A

F119 002 11 Sicherung Motor Fuse, motor 7,5A
F129 004 2 Sicherung, MD+ Fuse, MD+ 15A
F150 010 18 Sicherung GPS Receiver Fuse, GPS receiver 5 AMP
G01 002 1 Batterie Battery 102AH

G02 002 7 Generator Generator 90A
H01 003 14 Meldeleuchte Bremse Indicator light, brake

H02 017 6 Meldeleuchte Hundegang Indicator light, crab walk
H04 009 14 Meldeleuchte Betriebsstoerung Indicator light, breakdown
H05 007 8 Meldeleuchte Blinker Indicator light, indicators
H06 007 8 Meldeleuchte Warnblinker Indicator light, hazard light
H08 002 10 Meldeleuchte Ladekontrolle Indicator light, charge control
H09 004 10 Meldeleuchte Oeldruck Motor Indicator light, engine oil pressure
H13 008 8 Meldeleuchte 2.Gang Indicator light, 2nd speed range
H14 008 4 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer 0,7A
H15 004 13 Meldeleuchte Motorluftfilter Indicator light, engine air filter
H20 003 15 Meldeleuchte Sitzkontaktschalter Indicator light, drivers seat contact
H21 004 6 Meldeleuchte Oeltemperatur Indicator light, oil temperature
H23 004 14 Meldeleuchte Hydraulikoelfilter Indicator light, hydr.oil filter
H33 008 14 Meldeleuchte Splittstreuer Indicator light, gravel scratter
H38 004 17 Meldeleuchte Kraftstoff Indicator light, fuel oil
H49 004 11 Meldeleuchte Motorueberhitzung Indicator light, engine overheating
H52 002 16 Anzeige Gluehueberwachung Glow plug indicator
H58 013 5 Meldeleuchte Klimaanlage Indicator light, air conditioning
H60 006 9 Meldeleuchte Motordrehzahl Indicator light, motor speed
H70 004 16 Anzeige Wasser im Diesel Indicator water in fuel
H73 004 7 Meldeleuchte Kuelmittelvorrat Indicator light, eng. coolant res.
2
H79 004 5 Meldeleuchte Wasserrestmenge Indicator light, Water res.

H80 004 3 Meldeleuchte Wegfahrsperre Indicator light, anti−theft device
H82 003 18 Warnsummer Sitzkontakt Warning buzzer, seat contact
K03 017 18 Relais Hundegang Relay, crab walk BOSCHW

11
K03 020 6 Relais Hundegang Relay, crab walk

K05 003 8 Relais Startstrom Relay, starting current BOSCHW
K05 020 5 Relais Startstrom Relay, starting current
K08 002 14 Relais Heizgeraet Relay, heating unit BOSCHL
920 100 04
K11 002 19 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW

K11 020 4 Relais Klemme 30 auf 15 Relay, terminal 30 to 15
K14 002 17 Relais Vorgluehen Relay, glow plug system
K22 003 10 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K22 020 7 Relais Hubmagnet Motor Relay, shut off solenoid, engine
102
K32 014 17 Relais Kabine Relay, cabin BOSCHL

K35 006 12 Relais Selbsthaltung Relay, holding contact BOSCHW
008 910
K35 92 020 8 Relais Selbsthaltung BOMAG
Relay, holding contact 937
21.4 K62
K62
K79
002
020
005
7
9
12
Relais D+
Relais D+
Relais Berieselungspumpe
Relay, D+
Relay, D+
Relay, sprinkler pump
BOSCHW
BOSCHW
K79 020 10 Relais Berieselungspumpe Relay, sprinkler pump
K80 005 11 Relais Berieselungspumpe Relay, sprinkler pump BOSCHW
K82 005 18 Relais Kantenschneidgeraet ab Relay, edge cutter, up BOSCHW
K82 020 12 Relais Kantenschneidgeraet ab Relay, edge cutter, up
K83 005 19 Relais Kantenschneidgeraet auf Relay, edge cutter, down BOSCHW
K83 020 13 Relais Kantenschneidgeraet auf Relay, edge cutter, down
K85 014 18 Umschaltrelais Relay, switch over BOSCHW
K104 005 10 Relais, Stoermeldungen Relay, failure indication BOSCHW
K104 020 15 Relais, Stoermeldungen Relay, failure indication
K114 006 5 Relais Motordrehzahl Relay, engine rpm BOSCHW
Kneip
30.11. 4
K114 020 6 Relais Motordrehzahl Relay, engine rpm

K118 014 20 Relais Arbeisscheinwerfer Relay, working lights BOSCHW
K127 014 12 Relay, xenon worklamp 1 elay, xenon worklamp 1 BOSCHW
K139 006 11 Relais Kontrolleuchte Motordrehzahl Relay,indicator light, engine rpm BOSCHW
K139 020 14 Relais Kontrolleuchte Motordrehzahl Relay,indicator light, engine rpm
K141 015 19 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
M01 002 7 Starter Starter

M02 005 1 Berieselungspumpe Sprinkler pump 11A
M03 005 5 Emulsionsberieselungspumpe Emulsion sprinkler pump 7A
M04 015 12 Scheibenwischermotor vorne Windscreen wiper motor, front 7,9A
M05 015 15 Scheibenwischermotor hinten Windscreen wiper motor, rear 7,9A
M06 015 13 Scheibenwaschermotor vorne Windscreen washer motor, front 2,5A
M07 015 16 Scheibenwaschermotor hinten Windscreen washer motor, rear 2,5A
M09 013 1 Kabinenluefter Cabin ventilator MAX.11A
M18 005 2 Wasserpumpe Water pump 11A
M22 008 17 Elektromotor Splittstreuer Electric motor, chip spreader 6,5A
component listing
P00 002 10 Betriebsstundenzaehler Operating hour meter

P01 004 16 Tankanzeige Level gauge
Bauteilliste
P04 012 16 Geschwindigkeitsanzeige Speedometer

P09 011 5 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 010 10 Drucker Printer
P15 010 15 BCM 03 Bildschirm BCM 03 terminal
P16 009 4 Diagnose, Variomatic Diagnostics, varimatic
P18 013 18 Diagnose Diagnostics
P19 004 19 Anzeige Wasserstand links Water gauge level, lr.
P28 009 7 Temperaturanzeige Asphalt Temperature gauge, asphalt
P33 009 3 Opus 21 Opus 21
P34 009 6 Evib−Meter Evib−meter
R02 002 17 Gluehkerze Glow plug 50A

R03 004 16 Geber Tankanzeige Sender, level gauge
R09 002 8 Vorwiderstand Dropping resistor 82 OHM
R09 020 1 Vorwiderstand Dropping resistor
R14 004 19 Geber Wasserstand, links Sender, water level, lh. 4−20 mA
R19 002 5 Heizflansch heater flange 2000 WATT
R20 004 16 Widerstand Resistor
R20 009 3 Widerstand Resistor 120 OHM
R33 011 17 Widerstand Resistor 5 KOHM
R80 015 18 Heizung Heckscheibe heating rear screen MAX. 13A
S00 002 11 Startschalter Starter switch

S01 003 11 Schalter NOT AUS Switch, emergency off BOSCHW
S02 008 9 Fahrstufenschalter Switch, speed range selector
S03 006 18 Taster Signalhorn Push button, warning horn
S06 003 14 Sitzkontaktschalter links Switch, seat contact, lh.
S08 008 6 Vibrationsschalter man./autom. Switch, vibration, man./autom.
3
S12 008 2 Vibrationsschalter Fahrhebel links Switch, vibration, travel lever, lh.
S13 008 3 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 007 8 Warnblinkschalter Switch, hazard light
S15 007 18 Beleuchtungsschalter StVZO Switch, lighting StVZO
S19 005 5 Emulsionsberieselungsschalter Switch, emulsion sprinkler system
11
S20 015 12 Schalter Scheibenwischer vorne Switch, windscreen wiper, front

S21 015 15 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S26 007 4 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
920 100 04
S28 013 17 Schalter Kabinenheizung Switch, cabin heating
S30 002 1 Batterietrennschalter Switch, battery disconnect
S35 008 7 Vibrationsschalter klein/gross Switch, vibration low/high
S36 008 12 Vibrationsschalter Switch, vibration
103
S37 007 12 Schalter Blinker Switch, indicator

S38 015 3 Schalter Kennleuchte Switch, warning light
938 S44 013 1 Schalter Kabinenluefter BOMAG
Switch, cabin ventilator 008 910 92
S45
S53
015
S53 014
016
7
20
14
Schalter Kabineninnenleuchte
Schalter Arbeitsbeleuchtung
Schalter Arbeitsbeleuchtung
Switch, cabin inside light
Switch, working lights
Switch, working lights
21.4
S73 008 15 Schalter Splittstreuer Switch, gravel scratter
S74 008 17 Schalter Splittmenge Switch, gravel quantity
S82 005 18 Taster Kantenschneidgeraet abwaerts Push button, edge cutter, down MAX 0,2A
S83 005 19 Taster Kantenschneidgeraet auf Push button, edge cutter, up MAX 0,2A
S108 005 8 Schalter Berieselung Kantenschneidgeraet Switch,sprinkler sys.edge cutter
S114 005 7 Schalter Wasserpumpe Switch, water pump
S115 017 16 Taster, Hundehang links Push button, crab walk, lh.
S116 017 18 Taster, Hundegang rechts Push button, crab walk, rh.
S117 007 3 Schalter Steckdose Switch, socket
S120 006 4 Schalter Motordrehzahl Switch, engine speed
S147 014 13 Schalter Arbeitsbeleuchtung Switch, working lights
Kneip
30.11. 4

S153 010 8 Papiervorschub Paper formfeed
S158 015 6 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 015 19 Schalter Heckscheibenheizung switch rear screen heating unit
S166 010 18 Schalter GPS Switch, GPS
V01 002 7 Diode Diode UF4004

V01 020 12 Diode Diode
V02 003 12 Diode Diode STECKER
V09 013 6 Diode Diode FE5B
component listing

Bauteilliste

V41 003 2 Diode (A1) Diode (A1) MR756
V41 020 1 Diode (A1) Diode (A1)
X1:1 008 9 ELEKTROKASTEN Cross−bonding box

X1:1−208 020 1 ELEKTROKASTEN Cross−bonding box
X1:16 006 5 Elektrokasten Cross−bonding box
4

11

920 100 04

104

008 910
X1:33 92 012 16 ELEKTROKASTEN BOMAG
Cross−bonding box 939
21.4 X1:34
X1:35
X1:36
004
007
007
17
8
8
ELEKTROKASTEN
Elektrokasten
Elektrokasten
Cross−bonding box
Cross−bonding box
Cross−bonding box
Kneip
30.11. 4

component listing

Bauteilliste

5

11

920 100 04

105

940 X1:127 002 19 ELEKTROKASTEN BOMAG
Cross−bonding box 008 910 92
X1:127
X1:127
003
X1:127 004
004
8
4
16
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
21.4
Kneip
30.11. 4

component listing

Bauteilliste

X2:5−2 006 12 Elektrokasten Cross−bonding box
6

11

920 100 04

106

008 910 92
X2:17−2 009 2 ELEKTROKASTEN BOMAG
21.4 X2:18−1
X2:18−2
X2:19−1
005
005
007
7
7
14
ELEKTROKASTEN
ELEKTROKASTEN
Elektrokasten
Cross−bonding box
Cross−bonding box
Cross−bonding box
Kneip
30.11. 4

X3:1 008 4 RÜCKFAHRWARNSUMMER Back−up alarm buzzer
X4:1 007 12 Blende hinten Screen rear
X4:2 007 17 Blende vorne Screen front
X5:LA 007 9 Blende vorne Screen front
X5:LB 007 15 Blende vorne Screen front
component listing
X5:LC 007 9 Blende vorne Screen front

X5:R1 007 20 Blende vorne Screen front
Bauteilliste

X5:R4 007 16 Blende hinten Screen rear
X6:1 007 16 ARMATURENPULT Instrument board
X6:1−20 019 6
X7:1−20 019 6
7

11
X8:1 008 7 VIBRATIONSPUMPE Vibration pump

920 100 04
XS 002 20 Steckdose Socket

X10:1 004 17 KRAFTSTOFFTANK Fuel tank
107
X11:A 003 8 FAHRHEBEL Travel lever

X11:B 003 8 FAHRHEBEL Travel lever
942 X11:C 003 7 FAHRHEBEL BOMAG
Travel lever 008 910 92
X12:A
X12:C
017
X12:B 017
017
6
6
6
KNICKGELENK
KNICKGELENK
KNICKGELENK
Articulated joint
Articulated joint
Articulated joint
21.4
X13:A 002 11 FAHRERSTAND Operators platform
X13:A−C 020 3 ELEKTROKASTEN Cross−bonding box
X13:B 002 11 FAHRERSTAND Operators platform
X13:C 002 12 FAHRERSTAND Operators platform
X14:A−B 020 2 ELEKTROKASTEN Cross−bonding box
X15:1 005 5 EMULSIONSPUMPE Emulsion sprinkler pump
X16:1 005 2 BERIESELUNGSPUMPE Sprinkler pump
Kneip
30.11. 4

X19:1 018 5 KEYBOARD Keyboard
component listing

Bauteilliste

X21:1 013 7 KLIMAKOMPRESSOR Air conditioning compr.
X23:A 003 14 SITZKONSOLE Seating unit
X23:B 003 14 SITZKONSOLE Seating unit
X23:C 003 13 SITZKONSOLE Seating unit
X24:1 012 8 Bandage Roller drum
8

X25:1 007 4 BLENDE HINTEN Screen rear
11

X26:1 004 20 WASSERTANK Water tank
920 100 04

X28:1 008 9 MOTORRAUM Engine room
108

008 910
X30:2 92 012 6 Bandage BOMAG
Roller drum 943
21.4 X30:3
X30:4
X31:1
012
012
003
6
6
18
Bandage
Bandage
LENKSAEULE
Roller drum
Roller drum
Steering column
X31:2 003 18 LENKSAEULE Steering column
X39:1 014 4 Kabine cabin
Kneip
30.11. 4

X43:1 013 7 FAHRERSTAND Operators platform
X44:31b 015 13 Kabine cabin
X44:53a 015 12 Kabine cabin
X51:C 002 3 MOTORRAUM Engine room
component listing

Bauteilliste

X54:1 013 13 Kraftstoffpumpe fuel pump heating unit
X57:1 007 9 Steckdose Splittstreu Socket, chip spreader
X57:8 007 3 STECKDOSE SPLITTSTREU Socket, chip spreader
X58:1 007 9 Stecker Splittstreuer Connector,chip spreader
X60:1 008 17 STECKER SPLITTSTREUER Connector, chip spreader
X61:A 015 16 Kabine cabin
X61:B 015 16 Kabine cabin
X61:C 015 13 Kabine cabin
X63:8 014 17 KABINE Cabin
9

11

920 100 04

109

944 X67:B 015 8 Kabine BOMAG
cabin 008 910 92
X67:B
X67:C
015
X67:C 015
015
9
9
9
Kabine
Kabine
Kabine
cabin
cabin
cabin
21.4
X68:A 011 3 KABINE Cabin
X68:B 011 2 KABINE Cabin
X68:C 011 8 KABINE Cabin
Kneip
30.11. 4

X74:2 010 15 BCM05 BCM05
X74:7 010 14 BCM05 BCM05
X75:1 010 16 BCM05 BCM05
X75:2 010 16 BCM05 BCM05
X76:A 009 1 ARMATURENPULT Instrument board
X76:B 009 2 ARMATURENPULT Instrument board
X76:C 009 3 ARMATURENPULT Instrument board
X76:D 009 3 ARMATURENPULT Instrument board
X76:E 009 3 ARMATURENPULT Instrument board
X76:F 009 4 ARMATURENPULT Instrument board
X76:G 009 2 ARMATURENPULT Instrument board
X76:H 009 2 ARMATURENPULT Instrument board
X78:1 009 9 STÜTZE RECHTS Support rh.
component listing

Bauteilliste
X80:1 009 12 STÜTZE LINKS Support lh.

X88:1 009 11 ELEKTRONIK VARIOMATIC Electronic variomatic
X88:1−68 019 4 ELEKTRONIK VARIOMATIC Electronic variomatic
10

11

X91:A 002 4 MOTORRAUM Engine room
920 100 04

X91:B 002 3 MOTORRAUM Engine room
X93:1 008 3 SITZKONSOLE Seating unit
110

008 910
X9L:1 92 008 2 SITZKONSOLE BOMAG
Seating unit 945
21.4 X9L:2
X9L:3
X9L:4
008
017
017
2
16
16
SITZKONSOLE
SITZKONSOLE
SITZKONSOLE
Seating unit
Seating unit
Seating unit
X9L:5 017 18 SITZKONSOLE Seating unit
X9R:1 008 3 SITZKONSOLE Seating unit
X100:E 010 8 DRUCKER Printer
X100:F 010 7 DRUCKER Printer
X100:I 010 7 DRUCKER Printer
Kneip
30.11. 4
X100:K 010 3 DRUCKER Printer

X100:L 010 6 DRUCKER Printer
X101:1 010 8 DRUCKER Printer
X103:E 010 8 LENKKONSOLE Steering box
X103:F 010 7 LENKKONSOLE Steering box
X103:I 010 7 LENKKONSOLE Steering box
X103:K 010 3 LENKKONSOLE Steering box
X103:L 010 6 LENKKONSOLE Steering box
X105:1−32 010 9 DRUCKER Printer
Y01 002 9 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y04 003 10 Magnetventil Bremse Solenoid valve, brake 2,1A
Y13 003 3 Hubmagnet Motor Shut off solenoid, engine 4A
Y14 013 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit 2A
Y15 013 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y18 017 12 Magnetventil Hundegang Solenoid valve, crab walk 2,5A
component listing

Y20 005 14 Magnetventil Kantenschneidgeraet Solenoid valve, edge cutter 2,5A
Bauteilliste

Y30 008 9 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 1,5A
Y31 008 10 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear 1,5A
Y54 008 12 Magnetventil Vibration hinten ein Solenoid valve, vibration rear on 3A
Y55 008 13 Magnetventil Vibration vorne ein Solenoid valve, vibration front on 3A
Y56 008 7 Vibration klein Vibration low 2,1A
Y57 008 8 Vibration gross Vibration high 2,1A
Y66 008 15 Magnetventil Hydromotor Solenoid valve, hydraulic motor 1,5A
Y67 008 16 Magnetventil Verstellzylinder Solenoid valve, ajustable zylinder 1,5A
Y99 005 8 Magnetventil Berieselung Kantenschneidgeraet So.valve,sprinkler.sys.edge cutter 1,5A
Y120 006 12 Magnetventil Motordrehzahl hoch Solenoid valve, rpm engine high 70A/1A
Y138 013 9 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
Y139 002 11 Magnetventil Minusangleichung solenoid−valve boost−fuel 4,5AMP.
Y140 009 18 Magnetventil Erreger auf solenoid valve exciter up 1,26A
Y141 009 20 Magnetventil Erreger ab solenoid valve exciter down 1,26A
11
11
920 100 04
111
946 BOMAG 008 910 92

008 910 92 BOMAG 947

S/N 101 920 001 048 ⇔ 101 920 001 049 BW 141 AD-4
S/N 101 920 201 004 ⇔ 101 920 201 005 BW 141 AD-4 AM
S/N 101 920 101 027 ⇔ 101 920 101 037 BW 151 AC-4
S/N 101 920 411 008 ⇔ 101 920 411 008 BW 151 AC-4 AM
S/N 101 920 011 030 ⇔ 101 920 011 039 BW 151 AD-4
S/N 101 920 211 005 ⇔ 101 920 211 007 BW 151 AD-4 AM
S/N 101 920 311 008 ⇔ 101 920 311 011 BW 154 AD-4
S/N 101 920 511 022 ⇔ 101 920 511 028 BW 154 AD-4 AM
S/N 101 920 111 008 ⇔ 101 920 111 008 BW 161 AC-4
S/N 101 920 021 185 ⇔ 101 920 021 198 BW 161 AD-4
S/N 101 920 041 017 ⇔ 101 920 041 017 BW 161 ADH-4
S/N 101 920 061 016 ⇔ 101 920 061 017 BW 190 AD-4
S/N 101 920 261 014 ⇔ 101 920 261 015 BW 190 AD-4 AM
S/N 101 920 031 048 ⇔ 101 920 031 055 BW 202 AD-4
S/N 101 920 051 006 ⇔ 101 920 051 008 BW 203 AD-4
S/N 101 920 251 005 ⇔ 101 920 251 007 BW 203 AD-4 AM
948 BOMAG 008 910 92

Inhaltsverzeichnis: BW 141−4 ....... BW 203−4 Familie
008 910 92
table of contents: BW 141−4 ....... BW 203−4 family
008 920 100 05 Vibration,Fahrstufenumsch.,Rückfahrwarns., Splittstreuer vibration, warning buzzer, chip spreader, speed selection
014 920 100 05 Kabine cab
015 920 100 05 Kabine cab
BOMAG

10.02.2005
001 001
Kneip Stromlaufplan 920 100 05
10.02.2005
21.5
949
circuit diagram 001
Nallin
950
X2:3−1
X2:1−1 X2:1−2
X2:2−1
21.5
F01
X2:5−1 F105
6:1 Sicherung F05
X2:6−1 F37 fuse
fuse
X2:4−1 F93
9:2
X2:7−1 30
7:6 30 X2:3−2
30 X13:A K11
P0123
P01 2:19
S00
X89:B
X89:A
87 87a
50a
2 X1:10
X13:B X13:C
15 3:1 K11 6:1
X2:9−1
fuse
Sicherung Battrie
1 F119 2:13 2:12 6:1
X2:23−1
V01 X1:104
BW161−4 ...202−4 F15 X2:23−2 indicator light, charge control
fuse 86 1 K05 2:11 X6:+ 4:5
125A H08 3:8
2 K62 R09 H52
X1:27 X6:14 87 87a
BOMAG
30 (5) 85 2 A13 6:2
K08 2
2:14 X1:101 X6:6
P00
87 (6) W D+ X14:A X14:B X1:206
Generator
3:13 X1:135 X1:103
battery
G01 B+ B− B+ 2
− 2:3
X51:C
50(5) 15(7) S(2)
K11
86 +
Batterietrennschalter 30 50 XS
S30 3 Y01 Y01 Y139 L(1)
switch battery disconnect 2 1 A13 12V
1 85 −
4 X91:B 1 M01 T(4) R(6) 2 31(3)
K31 10:17 B53
R19 − 1 (R)_t K08
1 M− 3:3
BW161−4 ...203−4 Starter BW161...203−4 BW141...154−4 BW161...203−4 X1:127 X1:53
starter 31 3:1
heating−flange start boost fuel solenoid valve boost−fuel indicator light, glow plug
socket
Temperatursensor
temperature switch
Steuergerät Heizflansch
controll unit, heating−flange
10.02.2005
1 1
008 910 92

10.02.2005
2:12 15 15 4:1
X2:11−1 X2:10−1 F25

Sicherung
fuse
X2:11−2
008 910 92
X1:66 F25 5:1
X23:A 1
X11:A
Initiator Bremse
S06 8:5
B63 BR/BN 2 4
86 X23:C X23:B
X1:6 MD+ 4:1
X1:67
K22 X6:12
BL/BU SW/BK
85
X11:C X11:B
+
H20
X1:65 X6:− − X6:−
3:15 4:13
1(15/54)
K22 30
7
A68 H14
3:10 15 8:3
Modul Sitzkontakt
87 87a
modul seat contact (A8) 1
V48
2
6 4 13
5
B63
8:6 X1:8 X1:202
9 (GND)
X1:123 B20 4:8

A15
X6:9
21
X1:43
3:3
9:13
BOMAG
3:11
22 X1:205
X1:195
X31:1
X1:47 +
X6:11 −
86 1
2 V03 Y13 1 K05 Y04 1 + H01
Y04 X31:2
V02
30/40Amp
2 −
BW 141..154−4
V41 1 2
(1) 2 85
M− 2:11 X6:− X6:− 3:15
2:18 M− 4:7
BW 141..154−4 BW 161..203−4
X1:137 X1:63 X1:127 X1:118 X1:53
31 X1:137
2:20 31 4:1
10.02.2005
1 1 920 100 05
Kneip Bremse, Sitzkontakt, Not−Aus
21.5
10.02.2005
951
952
3:20 15
X2:13−1
F129
X2:12−1 F04
21.5

fuse
X2:12−2 X2:13−2
F04
9:6
X1:57
Meldeleuchte Motorüberhitzung indicator light, water res.
idicator ligh, engine overheating X26:1
Meldeleuchte Luftfilter 1 br
indicator light, air cleaner R14 p
X6:20 X7:20
Meldeleuchte Motoröl Differenzdruck Hy.
X6:+ indicator light, engine oil pressure idicator ligh, hydr.oil filter X7:+ 2 gn
2:17 6:8
H73 H09 H49 H15 H23
H79 X26:2
X1:72
X6:5 X6:16 X6:17 X6:15 X6:13
X7:15
X1:44
X7:2
R21
R22
H70
Tankanzeige
R20
level gauge
Q
X6:3
X6:4
P01
X1:17 X1:20 X1:21 X1:22 X1:23 Q X1:54 P19
1 X6:2
V42 Wasservorrat
(A2) water gauge
2
B20
3:17
BOMAG
X1:97
X7:− 17:5
X1:196
X1:197
30 X1:24 X1:34
B21 1 30
K62 K104
5:10
2:7 X6:− X6:−
X1:92 X1:91 X1:94 X1:95 X1:96 3:16 7:6
87 87a p 2 X1:125 X1:185
87 87a
X10:2 X10:1
X1:128
X27:1
X1:199
X1:200
B55 1 B06 B30 B03 B21 1
gn/gr
1 1 1 1 B33
R03
P _t p
2 2 2 2
br/br B124
p 2 2
X6:10 X7:10
X27:2
ws/wh
3:20 MD+ MD+ 5:1 3:5 M− M− 6:11
X10:3
X1:53 X1:127 X1:127 X1:53
3:20 31 31 5:1
Kühlmittelvorrat Motor Meldeleuchte Wasser im Diesel Wasserrestmenge
indicator light, eng. coolant res. indicator light, water in fuel water tank residual quantity
Wasserabscheider Geber Kraftstofftank
option sensor, water seperator fuel sender, level gauge
10.02.2005
1 1
008 910 92

10.02.2005
3:20 F25 F25 17:1
4:3 MD+ MD+ 9:1
F37 X2:18−1
2:5 Sicherung
fuse F06
008 910 92
Sicherung
X2:7−1 fuse X2:18−2
F06
F61 F37 17:1
fuse
modul vibration
X1:124
X2:7−2 X2:6−2
Sicherung
102 X1:69 X9R:3 X9R:5
S114 0
X18:2
8,5VOLT 8:1
44 24 34 14 S82 3 3
X18:1
GND 8:3 S83
+
X1:12
30 30
X1:14
5:12 5:11 5:18 5:19
X1:139 X1:140
87a 87 87 87a 87 87a 87 87a
23 13
1 0 2
S19 10
S108
24 14
5:8
X1:119 X1:120
13 5:8 X1:109 X1:111
15/54 A04
BOMAG
Modul Berieselung
S108
X1:145 X1:146 X1:50
87 X1:51
X17:1 X16:1 X1:173
13
+ + S108 86 86
X15:1 14 1 Y20 1
M02 M18 + X1:52 K82 K83
86 86 86
X1:117 2 Y21 2
− − M03 V14 V15 85 85
K104 K80 K79
X17:2 X16:2 − 1 Y99
85 85 85
nur AC−Version
only AC−version
X15:2
2
X1:147 X1:174 X1:118 X1:53 V29 X1:110 X1:112
X1:127 X1:127
4:20 31 31 6:1

option edge cutter
10.02.2005
1 1 920 100 05
21.5
10.02.2005
953
954
K11 K11 7:1
2:19
21.5
2:5 F105
X2:14−1
2:19 F119 F119 14:14

fuse F23
fuse
X2:5−2
X2:14−2
F23
10:2
K35 30 K114 30
6:12 6:5
87a 87
87a 87
X1:42 X1:30
86 86 X1:138
K139 K35 2
3
L0R 33 11 23 85 85
S120 0 S03
switch warning horn
BOMAG
34 12 24
Schalter Motordrehzahl 4:19 X7:+
X1:105
X1:106
+ H60
X1:60
2:14 A13 −
X7:5
X1:134
X1:16 X1:28
2
87 87a
AUX
86 + AW +
(A7) 2 HW
K114 V47 K139 Y120 B11
85 1 6:11 − −
30 Signalhorn
warning horn
4:13 M− M− 7:8
X1:127 X1:137
5:20 31 31 7:1
6:12 6:9 6:5
Motordrehzahl
motor speed
10.02.2005
1 1
008 910 92

10.02.2005
6:20 K11 K11 8:1
X2:16−1 Meldeleuchte Blinker H05
F08 indicatot light, indicators indicator light,hazard light
Sicherung Brücke entfäfft X1:39
X6:− Überwachungsmodul
X2:16−2 4:14 StVZO Beleuchtung monitoring module 11 23
008 910 92
Schalter Beleuchtung
X1:38 X6:7
2:5 30 is assembled A15 S15
7:20 31 31 8:1
13 F07 X7:8
Sicherung 12 24
S26 S14 S14
X2:7−2 7:11 7:9
X1:41
X1:40

0 1 23 11 53 33 43
X1:129 S14 S37 X2:19−1 X2:20−1 X2:21−1 X2:22−1

fuse fuse fuse fuse

F11
X2:19−2 X2:20−2 X2:21−2 X2:22−2
F09 14:9

X1:100 X1:73 X1:99 X1:74
1
S117
+ + + + 56b 56b
2 X4:4
X4:3 X4:1
E08 E10 E12 E14 E16 E17
X4:2
X57:2 X57:1 X25:3 X57:4 X57:7 X57:5
entfällt bei
X57:8 X25:4 − 31 31
ZA Splittstreuer
only acc. to option
X58:2 − X58:1 + − + X58:4 X58:7 + − + X58:5
E09 E11 E13 E15
− − −
−
BOMAG
X25:5
X1:35
X1:36
E02 E73 E04 X25:6
+ + + + + + +
X94:1 X5:R2
E11
E10
E13
E15
E12
E14
E09
E09 E11 E13 E15
X25:1
56b − − − − 7:10 7:11 7:12 − − 7:14 7:15 7:16 7:17 −
56b
56b E27 E28 56b E18 E19 49 49a
7:10 7:11 7:12 7:14 7:15 7:16 7:17
31 31 A02
X58:3
31 31
E11
E10
E13
E15
E12
E14
E09
rechts X57:3
right 31
links/left
links X5L:C X5L:C
rechts/right
X5:LC X5:R5
X1:148 6:20 7:18 7:2 7:11 M− M− 8:9
31 X1:53 X1:110 X1:127
6:20 31 7:9
Arbeitsscheinwerfer Blinkrelais Blinkleuchte VL Blinkleuchte VR Parkleuchte links Parkleuchte rechts Scheinwerfer links
Arbeitsscheinwerfer parking light lh. parking light rh.
working head light indicator relay indicator front,lh. indicator front,rh. head light LH
working head lights
Bel. Geschwindigkeitsanz. Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts Scheinwerfer rechts
ZA illum. speedometer indicator rear,lh indicator rear,rh. tail light,lh tail light,rh head light RH
Splittstreuer
option
10.02.2005
1 1 920 100 05
21.5
10.02.2005
955
956
7:20 K11 K11 9:1
Aufnehmer Fahrhebel F03 X2:15−1

21.5
X1:31 8:11 X1:31
8:9
B39 3 X1:31 BW161...BW203−4 13 23
X93:2
23 23 VBH
S36
2
S08 S36 13 13 23
1 L0R
X93:1 X93:3 3:9 B63 14 24 S73 0
24 24 S74
5:12 GND 14
X1:143 X1:70 X1:144 X1:49 X1:1 X1:7 X1:9 X1:11 14 24
1 (15/54)
9 (8,5V) 11 (GND) 8
1 (15/54)
14 16 12 14 11 15 X1:13 X1:15
Y31
A71
A03
modul vibration A71
8:15
15
10 (GND)
13 6 3 5 12 13 5 4 7 8 6
A03 A03.3 A03.3 X1:2
9 (GND)
8:9 3:20 9:1 A03
10 (GND)
R 8:2
9:2
K G 11 23 8:9 A71
V46 V45
3:20 H14 (A6) (A5) 12 24
1 2
X1:3 X1:5 V44 (4)
BOMAG
X1:64
1 2
BW161AD...BW203AD−4 8:10
A73
X1:126
Y31
9:2
X9L:2
X9R:2
Y57 X1:75 X1:186
X3:1 11:1 X1:83 X1:81
Asphalt
S12 3 S13 3 Manager X77:1 X90:1 X1:89
+ V2 11:1 X1:87
X28:1 X29:1 X1:118 X1:171
H14
− V08
4 4 X1:77 X1:79 Y30 Y31 V12 V11 V18
1 1
X8:1 X9:1 1 1 Y54 1 1 1 V19 V21 1
1
X3:2
Y56 Y57 2 2 Y131
X9L:1
X9R:1
2 2 2 2 2 Y55 2 2 2 2
V43 X28:2 X29:2
V49 (4) Y66 Y67
X8:2 1 X9:2 X77:2 X90:2
1
X1:118 X1:63 X1:127 7:20 M− M−13:6 X1:84 X1:82 X1:172 X1:88 X1:90
X1:78 X1:137 X1:80
7:10 31 31 9:1

Vibration hinten an
10.02.2005
1 1
008 910 92

10.02.2005
8:5 R
8:6 A03.3
2:5 F93 F93

Sicherung
008 910 92
A73
8:13 fuse
5:17 MD+
X20:9 X2:4−2
X2:53 X2:54 X20:25
X2:27−2
F10 RXD
7:17 V27 31 10:2
K11 X2:17−1 X1:59 X2:24−1 X2:25−1 X2:26−1 X20:23
8:20 CAN3+ 10:2 S01 TXD 10:2
V22 3:11 V25 V26
F101 CAN3− 10:2
Sicherung 32
X2:27−1
X20:13 R31 X20:14 B15.2 11:1
X2:17−2 fuse X20:43 X20:44 1 2 X2:24−2 X2:55 X2:25−2 X2:26−2
5
X2:52 F101 9:12 1 R32 2 X20:10 X2:57
X88:54
X88:36
X88:14
X88:4
X88:5
X88:35
X88:15
X88:41
X88:53
X88:33
X88:37
X88:56
X88:57
X88:59
X88:60
X88:32
X88:38
X88:58
CAN3+
CAN3−
X88:28
Messtechnik Rechner
A83
X88:27 X88:26
X88:1
X88:3
X88:6
X88:9
X88:7
X88:31
X88:30
X88:65
X88:66
X88:67
X88:55
X88:23
X88:29
X88:68
X88:47
X88:46
R21 F04 F101

1 2 4:20 F04 12:1 9:4 F101 10:1
R20
AGND
1 2 X20:20 X20:38 X20:35
+
BOMAG
X20:1 X20:2 X20:36
B106 −
X20:29
X20:30
X20:27
X20:31
X76:D X76:F _t
X20:34
X20:33
X1:121 X1:151 X20:11 X20:15
X76:A X20:3
X76:B X20:7
X20:17
X20:18
1
CAN+
CAN−
CAN−
CAN+
+
P34 + R30
X80:1
X79:1
X79:4
X79:3
X80:3
+
X80:4
X78:1
X78:2
15
P28 B85 B84 X107:1 X108:1
P33 _t 2
30
weiß/white
CAN2+ P16 − − G Y140 1 Y141 1
rot/reed
F1 F2
X20:5 X76:G CAN2− X20:39 B97
X80:2 X79:2 2 2
GND − − X78:3 X107:2 X108:2
X1:152
X76:C X76:E option X20:19 X20:24 X20:28 X20:32
AGND
X20:4 X20:8 X1:122 X20:40 X20:37 10:2 X2:51 X20:12 X20:16
8:20 31 31 10:1
_J
Display option Evib−Meter Temperatursensor Aufnehmer Verstellmotor Aufnehmer Beschleunigung links Prop−Ventil Erreger auf
Evib−meter
diagnostics
10.02.2005
1 1 920 100 05
Kneip Asphalt Manager, Evib−Meter, Temperatur Asphalt
21.5
10.02.2005
957
Nallin asphalt manager, Evib−meter, temperature asphalt 009
958
2:6 K30 K30 14:1
F101
21.5
9:15
9:9 CAN3−
9:9 CAN3+
9:19 RXD
TXD
9:19
X103:F X103:E

option TM2
Switch, GPS
1
CAN3+ CAN3− S166
X101:2 X101:1 X74:7 X74:2 X75:1
5
ST2:4
ST2:3
GPS Antenne
X103:K
X105:1−32
X20:22 X100:K X101:4 1
F150 A93
32 A87 Sicherung
2
BOMAG
X106:1−20
20
ST2:5
ST2:6
ST1:1
ST1:2
ST2:1
ST2:2
X101:3 P11
X101:5 X102:1 X102:2 Drucker
3 printer A92
P15 5
S153
4
GPS Receiver
X75:2 GPS receiver
BCM 05 A94
X100:L X100:I BCM05 BCM 05
Papiervorschub
2:4 K31 K31 11:1
X20:26
GPS
9:15 AGND
GPS Antenne
GPS antenna
31 31 12:1
9:20
ZA
option
10.02.2005
1 1
008 910 92
Kneip Drucker, BCM 05, GPS 920 100 05

10.02.2005
9:20 B15.2 B15.2 12:1
BW161 AD−4 11:7 X67:B X67:B 15:5

BW141 AD−4
V2 BW161 ADH−4 BW141 AD−4 AM
008 910 92
8:7 V2 11:10 BW190 AD−4 11:6 V2 BW151 AD−4
Y57 BW202 AD−4 BW151 AD−4 AM
8:7 Y57 11:10 BW203 AD−4 11:6 Y57 BW151 AC−4
X1:188 X1:187 X1:189 BW161 AD−4 AM X1:188 X1:187 X1:189
BW190 AD−4 AM
BW203 AD−4 AM
2 3 BW144 AD−4 2 3
BW154 AD−4 1 11:7 X67:A X67:A 15:5
4 BW144 AD−4 AM A51
A51 BW154 AD−4 AM
5 1 5 4
5 4 4:1 1:3 2:1 1:2
A16 A16
2 1 6 3 7.8.9
1:1
5:5
5:4
5:3
5:2
5:1
3:4
3:3
3:2
3:1
6:1
B3
B4
11:4 11:4 X67:B 11:10
11:4 11:4 X67:A 11:17
B3
B4
BOMAG
B4 B3 A2 A3 A1
A3 B1
A2 B2
P09
P09 C3 A1 B3
A5 B4
Anzeige
indicator
A6 C3
A5 A6 1
indicator
10:20 K31 2 K31 13:1

10.02.2005
1 1 920 100 05
Kneip Tachograph
21.5
10.02.2005
959
960
F04 F04
9:8 17:1
21.5
Lernmodus
to learn
Anzeigetest
diagnose
Lern Test
15/54
15/54
11:20 B15.2 IN A05
8:3 8,5VOLT OUT+ 1

OUT−
X2:58 X1:32 + X1:33
FM1
Multifuse P04
−
X2:59
X2:59 ZA
option
speedometer
X24:4 X24:3 X24:1 X24:4
BOMAG
X30:1
X30:3
X30:2
BW203 AD−4 BW144 AD−4
BW161 AD−4 AM BW154 AD−4
BR/BN
SW/BK
SW/BK
BR/BN
WS/white
SW/BK
BR/BN
BW190 AD−4 AM
BW202 AD−4 AM
BW203 AD−4 AM
B15 B15 B15 B15
X30:4 X32:3
BL/BU
BL/BU
BL/BU
X24:2
X1:191
10:20 31 31 13:12
transducer speed
10.02.2005
1 1
008 910 92
Kneip Geschwindigkeitsanzeige 920 100 05

10.02.2005
F31 14:1
D
F31 F40
Box 1 G 14:2
4 F68 H F F15 14:1
008 910 92
B Box 1
F40 F15
BOX 1 BOX 1
3
L M H C
4 2 A72:2 5
14:15
low
mid
high
A72
Steuergerät S28
control unit 1
6 11 12 6 2 1 3
ZA
X65:3
X65:2
30 option
X65:4
K85 X63:7 X63:4 X63:6 X53:6

14:18
X52:1 15 1 4 7 6
87 87a 1
Diagnose
X52:2
_t B131
X40:1
X50:1 P18
X40:3
X40:2
2
B104 P
3
BOMAG
X43:3 X43:4 5 8 10
X53:3
X53:5
X1:207
X1:18 X43:2
X45:3
X42:3
X45:2
X42:2
X45:4
X42:4
X55:1
X21:1 Y15 1 E30 13:18 13:14 E30
M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
8:11 M− Magnetventil Heizung 12:20 31 31 17:1
X56:2
X40:4 X55:2
11:20 K31 K31 14:1
Kabinenlüfter
Klimakompressor
ZA ZA
option option
10.02.2005
1 1 920 100 05
Kneip Heizung, Klimaanlage
21.5
10.02.2005
961
962
K30 X91:A
10:20 K30 16:1
F40 7:16 F09 X51:B F09

13:19 16:7
21.5
X65:1 30 X51:A
6:10 F119
K32
14:17 X63:8
A72:2
87 13:11
13:19 F31 F31 15:1

13:19 F15 F15 15:1
E
F110
Box 1
F113 F114 S147 13 X63:5
5 20A
30 30 14 S26 13
K 127 K 128 F115 F116
20A 20A
14:12 14:13
87 87a 87 87a 14 1
X66:1 K 129 30 K 130 30 S53
14:14 14:16
87 87a 87 87a
30 5
K118
14:20
X73:B
87 87a
X72:B
X64:2
A88 A89
X75:B
X74:B
BOMAG
A90 A91
X73:A
X72:A
86 86
K 127 K 128
+ +
X69:1
X70:1
X71:1
X39:1
X75:A
X74:A
E23 E25
E23 + + E25 − − 85 85
86 86
+ + K 129 K 130 86 K32 86 K85 86 K118
+ +
− −
E28 E27 E28 E27
− − 85
− − 85 85 85 85
X69:2
X70:2
X71:2
X39:2
13:19 K31 K31 15:1

10.02.2005
1 1
008 910 92

10.02.2005
Nallin cab 014
14:12 F31
Wischer vorne Wischer hinten
14:12 F15
A B C
008 910 92
13:11 F42 F27 F28
F41
Box 1 X67:A X67:A Box 1 Box 1
11:20 X67:A
1 option Tachograph 2 3
X67:B
11:14 X67:B
S20 S21
0 1 2 7 2 0 1 2 7 2
01 S163 5
01
30
K141 1
5 4 5 4
X67:B 15:19
87 87a
X67:B X67:A
1 +
X63:1
X62:1
X63:2
X62:2
S45
X64:5
X64:3
X64:6
X64:8
S38 A12 Radio
radio
1
5 15 30 E71 1
X64:4 S158 + R80
B51 31 B51 2
2
X64:7
max. 13A
BOMAG
+
E32 X67:C
X46:31b
X46:53
X44:31b
X44:53
X46:53a
X44:53a
E70 I 15
K141
− − G02 31
11:13
X67:C X46 +
53
53a
31b
53
53a
31b
3 min
+
XS option X44
+ X67:C
53a
Tachograph
Abfallverzögert
12V
E29 M04 M06 M05 M07
53a
31b 53
31
− 2,5A
− 31 − 31 −
31b 53
31
X61:2 X61:2
15:16 15:14
X48:2 X64:1 X44:31 X46:31 X61:B
14:20 K31 K31 16:1

Kabinenleuchte Wischermotor vorn Wischermotor hinten 15:18
cabin inside light wiper motor front wiper motor rear
Wascher hinten
indicator
10.02.2005
1 1 920 100 05
Kneip Kabine
21.5
10.02.2005
963
Nallin cab 015
964
14:20 K30
21.5
switch, worklamp
14:20 F09
13 A
13 S53
S147 F108
1
14
14
A B 30
13 K135
F113 F114 S26
16:14
1 2,5qmm 2 87 87a
30 C D 14
K127 30
K128
16:7 F115 F116
16:9
87 87a 87 87a 3 4
K129 30 30
K130
16:10 16:11
87 87a
87 87a
2,5qmm
BOMAG
86
+ + K127 86 K128 + +
E23 E25 E23 E25
− − − −
85 85 86 86 86
K135
+ + K129 K130 + +
E28 E27 E28 E27
− − 85 85 85 − −
15:20 K31



10.02.2005
1 1
008 910 92
Kneip Arbeitsscheinwerfer ROPS 920 100 05

10.02.2005
5:20 F25
5:17 F06
F04
12:20
008 910 92
Taster Hundegang
X1:131 X9L:3 X9L:5
S115 3 3
S116
X12:A
4
4
K138 30 K03 30
BR/BN
B10 17:16 17:18
87 87a 87 87a
BL/BU
SW/BK
X12:B X12:C X9L:4 X9L:6
X1:113 X1:115 X1:141 X1:142

X1:130
BOMAG
X1:56
X7:13
86 86
+ 1 Y19 Y18 1 K138 K03
H02
2 2
−
V16 V17 85 85
4:20 X7:−
X1:127 X1:114 X1:116 X1:127
13:15 31 31 18:1

ZA
option
10.02.2005
1 1 920 100 05
Kneip Hundegang
21.5
10.02.2005
965
966
21.5
A68 A05
option
A71 A04
AC−Maschine
A83
0000 Messtechnik Rechner
A03
option
BOMAG
P16
8 16 26 40
5 6 7 13 14 15 22 23 24 25 31 32 33 34 38 39
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 9 10 11 12 17 18 19 20 21 27 28 29 30 35 36 37
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
X20
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
X88:1−68
blau blau
(Buchse) blue blue
blau
blue
blau
blue

asphalt manager
10.02.2005
1 1
008 910 92

V48
A02
V47
2 2
K11 K05 K114 K03 K22 K35 K62 K79 K80 K82 K83 K138 K139 K104
008 910 92
V46
V45
2 2
V44 ZA
option
2
V43 ZA
1 1 1 1 1 1
2
3 4 5 6 7 8
option
V42
1
2
2
FM1
X2:1−26 asphalt
V41 manager
1
2
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
V22
V01
V25
V26
V27
51 52 53 54 55 56 57 5859 X2
60 61
F07
F61
F11
F01
F10
F12
F14
F05
F93
F37
F03
F06
F09
F25
F23
F08
F04
F119
F101
F105
F129
R09
X13:A−C
X14:A−B
X89:A−B
BOMAG
X1:1−208
V49
76 78 80 82 84 86 88 90 110 112 114 116 118 127 137 147 148 168 174 191 X1
75 77 79 81 82 83 100 101 102 103 104 105 106 107 108 109 111 113 115 117 119 120 121 122 123 124 125 126 128 129 130 131 132 133 134 135 136 138 139 140 141 142 143 144 145 146 151 152 165 166 167 173 185186 192 193194 198 199 200 204 205 206 208
85 87 89 91 92 93 94 95 96 97 98 99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 149 150 161 162 163 164 171 172 183 183 187 188 189 190 195 196 197 201 202 203 207

blau
blue
blue
blau
blau
blue
blau
blau
blau
blue
blue
blau
blue
blue
blau
blue
10.02.2005
1 1 920 100 04
Kneip Elektrokasten
21.5
967
968
X7:1−20 X6:1−20
21.5
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
201918 1716151413 121110 201918 1716151413 121110
A15 A15
Zentralstecker Sammelanzeige (Ansicht von hinten) Zentralstecker Sammelanzeige (Ansicht von hinten)
mainplug monitoring module (view from backside) mainplug monitoring module (view from backside)
BOMAG
1 4 6
3 2 1 3 2 1 2 1
5 4 3 2 1
5 3
1
4 3 2 1
2 3 4 5
A16
A51 Elektronik Tachograph
Platine Frequenzanzeige electronic system, tachograph
Printed circuit board,frequenzy m. 1 2 3
10.02.2005
1 1
008 910 92

A01
A02
005
A02 007
020
11
8
17
Intervallschalter
Blinkrelais
Blinkrelais
intervall switch
indicator relay
indicator relay
4/6X21 WATT 21.5
11.2.05
Kneip
11. 2. 5


component listing

Bauteilliste


1

11
920 100 05
E25 016 18 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55 WATT
101
008 910
E27 92 016 6 Arbeitsscheinwerfer hinten links BOMAG
Working head light, rear, lh. 3,5A 969
21.5 E27
E28
E28
016
007
014
19
2
2
55 WATT
55 WATT
55W

11.2.05
Kneip
11. 2. 5

F68 013 9 Sicherung Potential 30 Fuse, potential 30 10A
FM1 020 16 Platinensicherung Multifuse
component listing

Bauteilliste



2

11

K32 014 17 Relais Kabine Relay, cabin BOSCHL
920 100 05
K35 006 12 Relais Selbsthaltung Relay, holding contact BOSCHW

K35 020 8 Relais Selbsthaltung Relay, holding contact
K62 002 7 Relais D+ Relay, D+ BOSCHW
K62 020 9 Relais D+ Relay, D+
102

970 K80 020 11 Relais Berieselungspumpe BOMAG
Relay, sprinkler pump 008 910 92
K82
K83
005
K82 020
005
18
12
19
Relais Kantenschneidgeraet ab
Relais Kantenschneidgeraet ab
Relais Kantenschneidgeraet auf
Relay, edge cutter, up
Relay, edge cutter, up
Relay, edge cutter, down
BOSCHW
BOSCHW
21.5
11.2.05
Kneip
11. 2. 5



component listing

Bauteilliste

P33 009 3 Opus 21 Opus 21


3
11

920 100 05

S44 013 1 Schalter Kabinenluefter Switch, cabin ventilator
S45 015 7 Schalter Kabineninnenleuchte Switch, cabin inside light
103

008 910
S82 92 005 18 Taster Kantenschneidgeraet abwaerts BOMAG
Push button, edge cutter, down MAX 0,2A 971
21.5 S83
S108
S114
005
005
005
19
8
7
Taster Kantenschneidgeraet auf
Schalter Berieselung Kantenschneidgeraet
Schalter Wasserpumpe
Push button, edge cutter, up
Switch,sprinkler sys.edge cutter
Switch, water pump
MAX 0,2A
11.2.05
Kneip
11. 2. 5

component listing

Bauteilliste


4

11

920 100 05

104

972 X1:40 007 18 Elektrokasten BOMAG
X1:41
X1:43
007
X1:42 006
003
19
5
11
Elektrokasten
Elektrokasten
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
21.5
11.2.05
Kneip
11. 2. 5

component listing

Bauteilliste

5

11

920 100 05

105

008 910
X1:12792 017 6 ELEKTROKASTEN BOMAG
21.5 X1:127
X1:128
X1:129
017
004
007
18
17
4
ELEKTROKASTEN
ELEKTROKASTEN
Elektrokasten
Cross−bonding box
Cross−bonding box
Cross−bonding box
11.2.05
Kneip
11. 2. 5

component listing

Bauteilliste

6

11

920 100 05

106

974 X2:22−2 007 20 Elektrokasten BOMAG
X2:23−1
X2:24−1
002
X2:23−2 002
009
7
7
12
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
21.5
11.2.05
Kneip
11. 2. 5

X6:1−20 021 16
component listing

Bauteilliste

X7:1−20 021 8
X11:C 003 7 FAHRHEBEL Travel lever
X12:A 017 6 KNICKGELENK Articulated joint
X12:B 017 6 KNICKGELENK Articulated joint
X12:C 017 6 KNICKGELENK Articulated joint
7

11

920 100 05

107

008 910
X19:1 92 018 5 KEYBOARD BOMAG
Keyboard 975
21.5 X19:2
X19:3
X19:4
018
018
018
5
5
5
KEYBOARD
KEYBOARD
KEYBOARD
Keyboard
Keyboard
Keyboard
11.2.05
Kneip
11. 2. 5

component listing

Bauteilliste

8

11

920 100 05

108

976 X43:3 013 7 FAHRERSTAND BOMAG
Operators platform 008 910 92
X43:4
X44:53
013
X44:31 015
015
7
12
12
FAHRERSTAND
Kabine
Kabine
Operators platform
cabin
cabin
21.5
11.2.05
Kneip
11. 2. 5

component listing

Bauteilliste

9

11

920 100 05

109

008 910
X73:B92 014 9 Kabine BOMAG
cabin 977
21.5 X74:2
X74:7
X74:A
010
010
014
15
14
10
BCM05
BCM05
Kabine
BCM05
BCM05
cabin
X75:1 010 16 BCM05 BCM05
X75:2 010 16 BCM05 BCM05
11.2.05
Kneip
11. 2. 5

component listing

Bauteilliste

10

11

920 100 05

110

978 X101:2 010 7 DRUCKER BOMAG
Printer 008 910 92
X101:3
X101:5
010
X101:4 010
010
6
4
7
DRUCKER
DRUCKER
DRUCKER
Printer
Printer
Printer
21.5
11.2.05
Kneip
11. 2. 5

component listing
Bauteilliste
11
11
920 100 05
111
008 910 92 BOMAG 979

980 BOMAG 008 910 92

008 910 92 BOMAG 981

S/N 101 920 001 050 ⇔ 101 920 001 070 BW 141 AD-4
S/N 101 920 201 006 ⇔ 101 920 201 014 BW 141 AD-4 AM
S/N 101 920 101 038 ⇔ 101 920 101 042 BW 151 AC-4
S/N 101 920 011 039 ⇔ 101 920 011 050 BW 151 AD-4
S/N 101 920 211 008 ⇔ 101 920 211 009 BW 151 AD-4 AM
S/N 101 920 311 012 ⇔ 101 920 311 014 BW 154 AD-4
S/N 101 920 511 029 ⇔ 101 920 511 031 BW 154 AD-4 AM
S/N 101 920 111 009 ⇔ 101 920 111 010 BW 161 AC-4
S/N 101 920 021 199 ⇔ 101 920 021 215 BW 161 AD-4
S/N 101 920 041 018 ⇔ 101 920 041 019 BW 161 ADH-4
S/N 101 920 061 018 ⇔ 101 920 061 020 BW 190 AD-4
S/N 101 920 261 016 ⇔ 101 920 261 018 BW 190 AD-4 AM
S/N 101 920 031 056 ⇔ 101 920 031 058 BW 202 AD-4
S/N 101 920 051 009 ⇔ 101 920 051 011 BW 203 AD-4
S/N 101 920 251 008 ⇔ 101 920 251 011 BW 203 AD-4 AM
982 BOMAG 008 910 92

Inhaltsverzeichnis: BW 141ï4 ... BW 203ï4
008 910 92
table of contents:
sheet no.: drawing ï no.
003 920 100 06 Bremse, Sitzkontakt, NotïAus brake, seat contact, emergency off
008 920 100 06 Vibration,Fahrstufenumsch.,Rückfahrwarns,Splittstr. vibration, warning buzzer, chip spreader, speed selection
009 920 100 06 ZA Stellkammer Fahrpumpe, PhaseïSynchro option control chamber trav.ïpump, phaseïsynchro
010 920 100 06 Asphalt Manager, EvibïMeter, Temperatur Asphalt asphalt manager, Evibïmeter, temperature asphalt
015 920 100 06 Kabine cab
016 920 100 06 Kabine cab
BOMAG
019 920 100 06 Diebstahlschutz System anti ï theft system
020
021 920 100 06 Elektrokasten crossïbonding box
022 920 100 06 Elektrokasten crossïbonding box
21.10.05
001 001
Seis Stromlaufplan 920 100 06
21.10.05
21.6
983
circuit diagram 001
Vogt
984
X2:3ï1
X2:1ï1 X2:1ï2
X2:2ï1
21.6
F01
X2:5ï1 F105
6:1 Sicherung F05
X2:6ï1 F37 fuse
5:2 X2:2ï2 Sicherung
fuse
X2:4ï1 F93
10:2
X2:7ï1 30
7:6 30 X2:3ï2
30 X13:A K11
P0123
P01 2:19
S00
X89:B
X89:A
87 87a
50a
2 X1:10
X13:B X13:C
15 3:1 K11 6:1
X2:9ï1
fuse
Sicherung Battrie
fuse, battery X2:9ï2 F119 F119
1 F119 2:13 2:12 6:1
X2:23ï1
V01 X1:104
BW161ï4 ...202ï4 F15 X2:23ï2 indicator light, charge control
fuse 86 1 K05 2:11 X6:+ 4:5
125A H08 3:8
2 K62 R09 H52
X1:27 X6:14 87 87a
BOMAG
30 (5) 85 2 A13 6:2
K08 2
X1:27
2:14 X1:101 9:12 X6:6
P00
87 (6) W D+ X14:A X14:B X1:206
Generator
+ Batterie generator X6:ï
3:13 X1:135 X1:103
battery 2
G01 B+ Bï B+
ï 2:3
X51:C
S182 S182 50(5) 15(7) S(2)
A 2 K11
86 +
Batterietrennschalter 30 50 T XS
S30 3 B 3 L(1)
switch battery disconnect Y01 2 Y01 1 Y139 1 A13 12V
85 ï
4 X91:B 1 M01 T(4) R(6) 2 31(3)
K31 11:17 B53
R19 ï 1 (R)_t K08
1 Mï 3:3
BW161ï4 ...203ï4 Starter BW161...203ï4 BW141...154ï4 BW161...203ï4 X1:127 X1:53
starter 31 3:1
heatingïflange start boost fuel solenoid valve boostïfuel indicator light, glow plug
socket
Schalter Startmehrmenge Temperatursensor
switch boostïfuel temperature switch
Schalter Startmehrmenge Steuergerät Heizflansch
switch boostïfuel controll unit, heatingïflange
26.07.2005
1 1
008 910 92

10.02.2005
2:12 15 15 4:1
X2:11ï1 X2:10ï1 F25

Sicherung
fuse
X2:10ï2 switch, seat contact
X2:11ï2
008 910 92
X1:66 F25 5:1
X23:A 1
X11:A
Initiator Bremse
S06 8:5
B63 BR/BN 2 4
86 X23:C X23:B
X1:6 MD+ 4:1
X1:67
K22 X6:12
BL/BU SW/BK
85
X11:C X11:B
+
H20
X1:65 X6:ï ï X6:ï
3:15 4:13
1(15/54)
30 7
K22 A68 H14
15 8:3
3:10 Modul Sitzkontakt
87 87a modul seat contact (A8) 1
V48
2
6 4 13
5
B63
8:6 X1:8 X1:202
9 (GND)
X1:123 B20 4:8

A15
X6:9
21
X1:43
3:3
10:13
BOMAG
S01 NotïAusïSchalter 11 21 31 X7:9
3:11
NotïAusïSchalter
22 X1:205
X1:195
X31:1
X1:47 +
X6:11 ï
86 1
2 V03 Y13 1 K05 Y04 1 + H01
Y04 X31:2
V02
30/40Amp
2 ï
BW 141..154ï4
V41 1 2
(1) 2 85
Mï 2:11 X6:ï X6:ï 3:15
2:18 Mï 4:7
BW 141..154ï4 BW 161..203ï4
X1:137 X1:63 X1:127 X1:118 X1:53
31 X1:137
2:20 31 4:1
26.07.2005
1 1 920 100 06
Kneip Bremse, Sitzkontakt, NotïAus
10.02.2005
21.6
985
986
3:20 15
X2:13ï1
F129
X2:12ï1 F04
21.6

fuse
X2:12ï2 X2:13ï2
F04
10:6
X1:57
X6:20 X7:20
X6:+ indicator light, engine oil pressure idicator ligh, hydr.oil filter X7:+ 2 gn
2:17 6:8
H73 H09 H49 H15 H23
H79 X26:2
X1:72
X6:5 X6:16 X6:17 X6:15 X6:13
X7:15
X1:44
X7:2
R21
R22
H70
Tankanzeige
R20
level gauge
Q
X6:3
X6:4
P01
X1:17 X1:20 X1:21 X1:22 X1:23 Q X1:54 P19
1 X6:2
V42 Wasservorrat
(A2) water gauge
2
B20
3:17
BOMAG
X1:97
X7:ï 18:5
X1:196
X1:197
30 X1:24 X1:34
B21 1 30
K62 K104
5:10
2:7 X6:ï X6:ï
X1:92 X1:91 X1:94 X1:95 X1:96 3:16 7:6
87 87a p 2 X1:125 X1:185
87 87a
X10:2 X10:1
X1:128
X27:1
X1:199
X1:200
B55 1 B06 B30 B03 1
gn/gr
1 1 1 B33
R03
P _t p
2 2 2
br/br B124
2 2
X6:10 X7:10
X27:2
ws/wh
3:20 MD+ MD+ 5:1 3:5 Mï Mï 6:11
X10:3
X1:53 X1:127 X1:127 X1:53
3:20 31 31 5:1
26.07.2005
1 1
008 910 92

10.02.2005
3:20 F25 F25 18:1
4:3 MD+ MD+ 10:1
F37 X2:18ï1
2:5 Sicherung
fuse F06
008 910 92
Sicherung
X2:7ï1 fuse X2:18ï2
F06
F61 F37 18:1
fuse
modul vibration
X1:124
X2:7ï2 X2:6ï2
Sicherung
102 X1:69 X9R:3 X9R:5
S114 0
X18:2
8,5VOLT 8:1
44 24 34 14 S82 3 3
X18:1
GND 8:3 S83
+
X1:12
30 30
X1:14
K79 K80 Emulsionsberieselung A01 1ï12 X9R:4 X9R:6
5:12 5:11 5:18 5:19
X1:139 X1:140
87a 87 87 87a 87 87a 87 87a
23 13
1 0 2
S19 10
S108
24 14
5:8
X1:119 X1:120
13 5:8 X1:109 X1:111
15/54 A04
BOMAG
Modul Berieselung
S108
X1:145 X1:146 X1:50
87 X1:51
X17:1 X16:1 X1:173
13
+ + S108 86 86
X15:1 14 1 Y20 1
M02 M18 + X1:52 K82 K83
86 86 86
X1:117 2 Y21 2
ï ï M03 V14 V15 85 85
K104 K80 K79
X17:2 X16:2 ï 1 Y99
85 85 85
nur ACïVersion
only ACïversion
X15:2
2
X1:147 X1:174 X1:118 X1:53 V29 X1:110 X1:112
X1:127 X1:127
4:20 31 31 6:1

option edge cutter
26.07.2005
1 1 920 100 06
10.02.2005
21.6
987
988
K11 K11 7:1
2:19
21.6
2:5 F105
X2:14ï1
2:19 F119 F119 9:7

fuse F23
fuse
X2:5ï2
X2:14ï2
F23
11:2
K35 30 K114 30
6:12 6:5
87a 87
87a 87
X1:42 X1:30
86 86 X1:138
K139 K35 2
3
L0R 33 11 23 85 85
S120 0 S03
switch warning horn
BOMAG
34 12 24
X1:105
X1:106
+ H60
X1:60
2:14 A13 ï
X7:5
X1:134
X1:16 X1:28
2
87 87a
AUX
86 + AW +
(A7) 2 HW
K114 V47 K139 Y120 B11
85 1 6:11 ï ï
30 Signalhorn
warning horn
4:13 Mï Mï 7:8
X1:127 X1:137
5:20 31 31 7:1
6:12 6:9 6:5
Motordrehzahl
motor speed
26.07.2005
1 1
008 910 92

10.02.2005
6:20 K11 K11 8:1
X2:16ï1 Meldeleuchte Blinker H05
Sicherung Brücke entfällt X1:39
X6:ï Überwachungsmodul
X2:16ï2 4:14 StVZO Beleuchtung monitoring module 11 23
008 910 92
X1:38 X6:7
7:20 31 31 8:1
13 F07 X7:8
Sicherung 12 24
S26 S14 S14
X2:7ï2 7:11 7:9
X1:41
X1:40

0 1 23 11 53 33 43
X1:129 S14 S37 X2:19ï1 X2:20ï1 X2:21ï1 X2:22ï1

fuse fuse fuse fuse

F11
X2:19ï2 X2:20ï2 X2:21ï2 X2:22ï2
F09 15:9

X1:100 X1:73 X1:99 X1:74
1
S117
+ + + + 56b 56b
2 X4:4
X4:3 X4:1
E08 E10 E12 E14 E16 E17
X4:2
X57:2 X57:1 X25:3 X57:4 X57:7 X57:5
entfällt bei
X57:8 X25:4 ï 31 31
ZA Splittstreuer
only acc. to option
X58:2 ï X58:1 + ï + X58:4 X58:7 + ï + X58:5
E09 E11 E13 E15
ï ï ï
ï
BOMAG
X25:5
X1:35
X1:36
E02 E73 E04 X25:6
+ + + + + + +
X94:1 X5:R2
E11
E10
E13
E15
E12
E14
E09
E09 E11 E13 E15
X25:1
56b ï ï ï ï 7:10 7:11 7:12 ï ï 7:14 7:15 7:16 7:17 ï
56b
56b E27 E28 56b E18 E19 49 49a
7:10 7:11 7:12 7:14 7:15 7:16 7:17
31 31 A02
X58:3
31 31
E11
E10
E13
E15
E12
E14
E09
rechts X57:3
right 31
links/left
links X5L:C X5L:C
rechts/right
X5:LC X5:R5
X58:3 7:13 X94:2 Bel. EvibïMeter
illum. Evibïmeter Mï Mï X4:5 X58:3
X1:148 6:20 7:18 7:2 7:11 Mï Mï 8:9
31 X1:53 X1:110 X1:127
6:20 31 7:9
Begrenzungsleuchte rechts
Arbeitsscheinwerfer Arbeitsscheinwerfer Blinkrelais Blinkleuchte VL Blinkleuchte VR limitation light rh. Scheinwerfer links
working head light indicator relay indicator front,lh. indicator front,rh. Begrenzungsleuchte links head light LH
working head lights
limitation light lh.
ZA Bel. Geschwindigkeitsanz. Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts Scheinwerfer rechts
Splittstreuer illum. speedometer indicator rear,lh indicator rear,rh. tail light,lh tail light,rh head light RH
option
26.07.2005
1 1 920 100 06
10.02.2005
21.6
989
990
7:20 K11 K11 10:1
Aufnehmer Fahrhebel F03 X2:15ï1

21.6
fuse X2:15ï2 switch, vibration, man./autom. speed range selector Schalter vorne hinten Schalter Splittstreuer Schalter Splittmenge
X1:31 X1:31 8:11
8:10 X1:31 X1:31 9:1
B39 3 X1:31 BW161...BW203ï4 13 23
X93:2
23 23 VBH
S36
2
S08 S02 13 13 23
1 L0R
X93:1 X93:3 3:9 B63 14 24 S73 0
24 24 S74
5:12 GND 14
X1:143 X1:70 X1:144 X1:49 X1:1 X1:7 X1:9 X1:11 14 24
1 (15/54)
9 (8,5V) 11 (GND) 8
1 (15/54)
14 16 12 14 11 15 X1:13 X1:15
Y31
A71
A03
modul vibration A71
8:15
15
10 (GND)
13 6 3 5 12 13 5 4 7 8 6
3:20 A03.3 A03.3 9:1

A03 X1:2 X1:2
9 (GND)
8:9 R 9:12
10 (GND)
10:2
A03
K G 11 23 8:2 8:9 A71
V46 V45
3:20 H14 (A6) (A5) 12 24 GA 10:8
1 2
X1:5 V44 (4)
BOMAG
X1:64 X1:3
1 2
BW161AD...BW203ADï4 8:10
Brücke bei AC/AM

A73
X1:126
Y31
10:2
X9L:2
X9R:2
Y57 X1:75 X1:186 X1:83 9:12
X3:1 12:1
Asphalt X1:81
S12 3 S13 3 Manager X77:1 X90:1 9:12 X1:89
+ V2 12:1 X1:87
X28:1 X29:1 X1:118 X1:171
H14 X1:83 X1:81
ï V08
4 4 X1:77 X1:79 Y30 Y31 V12 V11 V18
1 1
X8:1 X9:1 1 1 Y54 1 1 1 V19 V21 1
1
X3:2
Y56 Y57 2 2 Y131
X9L:1
X9R:1
2 2 2 2 2 Y55 2 2 2 2
V43 X28:2 X29:2
V49 (4) Y66 Y67
X8:2 1 X9:2 X77:2 X90:2
1
X1:118 X1:63 X1:127 7:20 Mï Mï14:6 X1:84 X1:82 X1:172 X1:88 X1:90
X1:78 X1:137 X1:80
7:10 31 31 9:1

Vibration hinten an
nur ADïVersion option
switch over vibration, only ADïversion
26.07.2005
1 1
008 910 92

10.02.2005
A03.3 Aufn. Vibrationsfrequenz vorn
8:6 A03.3 10:1
transducer vibration frequency front
8:19 X1:31
Aufn. Vibrationsfrequenz hinten
transducer vibration frequency rear
6:10 F119 F119 15:14
008 910 92
2:8 X1:27
15/54 GND X1:2
8:9 B16 B17
X1:83
X110:1 X20:54
X110:2 X20:57
X111:1 X20:58
X111:2 X20:61
8:13
use conn. S02/23

8:13 X1:81
+
+
Anschluß S02/23 nutzen

X2:49ï1 ï ï
13 P35
F1 F2
Schalter Bremse V28 1
switch, brake S49
SPEED
SPEED
2
14 CAN+ CANï
X110:4 DIR
X110:3
X111:4 DIR
X111:3
X2:49ï2
diagnosis phaseïsynchro
Diagnose PhaseïSynchro
Vib front
Vib rear
Vib on
D+
X20:55
X20:60
(15/54)
X1:153
X109:1
X109:15
X109:16
X109:13
X109:12 X20:59
X109:14 X20:56
X109:2
X109:8
X109:4
X1:155 X109:9
Steuerung PhaseïSynchro X109:11

A101
X109:3 controller phaseïsynchro GND
BOMAG
X109:5
X109:6
X20:52 X20:50
2.41A
2.41A
2.41A
Y165 Y172
Y11 1 1
Stellkammer 1
control chamber
2 2 2
X1:156 X20:53 X20:51
8:20 31 31 10:1
Magnetventil PhaseïSynchro 2
solenoid phaseïsynchro 2
Magnetventil PhaseïSynchro 1
solenoid phaseïsynchro 1
18.10.2005
1 1 920 100 06
Seis ZA Stellkammer Fahrpumpe, PhaseïSynchro
18.10.2005
21.6
991
Vogt option control chamber trav.ïpump, phaseïsynchro 009
992
8:4 R
9:6 A03.3
21.6
2:5 F93 F93

A73 Sicherung
8:13 fuse
5:17 MD+
X2:55 X20:9 X2:4ï2
X2:53 X2:54 X20:25
F10 RXD
7:17 31 11:2
K11 X2:17ï1 X1:59 X2:25ï1 X2:26ï1 X20:23
8:20 TXD
X2:24ï1
X2:27ï2
CAN3+ 11:2 S01 11:2
V22 V27 3:11 V25 V26
F101 CAN3ï 11:2
Sicherung 32
X20:13 R31 X20:14 B15.2 12:1
X2:17ï2 fuse X20:43 X20:44 1 2 X2:25ï2 X2:26ï2
5
X2:27ï1
1 R32 2 X20:10 X2:57
X2:24ï2
X2:52 F101 10:12
X88:54
X88:36
X88:14
X88:4
X88:5
X88:35
X88:15
X88:41
X88:53
X88:33
X88:37
X88:56
X88:57
X88:59
X88:60
X88:32
X88:38
X88:58
CAN3+
CAN3ï
X88:28
Messtechnik Rechner
A83
X88:27 X88:26
X88:1
X88:3
X88:6
X88:9
X88:7
X88:31
X88:39
X88:30
X88:65
X88:66
X88:67
X88:55
X88:23
X88:29
X88:68
X88:47
X88:46
8:9 GA
R21 F04 F101

1 2 4:20 F04 13:1 10:4 F101 11:1
R20
AGND
BOMAG
1 2 X20:20 X20:38 X20:35
+
X20:1 X20:2 X20:36
B106 ï
X20:29
X20:30
X20:27
X20:31
X76:D X76:F _t
X20:34
X20:33
X1:121 X1:151 X20:11 X20:15
X76:A X20:3
X76:B X20:7
X20:17
X20:18
1
CAN+
CANï
CANï
CAN+
+
P34 + R30
X80:1
X79:1
X79:4
X79:3
X80:3
+
X80:4
X78:1
X78:2
15
P28 B85 B84 X107:1 X108:1
P33 _t 2
30
weiß/white
CAN2+ P16 ï ï G Y140 1 Y141 1
rot/reed
F1 F2
X20:5 X76:G CAN2ï X20:39 B97
X80:2 X79:2 2 2
X20:6 X76:H ï schw/black
GND ï ï X78:3 X107:2 X108:2
X1:152
X76:C X76:E option X20:19 X20:24 X20:28 X20:32
AGND
X20:4 X20:8 X1:122 X20:40 X20:37 11:2 X2:51 X20:12 X20:16
9:20 31 31 11:1
_J
Display EvibïMeter Temperatursensor Aufnehmer Verstellmotor Aufnehmer Beschleunigung links PropïVentil Erreger auf
Evibïmeter
Diagnose Temperaturanzeige Aufnehmer Beschleunigung rechts PropïVentil Erreger ab
diagnostics
ZA EïVIBïMeter
option EVIBïmeter
26.07.2005
1 1
008 910 92
Kneip Asphalt Manager, EvibïMeter, Temperatur Asphalt 920 100 06

10.02.2005
Nallin asphalt manager, Evibïmeter, temperature asphalt 010
2:6 K30 K30 15:1
10:15 F101
008 910 92
10:9 CAN3ï
10:9 CAN3+
10:19 RXD
TXD
10:19
X103:F X103:E

option TM2
Switch, GPS
1
CAN3+ CAN3ï S166
X101:2 X101:1 X74:7 X74:2 X75:1
5
ST2:4
ST2:3
GPS Antenne
X103:K
X105:1ï32
X20:22 X100:K X101:4 1
F150 A93
32 A87 Sicherung
2
USBïCAN Schnittst. fuse
USBïCAN Interface BCM
BOMAG
X106:1ï20
20
ST2:5
ST2:6
ST1:1
ST1:2
ST2:1
ST2:2
X101:3 P11
X101:5 X102:1 X102:2 Drucker
3 printer A92
P15 5
S153
4
GPS Receiver
X75:2 GPS receiver
BCM 05 A94
X100:L X100:I BCM05 BCM 05
Papiervorschub
2:4 K31 K31 12:1
X20:26
GPS
10:15 AGND
GPS Antenne
GPS antenna
31 31 13:1
10:20
ZA
option
26.07.2005
1 1 920 100 06
Kneip Drucker, BCM 05, GPS
10.02.2005
21.6
993
994
10:20 B15.2 B15.2 13:1
21.6
12:7 X67:B X67:B 16:5

BW161 ADï4 BW141 ADï4
V2 BW161 ADHï4 V2 BW141 ADï4 AM
8:7 V2 12:10 BW190 ADï4 12:6 BW151 ADï4
Y57 BW202 ADï4 Y57 BW151 ADï4 AM
8:7 Y57 12:10 BW203 ADï4 12:6 BW151 ACï4
X1:188 X1:187 X1:189 BW161 ADï4 AM X1:188 X1:187 X1:189
BW190 ADï4 AM
X68:B X68:A X68:C BW202 ADï4 AM X68:B X68:A X68:C
BW203 ADï4 AM
2 3 BW144 ADï4 2 3
BW154 ADï4 1 12:7 X67:A X67:A 16:5
4 BW144 ADï4 AM A51
A51 BW154 ADï4 AM
5 1 5 4
5 4 4:1 1:3 2:1 1:2
A16 A16
2 1 6 3 7.8.9
1:1
5:5
5:4
5:3
5:2
5:1
3:4
3:3
3:2
3:1
6:1
B3
B4
12:4 12:4 X67:B 12:10
12:4 12:4 X67:A 12:17
B3
B4
BOMAG
B4 B3 A2 A3 A1
A3 B1
A2 B2
P09
P09 C3 A1 B3
A5 B4
Anzeige
indicator
A6 C3
A5 A6 1
indicator
11:20 K31 2 K31 14:1

26.07.2005
1 1
008 910 92
Kneip Tachograph 920 100 06

10.02.2005
F04 F04
10:8 18:1
008 910 92
Lernmodus
to learn
Anzeigetest
diagnose
Lern Test
15/54
15/54
12:20 B15.2
IN A05
8:3 8,5VOLT OUT+ 1

OUTï
X2:58 X1:32 + X1:33
FM1
Multifuse P04
ï
X2:59
X2:59 ZA
option
speedometer
X24:4 X24:3 X24:1 X24:4
BOMAG
BW161 ADï4 BW141 ADï4 BW141 ADï4 AM BW151 ACï4
BW161 ADHï4 BW151 ADï4 BW151 ADï4 AM BW161 ACï4 X32:1 X32:2
X30:1
X30:3
X30:2
BW190 ADï4 BW154 ADï4 AM
BW202 ADï4 BW154 ADï4
BW203 ADï4
BW190 ADï4 AM
BR/BN
SW/BK
SW/BK
BR/BN
WS/white
SW/BK
BR/BN
BW203 ADï4 AM
B15 B15 B15 B15
X30:4 X32:3
BL/BU
BL/BU
BL/BU
X24:2
X1:191
11:20 31 31 14:12
transducer speed
26.07.2005
1 1 920 100 06
Kneip Geschwindigkeitsanzeige
10.02.2005
21.6
995
996
F31 15:1
D
F31 F40
21.6
Box 1 G 15:2
4 F68 H F F15 15:1

B Box 1
F40 F15
BOX 1 BOX 1
3
L M H C
4 2 A72:2 5
15:15
low
mid
high
A72
Steuergerät S28
control unit 1
6 11 12 6 2 1 3
ZA
X65:3
X65:2
30 option
X65:4
K85 X63:7 X63:4 X63:6 X53:6
15:18
X52:1 15 1 4 7 6
87 87a 1
Diagnose
X52:2
_t B131
X40:1
X50:1 P18
X40:3
X40:2
2
B104 P
3
BOMAG
X43:3 X43:4 5 8 10
X53:3
X53:5
X1:207
X1:18 X43:2
X45:3
X42:3
X45:2
X42:2
X45:4
X42:4
X55:1
X21:1 Y15 1 E30 14:18 14:14 E30
M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
8:11 Mï Magnetventil Heizung 13:20 31 31 18:1
X56:2
X40:4 X55:2
12:20 K31 K31 15:1
Kabinenlüfter
Klimakompressor
ZA ZA
option option
26.07.2005
1 1
008 910 92
Kneip Heizung, Klimaanlage 920 100 06

10.02.2005
X91:A
11:20 K30 K30 17:1
F40 7:16 F09 X51:B F09

14:19 17:7
X65:1 30 X51:A
9:19 F119
K32
008 910 92
15:17 X63:8
A72:2
87 14:11
14:19 F31 F31 16:1

14:19 F15 F15 16:1
E
F110
Box 1
F113 F114 S147 13 X63:5
5 20A
30 30 14 S26 13
K 127 K 128 F115 F116
20A 20A
15:12 15:13
87 87a 87 87a 14 1
X66:1 K 129 30 K 130 30 S53
15:14 15:16
87 87a 87 87a
30 5
K118
15:20
87 87a
X73:B
X72:B
X64:2
A88 A89
X75:B
X74:B
A90 A91
BOMAG
X73:A
X72:A
86 86
K 127 K 128
+ +
X69:1
X70:1
X71:1
X39:1
X75:A
X74:A
E23 E25
E23 + + E25 ï ï 85 85
86 86
+ + K 129 K 130 86 K32 86 K85 86 K118
+ +
ï ï
E28 E27 E28 E27
ï ï 85
ï ï 85 85 85 85
X69:2
X70:2
X71:2
X39:2
14:19 K31 K31 16:1

26.07.2005
1 1 920 100 06
Kneip Kabine
10.02.2005
21.6
997
Nallin cab 015
998
15:12 F31 Wischer vorne Wischer hinten
21.6
15:12 F15
A B C 1
14:11 F42 F27 F28 F143
F41
Box 1 X67:A X67:A Box 1 Box 1 InlineïFuse
12:20 X67:A
1 option Tachograph 2 3 2
X67:B
12:14 X67:B
S20 S21
0 1 2 7 2 0 1 2 7 2
01 S163 5
01
30
K141 1
5 4 5 4
X67:B 16:19
87 87a
X67:B X67:A
1 +
X63:1
X62:1
X63:2
X62:2
+ S45
X64:5
X64:3
X64:6
X64:8
S38 A12 Radio
E72
radio
ï 1
5 15 30 E71 1
4Stck/4pcs
X64:4 S158 + R80
B51 31 B51 2
2
BOMAG
X64:7
max. 13A
+
E32 X67:C
X46:31b
X46:53
X44:31b
X44:53
X46:53a
X44:53a
E70 I 15
K141
ï ï G02 31
12:13
X67:C X46 +
53
53a
31b
53
53a
31b
3 min
+
XS option X44
+ X67:C
53a
Tachograph
Abfallverzögert
12V
E29 M04 M06 M05 M07
53a
31b 53
31
ï 2,5A
ï 31 ï 31 ï
31b 53
31
X61:2 X61:2
16:16 16:14
X48:2 X64:1 X44:31 X46:31 X61:B
15:20 K31 K31 17:1

Schalterbeleuchtung Kabinenleuchte Wischermotor vorn Wischermotor hinten 16:18
switchïillumination cabin inside light wiper motor front wiper motor rear
Wascher hinten
indicator
26.07.2005
1 1
008 910 92

10.02.2005
Nallin cab 016
15:20 K30
switch, worklamp
008 910 92
15:20 F09
13 A
13 S53
S147 F108
1
14
14
A B 30
13 K135
F113 F114 S26
17:14
1 2,5qmm 2 87 87a
30 C D 14
K127 30
K128
17:7 F115 F116
17:9
87 87a 87 87a 3 4
K129 30 30
K130
17:10 17:11
87 87a
87 87a
2,5qmm
86
BOMAG
+ + K127 86 K128 + +
E23 E25 E23 E25
ï ï ï ï
85 85 86 86 86
K135
+ + K129 K130 + +
E28 E27 E28 E27
ï ï 85 85 85 ï ï
16:20 K31



26.07.2005
1 1 920 100 06
Kneip Arbeitsscheinwerfer ROPS
10.02.2005
21.6
999
1000
5:20 F25
5:17 F06
21.6
F04
13:20
Taster Hundegang
X1:131 X9L:3 X9L:5
S115 3 3
S116
X12:A
4
4
K138 30 K03 30
BR/BN
B10 18:16 18:18
87 87a 87 87a
BL/BU
SW/BK
X12:B X12:C X9L:4 X9L:6
X1:113 X1:115 X1:141 X1:142
BOMAG
X1:130
X1:56
X7:13
86 86
+ 1 Y19 Y18 1 K138 K03
H02
2 2
ï
V16 V17 85 85
4:20 X7:ï
X1:127 X1:114 X1:116 X1:127
14:15 31 31 19:1

ZA
option
26.07.2005
1 1
008 910 92
Kneip Hundegang 920 100 06

10.02.2005
A68 A05 A101
Steuerung PhaseïSynchro
controller phaseïsynchro
008 910 92
option
A71 A04
ACïMaschine
A83
A03
option
P16
BOMAG
P35
8 16 26 40 51 57
5 6 7 13 14 15 22 23 24 25 31 32 33 34 38 39 50 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 9 10 11 12 17 18 19 20 21 27 28 29 30 35 36 37 52 53 58 59 6061
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
X20
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
X88:1ï68
blau blau
(Buchse) blue blue
blau
blue
blau
blue
blau
blue
Asphalt Manager X20:1ï61

asphalt manager
26.07.2005
1 1 920 100 06
Kneip Elektrokasten
21.6
1001
crossïbonding box 020
1002
V48
21.6
A02
V47
2 2
K11 K05 K114 K03 K22 K35 K62 K79 K80 K82 K83 K138 K139 K104
V46
V45
2 2
V44 ZA
option
2
V43 ZA
1 1 1 1 1 1
2
3 4 5 6 7 8
option
V42
1
2
ZA
2
option FM1
X2:1ï61 asphalt
V41 manager
1
2
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 49
191
V22
V01
V25
V26
V27
V28
51 52 53 54 55 56 57 5859 X2 X1
192 193194 198 199 200 204 205 206 208
60 61
187 188 189 190 195 196 197 201 202 203 207
F07
F61
F11
F01
F10
F12
F14
F05
F93
F37
F03
F06
F09
F25
F23
F08
F04
F119
F101
F105
F129
R09
BOMAG
X13:AïC
X14:AïB
X89:AïB
blau
X1:1ï208 blue
blau
blue
blau
blue
V49
76 78 80 82 84 86 88 90 110 112 114 116 118 122 127 137 147 148 156 168 174
75 77 79 81 82 83 100 101 102 103 104 105 106 107 108 109 111 113 115 117 119 120 121 123 124 125 126 128 129 130 131 132 133 134 135 136 138 139 140 141 142 143 144 145 146 151 152 155 165 166 167 173 185186
85 87 89 91 92 93 94 95 96 97 98 99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 149 150 153154 161 162 163 164 171 172 183 183
X1
blau blau blau blau

blau
blue
blue blue blue blue
blue
blau
blau
blue
blau
blau
blau
blue
blue
blau
blue
blue
26.07.2005
1 1
008 910 92

X7:1ï20 X6:1ï20
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
008 910 92
201918 1716151413 121110 201918 1716151413 121110
A15 A15
1 4 6
BOMAG
3 2 1 3 2 1 2 1
5 4 3 2 1
5 3
1
4 3 2 1
2 3 4 5
A16
26.07.2005
1 1 920 100 06
Kneip Elektrokasten
21.6
1003
21.6 021 14
021 14 Wiring diagram 920 100 06
A01 005 11 Intervallschalter intervall switch
A02 007 8 Blinkrelais indicator relay 4/6X21 WATT
A02 021 17 Blinkrelais indicator relay
A03 005 10 Modul Vibration modul vibration
A04 005 5 Modul Berieselung modul sprinkler system
Vogt
21.10.05
Seis
21.10.05

A83 010 7 Elektronik Messtechnik electronic measurementïequipment TYP 18633
A83 020 16 Elektronik Messtechnik electronic measurementïequipment
A87 011 14 USBïCAN Schnittstelle BCM USBïCAN Interface BCM
A88 015 8 Vorschaltgerät, Xenon Licht ballast system, Xenonïlight
component listing

A101 009 11 Steuergerät Phasensynchronisation control unit phaseïsynchronisation
Bauteilliste
A101 020 16 Steuergerät Phasensynchronisation control unit phaseïsynchronisation

B16 009 15 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B17 009 16 Aufnehmer Vibrationsfrequenz hinten Transducer, vibration frequency, rear
B21 004 12 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B39 008 3 Aufnehmer Fahrhebel Transducer, travel lever 4ï20 mA

1

12

920 100 06

101
1004 E25 015 9 Arbeitsscheinwerfer vorne rechts BOMAG
Working head light, front, rh. 3,5A 008 910 92
E25
E27
017
E25 017
007
4
18
1
Arbeitsscheinwerfer vorne rechts
Working head light, front, rh.
3,5A
55 WATT
55 WATT
21.6
E28 015 2 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
Vogt
21.10.05
Seis
21.10.05

E72 016 2 Beleuchtung Bedienschalter illum. Switches 24V/1.2W
E73 007 6 Beleuchtung, EvibïMeter Illumination, Evibïmeter

F09 007 14 Sicherung Parkï u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 007 17 Sicherung Parkï u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
component listing

Bauteilliste

F143 016 18 Sicherung Heckscheibenheizung fuse rear screen heating unit 15A


H14 008 4 Warnsummer Rueckwaertsfahrt Backïup alarm buzzer 0,7A
2

12

920 100 06

102
008 910
K32 92 015 17 Relais Kabine BOMAG
Relay, cabin BOSCHL 1005
21.6 K35
K35
K62
006
021
002
12
8
7
Relais Selbsthaltung
Relais D+
Relay, holding contact
Relay, D+
BOSCHW
BOSCHW
Vogt
21.10.05
Seis
21.10.05


component listing

Bauteilliste

P09 012 5 Frequenzï und Geschwindigkeitsanzeige Frequencyï and Speedometer
P09 012 15 Frequenzï und Geschwindigkeitsanzeige Frequencyï and Speedometer
P33 010 3 Opus 21 Opus 21
P34 010 6 EvibïMeter Evibïmeter
P35 009 9 Diagnose Phasensynchronisation diagnosis phaseïsynchronisation BMFSA
P35 020 12 Diagnose Phasensynchronisation diagnosis phaseïsynchronisation

R14 004 19 Geber Wasserstand, links Sender, water level, lh. 4ï20 mA

3

12
920 100 06

103

1006 S35 008 7 Vibrationsschalter klein/gross BOMAG
Switch, vibration low/high 008 910 92
S36
S38
008
S37 007
016
12
12
3
Vibrationsschalter
Schalter Blinker
Schalter Kennleuchte
Switch, vibration
Switch, indicator
Switch, warning light
21.6
S49 009 3 Schalter Bremse Switch, brake
Vogt
21.10.05
Seis
21.10.05
S182 002 9 Schalter Startmehrmengenunterdrückung switch boostïfuel rejection LU DEUTZ
S182 002 10 Schalter Startmehrmengenunterdrückung switch boostïfuel rejection

component listing

Bauteilliste

X1:1 008 9 ELEKTROKASTEN Crossïbonding box

X1:1ï208 021 1 ELEKTROKASTEN Crossïbonding box
4

12

X1:16 006 5 Elektrokasten Crossïbonding box
920 100 06

104

008 910
X1:26 92 007 10 Elektrokasten BOMAG
Crossïbonding box 1007
21.6 X1:27
X1:28
X1:29
002
006
002
9
9
16
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Crossïbonding box
Crossïbonding box
Crossïbonding box
Vogt
21.10.05
Seis
21.10.05

component listing

Bauteilliste

5

12

920 100 06

105

Crossïbonding box 008 910 92
X1:123
X1:125
003
X1:124 005
004
3
9
15
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Crossïbonding box
Crossïbonding box
Crossïbonding box
21.6
Vogt
21.10.05
Seis
21.10.05

component listing

Bauteilliste

X2:5ï2 006 12 Elektrokasten Crossïbonding box
6

12

920 100 06

106

008 910 92
X2:14ï1 006 18 Elektrokasten BOMAG
Crossïbonding box 1009
21.6 X2:14ï2
X2:15ï1
X2:15ï2
006
008
008
18
5
4
Elektrokasten
ELEKTROKASTEN
ELEKTROKASTEN
Crossïbonding box
Crossïbonding box
Crossïbonding box
Vogt
21.10.05
Seis
21.10.05

X3:1 008 4 RÜCKFAHRWARNSUMMER Backïup alarm buzzer
X3:2 008 4 RÜCKFAHRWARNSUMMER Backïup alarm buzzer
component listing

Bauteilliste

X6:1ï20 022 16
X7:1ï20 022 8
7

12

920 100 06

107

1010 X12:A 018 6 KNICKGELENK BOMAG
X12:B
X13:A
018
X12:C 018
002
6
6
11
KNICKGELENK
KNICKGELENK
FAHRERSTAND
Articulated joint
Articulated joint
Operators platform
21.6
X13:AïC 021 4 ELEKTROKASTEN Crossïbonding box
X14:AïB 021 3 ELEKTROKASTEN Crossïbonding box
Vogt
21.10.05
Seis
21.10.05

component listing

Bauteilliste

8

12

920 100 06

108

008 910
X25:5 92 007 10 BLENDE HINTEN BOMAG
Screen rear 1011
21.6 X25:6
X26:1
X26:2
007
004
004
14
20
20
BLENDE HINTEN
WASSERTANK
WASSERTANK
Screen rear
Water tank
Water tank
Vogt
21.10.05
Seis
21.10.05

component listing

Bauteilliste

9

12

920 100 06

109

1012 X64:7 016 5 Kabine BOMAG
cabin 008 910 92
X64:8
X65:2
016
X65:1 015
014
15
3
1
Kabine
Kabine
Kabine
cabin
cabin
cabin
21.6
Vogt
21.10.05
Seis
21.10.05

X74:2 011 15 BCM05 BCM05
X74:7 011 14 BCM05 BCM05
X75:1 011 16 BCM05 BCM05
X75:2 011 16 BCM05 BCM05
component listing

Bauteilliste

X88:1ï68 020 3 ELEKTRONIK VARIOMATIC Electronic variomatic
10

12

920 100 06

110

008 910
X88:6892 010 17 ELEKTRONIK VARIOMATIC BOMAG
Electronic variomatic 1013
21.6 X89:A
X89:AïB
X89:B
002
021
002
1
2
2
FAHRERSTAND
ELEKTROKASTEN
FAHRERSTAND
Operators platform
Crossïbonding box
Operators platform
Vogt
21.10.05
Seis
21.10.05

X105:1ï32 011 9 DRUCKER Printer
component listing
X106:1ï20 011 10 DRUCKER Printer

Bauteilliste

X109:1 009 9 STEUERUNG PHASENSYNCH controller phaseïsynchro
X110:1 009 14 VIBïAUFNEHMER VORNE vibïsensor front
X111:1 009 15 VIBïAUFNEHMER HINTEN vibïsensor rear
Y11 009 3 Magnetventil Stellkammer Fahrpumpe Sol. valve, control chamber travel pump 2.41A
11

12

920 100 06

Y139 002 11 Magnetventil Minusangleichung solenoidïvalve boostïfuel 4,5AMP.
111

1014 Y165 009 11 Magnetventil Phasensynchronisation 1 BOMAG
solenoid phaseïsynchro 1 2.41A 008 910 92
Vogt
21.10.05
Y172 009 12 Magnetventil Phasensynchronisation 2
solenoid phaseïsynchro 2 2.41A
21.6
Seis
21.10.05
component listing
Bauteilliste
12
12
920 100 06
112
008 910 92 BOMAG 1015

1016 BOMAG 008 910 92

008 910 92 BOMAG 1017

S/N 101 920 001 071 ⇔ 101 920 001 ... BW 141 AD-4
S/N 101 920 201 015 ⇔ 101 920 201 ... BW 141 AD-4 AM
S/N 101 920 101 043 ⇔ 101 920 101 ... BW 151 AC-4
S/N 101 920 411 009 ⇔ 101 920 411 ... BW 151 AC-4 AM
S/N 101 920 011 051 ⇔ 101 920 011 ... BW 151 AD-4
S/N 101 920 211 010 ⇔ 101 920 211 ... BW 151 AD-4 AM
S/N 101 920 311 015 ⇔ 101 920 311 ... BW 154 AD-4
S/N 101 920 511 032 ⇔ 101 920 511 ... BW 154 AD-4 AM
S/N 101 920 111 011 ⇔ 101 920 111 ... BW 161 AC-4
S/N 101 920 021 216 ⇔ 101 920 021 ... BW 161 AD-4
S/N 101 920 041 020 ⇔ 101 920 041 ... BW 161 ADH-4
S/N 101 920 061 021 ⇔ 101 920 061 ... BW 190 AD-4
S/N 101 920 261 019 ⇔ 101 920 261 ... BW 190 AD-4 AM
S/N 101 920 031 059 ⇔ 101 920 031 ... BW 202 AD-4
S/N 101 920 051 012 ⇔ 101 920 051 ... BW 203 AD-4
S/N 101 920 251 012 ⇔ 101 920 251 ... BW 203 AD-4 AM
1018 BOMAG 008 910 92

Inhaltsverzeichnis: BW 141−4 ... BW 203−4
008 910 92
table of contents:
003 920 100 07 Motor Vorglühanlage engine grid−heater, glow−plug

009 920 100 07 Vibr., Fahrstufenumsch., Rückfahrwarns., Splittstr. vibration, warning buzzer, chip spreader, speed selection
010 920 100 07 ZA Stellkammer Fahrpumpe, Phase−Synchro option control chamber trav.−pump, phase−synchro
016 920 100 07 Kabine cab
BOMAG
017 920 100 07 Kabine cab
020 920 100 07 Diebstahlschutz System anti − theft system
021
12.6.2006
001 001
Seis Stromlaufplan 920 100 07
13.6.2006
21.7
1019
circuit diagram 001
Vogt
X2:3−1
1020
X2:1−1 X2:1−2
X2:2−1
21.7
F01
X2:5−1 F105
7:1 Sicherung F05
X2:6−1 F37 fuse
fuse
X2:4−1 F93
11:2
X2:7−1 30
8:6 30 X2:3−2
30 X13:A K11
P0123
P01 2:17
S00
X89:B
X89:A
87 87a
50a
2 X1:10
X13:B X13:C
15 4:1 K11 7:1
X2:9−1
fuse
Sicherung Battrie
1 F119 2:15 2:14 3:4
X2:23−1
K14 3:2 V01
Meldeleuchte Ladekontrolle
X2:23−2 indicator light, charge control
X6:+ 3:8 30
86 1 K05
K62 R09 H08 4:8
X1:27 X6:14 87 87a
BOMAG
85 2
2
X1:27
X1:101 10:12
P00
W D+ X14:A X14:B
G02 Betriebsstundenzähler
operating hour meter
Generator
4:13
battery 2 50
G01 B− B+ 3:4
−
X51:C
S182 S182
A 2 K11
86 +
Batterietrennschalter 30 50 T XS
S30 3 B 3
switch battery disconnect Y01 2 Y01 1 Y139 1 12V
85 −
4 X91:B M01
K31 12:17
− 1
M− 3:1
Starter BW161...203−4 BW141...154−4 X1:127 X1:53
starter 31 3:1
5:2 Startmehrmenge Magnetventil Minusabgleich 2:14 Steckdose

start boost fuel solenoid valve boost−fuel
socket
Schalter Startmehrmenge
switch boost−fuel
Schalter Startmehrmenge
switch boost−fuel
12.06.2006
1 1
008 910 92
Seis Versorgung, Starten, Steckdose 920 100 07

13.06.2006
Vogt supply, starting unit, socket 002
008 910 92
Kontrollampe Glühüberwachung
indicator light, glow plug
2:5 K14
2:15 50
2:19 F119 F119 7:1 2:13 X6:+ X6:+

5:5
H52
1
X6:6 1
F158 F159
X1:29 50A 50A 2

2
X1:104 X1:103
A13
7:2
F48 1 X1:206 1
Sicherung R23
fuse
BOMAG
125A
2 X1:135 220K−OHM 2
50(5) 15(7) S(2) 15 TK 50 30 86 30
30 (5) K14
K08 L(1) L K14
3:6 A13
A13 3:16 87
87 (6) 85
T(4) R(6) 31(3) 31 H R
2
1 1 1
R19 K08 220Amp R02 R02
2000 WATT
50A 50A
B53 1
(R)_t
M− X1:78
2:14 M− 4:3
2:20 31 31 4:1
BW161...203−4 BW141−4 ...154−4
3:3 Glühkerze Glühkerze

glow−plug glow−plug
Heizflansch Temperatursensor
heating−flange temperature switch
Steuergerät Heizflansch Relais Vorglühen
controll unit, heating−flange Relais glow−plug
12.06.2006
1 1 920 100 07
Seis Motor Vorglühanlage
21.7
13.06.2006
1021
Vogt engine grid−heater, glow−plug 003
15
1022
2:12 15 5:1
X2:11−1 X2:10−1 F25

Sicherung
21.7

fuse
X2:11−2 X1:66 F25 6:1
X23:A 1
X11:A
Initiator Bremse
S06 9:5
B63 BR/BN 2 4
86 X23:C X23:B
X1:6 MD+ 5:1
X1:67
K22 X6:12
BL/BU SW/BK
85
X11:C X11:B
+
H20
X1:65 X6:− − X6:−
4:15 5:13
1(15/54)
30 7
K22 A68 H14
15 9:3
4:10 Modul Sitzkontakt
87 87a modul seat contact (A8) 1
V48
2
6 4 13
5
B63
9:6 X1:8 X1:202
9 (GND)
X1:123 B20 5:8

A15
BOMAG
X6:9
21
X1:43
4:3
11:13
4:11
22 X1:205
X1:195
X31:1
X1:47 +
X6:11 −
86 1
2 V03 Y13 1 K05 Y04 1 + H01
Y04 X31:2
V02
30/40Amp
2 −
BW 141..154−4
V41 1 2
(1) 2 85
M− 2:13 X6:− X6:− 4:15
3:20 M− 5:7
BW 141..154−4 BW 161..203−4
X1:137 X1:63 X1:127 X1:118 X1:53
31 X1:137
3:20 31 5:1
16.06.2006
1 1
008 910 92
Seis Bremse, Sitzkontakt, Not−Aus 920 100 07

13.06.2005
Vogt brake, seat contact, emergency off 004
4:20 15
X2:13−1
F129
X2:12−1 F04
fuse
X2:13−2
008 910 92
X2:12−2
F04
11:6
X1:57
X6:20 X7:20
indicator light, engine oil pressure idicator ligh, hydr.oil filter X7:+ 2 gn
3:11 X6:+ 7:8
H73 H09 H49 H15 H23
H79 X26:2
X1:72
X6:5 X6:16 X6:17 X6:15 X6:13
X7:15
X1:44
X7:2
R21
R22
H70
Tankanzeige
R20
level gauge
Q
X6:3
X6:4
P01
X1:17 X1:20 X1:21 X1:22 X1:23 Q X1:54 P19
1 X6:2
V42 Wasservorrat
(A2) water gauge
2
B20
4:17
X1:97
X7:− 19:5
BOMAG
X1:196
X1:197
30 X1:24 X1:34
B21 1 30
K62 K104
6:10
2:7 X6:− X6:−
X1:92 X1:91 X1:94 X1:95 X1:96 4:16 8:6
87 87a p 2 X1:125 X1:185
87 87a
X10:2 X10:1
X1:128
X27:1
X1:199
X1:200
B55 1 B06 B30 B03 1
gn/gr
1 1 1 B33
R03
P _t p
2 2 2
br/br B124
2 2
X6:10 X7:10
X27:2
ws/wh
4:20 MD+ MD+ 6:1 4:5 M− M− 7:11
X10:3
X1:53 X1:127 X1:127 X1:53
4:20 31 31 6:1
12.06.2006
1 1 920 100 07
Seis Überwachung, Warnsummer
21.7
13.06.2006
1023
Vogt monitoring unit, warning buzzer 005
1024
4:20 F25 F25 19:1
5:3 MD+ MD+ 11:1

21.7
F37 X2:18−1
2:5 Sicherung
fuse F06
Sicherung
X2:7−1 fuse X2:18−2
F06
F61 F37 19:1
fuse
modul vibration
X1:124
X2:7−2 X2:6−2
Sicherung
102 X1:69 X9R:3 X9R:5
S114 0
X18:2
8,5VOLT 9:1
44 24 34 14 S82 3 3
X18:1
− GND 9:3 S83
+
X1:12
30 30
X1:14
6:12 6:11 6:18 6:19
X1:139 X1:140
87a 87 87 87a 87 87a 87 87a
23 13
1 0 2
S19 10
S108
24 14
6:8
X1:119 X1:120
BOMAG
13 6:8 X1:109 X1:111
15/54 A04
Modul Berieselung
S108
X1:145 X1:146 X1:50
87 X1:51
X17:1 X16:1 X1:173
13
+ + S108 86 86
X15:1 14 1 Y20 1
M02 M18 + X1:52 K82 K83
86 86 86
X1:117 2 Y21 2
− − M03 V14 V15 85 85
K104 K80 K79
X17:2 X16:2 − 1 Y99
85 85 85
nur AC−Version
only AC−version
X15:2
2
X1:147 X1:174 X1:118 X1:53 V29 X1:110 X1:112
X1:127 X1:127
5:20 31 31 7:1

option edge cutter
12.06.2006
1 1
008 910 92
Seis Berieselung, Kantenschneidgerät 920 100 07

13.06.2006
Vogt sprinkler system, edge cutter 006
K11 K11 8:1
2:19
2:5 F105
X2:14−1
008 910 92
3:7 F119 F119 10:7
fuse F23
fuse
X2:5−2
X2:14−2
F23
12:2
K35 30 K114 30
7:12 7:5
87a 87
87a 87
X1:42 X1:30
86 86 X1:138
K139 K35 2
3
L0R 33 11 23 85 85
S120 0 S03
switch warning horn
34 12 24
BOMAG
X1:105
X1:106
+ H60
X1:60
3:6 A13 −
X7:5
X1:134
X1:16 X1:28
2
87 87a
AUX
86 + AW +
(A7) 2 HW
K114 V47 K139 Y120 B11
85 1 7:11 − −
30 Signalhorn
warning horn
5:13 M− M− 8:8
X1:127 X1:137
6:20 31 31 8:1
7:12 7:9 7:5
Motordrehzahl
motor speed
12.06.2006
1 1 920 100 07
Seis Drehzahlverstellung Motor, Signalhorn
21.7
13.06.2006
1025
Vogt motor speed, warning horn 007
K11
1026
7:20 K11 9:1
X2:16−1 Meldeleuchte Blinker H05
Sicherung Brücke entfällt X1:39
21.7

X6:− Überwachungsmodul
X2:16−2 5:14 StVZO Beleuchtung monitoring module 11 23
X1:38 X6:7
8:20 31 31 9:1
13 F07 X7:8
Sicherung 12 24
S26 S14 S14
X2:7−2 8:11 8:9
X1:41
X1:40

0 1 23 11 53 33 43
X1:129 S14 S37 X2:19−1 X2:20−1 X2:21−1 X2:22−1

fuse fuse fuse fuse
F11
X2:19−2 X2:20−2 X2:21−2 X2:22−2
F09 16:9

X1:100 X1:73 X1:99 X1:74
1
S117
+ + + + 56b 56b
2 X4:4
X4:3 X4:1
E08 E10 E12 E14 E16 E17
X4:2
X57:2 X57:1 X25:3 X57:4 X57:7 X57:5
entfällt bei
X57:8 X25:4 − 31 31
ZA Splittstreuer
only acc. to option
X58:2 − X58:1 + − + X58:4 X58:7 + − + X58:5
E09 E11 E13 E15
BOMAG
− − −
−
X25:5
X1:35
X1:36
E02 E73 E04 X25:6
+ + + + + + +
X94:1 X5:R2
E11
E10
E13
E15
E12
E14
E09
E09 E11 E13 E15
X25:1
56b − − − − 8:10 8:11 8:12 − − 8:14 8:15 8:16 8:17 −
56b
56b E27 E28 56b E18 E19 49 49a
8:10 8:11 8:12 8:14 8:15 8:16 8:17
31 31 A02
X58:3
31 31
E11
E10
E13
E15
E12
E14
E09
rechts X57:3
right 31
links/left
links X5L:C X5L:C
rechts/right
X5:LC X5:R5
X1:148 7:20 8:18 8:2 8:11 M− M− 9:9
31 X1:53 X1:110 X1:127
7:20 31 8:9
Begrenzungsleuchte rechts
Arbeitsscheinwerfer Arbeitsscheinwerfer Blinkrelais Blinkleuchte VL Blinkleuchte VR limitation light rh. Scheinwerfer links
working head light indicator relay indicator front,lh. indicator front,rh. Begrenzungsleuchte links head light LH
working head lights
limitation light lh.
ZA Bel. Geschwindigkeitsanz. Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts Scheinwerfer rechts
Splittstreuer illum. speedometer indicator rear,lh indicator rear,rh. tail light,lh tail light,rh head light RH
option
12.062006
1 1
008 910 92
Seis Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) 920 100 07

13.06.2006
Vogt illumination, working light (StVZO) 008
8:20 K11 K11 11:1
Aufnehmer Fahrhebel F03 X2:15−1

X1:31
008 910 92
X1:31 9:11
9:10 X1:31 X1:31 10:1
B39 3 X1:31 BW161...BW203−4 13 23
X93:2
23 23 VBH
S36
2
S08 S02 13 13 23
1 L0R
X93:1 X93:3 4:9 B63 14 24 S73 0
24 24 S74
6:12 GND 14
X1:143 X1:70 X1:144 X1:49 X1:1 X1:7 X1:9 X1:11 14 24
1 (15/54)
9 (8,5V) 11 (GND) 8
1 (15/54)
14 16 12 14 11 15 X1:13 X1:15
Y31
A71
A03
modul vibration A71
9:15
15
10 (GND)
13 6 3 5 12 13 5 4 7 8 6
4:20 A03.3 A03.3 10:1

A03 X1:2 X1:2
9 (GND)
9:9 R 10:12
10 (GND)
11:2
A03
K G 11 23 9:2 9:9 A71
V46 V45
4:20 H14 (A6) (A5) 12 24 GA 11:8
1 2
X1:5 V44 (4)
X1:64 X1:3
1 2
BOMAG
BW161AD...BW203AD−4 9:10
Brücke bei AC/AM

A73
X1:126
Y31
11:2
X9L:2
X9R:2
Y57 X1:75 X1:186 X1:83 10:12
X3:1 13:1
Asphalt X1:81
S12 3 S13 3 Manager X77:1 X90:1 10:12 X1:89
+ V2 13:1 X1:87
X28:1 X29:1 X1:118 X1:171
H14 X1:83 X1:81
− V08
4 4 X1:77 X1:79 Y30 Y31 V12 V11 V18
1 1
X8:1 X9:1 1 1 Y54 1 1 1 V19 V21 1
1
X3:2
Y56 Y57 2 2 Y131
X9L:1
X9R:1
2 2 2 2 2 Y55 2 2 2 2
V43 X28:2 X29:2
V49 (4) Y66 Y67
X8:2 1 X9:2 X77:2 X90:2
1
X1:118 X1:63 X1:127 8:20 M− M−15:6 X1:84 X1:82 X1:172 X1:88 X1:90
X1:78 X1:137 X1:80
8:10 31 31 10:1

Vibration hinten an
12.06.2006
1 1 920 100 07
Seis Vibration, Fahrstufenumschaltung, Rückfahrwarnsummer, Splittstreuer
21.7
13.06.2006
1027
Vogt vibration, warning buzzer, chip spreader, speed selection 009
A03.3 Aufn. Vibrationsfrequenz vorn
1028
9:6 A03.3 11:1
transducer vibration frequency front
9:19 X1:31
Aufn. Vibrationsfrequenz hinten
transducer vibration frequency rear
21.7
7:10 F119 F119 16:14
X2:53
2:8 X1:27
15/54 GND X1:2
9:9 B16 B17
X1:83
X110:1 X20:54
X110:2 X20:57
X111:1 X20:58
X111:2 X20:61
9:13
use conn. S02/23

9:13 X1:81
+
+
Anschluß S02/23 nutzen

X2:49−1 − −
13 P35
F1 F2
Schalter Bremse V28 1
switch, brake S49
SPEED
SPEED
2
14 CAN+ CAN−
X110:4 DIR
X110:3
X111:4 DIR
X111:3
X2:49−2
diagnosis phase−synchro
Diagnose Phase−Synchro
Vib front
Vib rear
Vib on
D+
X20:55
X20:60
(15/54)
X1:153
X109:1
X109:15
X109:16
X109:13
X109:12 X20:59
X109:14 X20:56
X109:2
X109:8
X109:4
X1:155 X109:9
Steuerung Phase−Synchro X109:11

A101
X109:3 controller phase−synchro GND
BOMAG
X109:5
X109:6
X20:52 X20:50
2.41A
2.41A
2.41A
Y165 Y172
Y11 1 1
Stellkammer 1
control chamber
2 2 2
X1:156 X20:53 X20:51
9:20 31 31 11:1
Magnetventil Phase−Synchro 2
solenoid phase−synchro 2
Magnetventil Phase−Synchro 1
solenoid phase−synchro 1
12.06.2006
1 1
008 910 92
Seis ZA Stellkammer Fahrpumpe, Phase−Synchro 920 100 07

13.06.2006
Vogt option control chamber trav.−pump, phase−synchro 010
9:4 R
10:6 A03.3
2:5 F93 F93

Sicherung
008 910 92
A73
9:13 fuse
6:17 MD+
X2:55 X20:9 X2:4−2
X2:53 X2:54 X20:25
F10 RXD
8:17 31 12:2
K11 X2:17−1 X1:59 X2:25−1 X2:26−1 X20:23
9:20 TXD
X2:24−1
X2:27−2
CAN3+ 12:2 S01 12:2
V22 V27 4:11 V25 V26
F101 CAN3− 12:2
Sicherung 32
X20:13 R31 X20:14 B15.2 13:1
X2:17−2 fuse X20:43 X20:44 1 2 GPS X2:25−2 X2:26−2
5
X2:27−1
1 R32 2 X20:10 X2:57
X2:24−2
X2:52 F101 11:12
X88:54
X88:36
X88:14
X88:4
X88:5
X88:35
X88:15
X88:41
X88:53
X88:33
X88:37
X88:56
X88:57
X88:59
X88:60
X88:32
X88:38
X88:25
X88:58
CAN3+
CAN3−
X88:28
Messtechnik Rechner
A83
X88:27 X88:26
X88:1
X88:3
X88:6
X88:9
X88:7
X88:31
X88:39
X88:30
X88:65
X88:66
X88:67
X88:55
X88:23
X88:29
X88:68
X88:47
X88:46
9:9 GA
R21 F04 F101

1 2 5:20 F04 14:1 11:4 F101 12:1
R20
AGND
1 2 X20:20 X20:38 X20:35
+
BOMAG
X20:1 X20:2 X20:36
B106 −
X20:29
X20:30
X20:27
X20:31
X76:D X76:F _t
X20:34
X20:33
X1:121 X1:151 X20:11 X20:15
X76:A X20:3
X76:B X20:7
X20:17
X20:18
1
CAN+
CAN−
CAN−
CAN+
+
P34 + R30
X80:1
X79:1
X79:4
X79:3
X80:3
+
X80:4
X78:1
X78:2
15
P28 B85 B84 X107:1 X108:1
P33 _t 2
30
weiß/white
CAN2+ P16 − − G Y140 1 Y141 1
rot/reed
F1 F2
X20:5 X76:G CAN2− X20:39 B97
X80:2 X79:2 2 2
GND − − X78:3 X107:2 X108:2
X1:152
X76:C X76:E option X20:19 X20:24 X20:28 X20:32
AGND
X20:4 X20:8 X1:122 X20:40 X20:37 12:2 X2:51 X20:12 X20:16
10:20 31 31 12:1
Display Evib−Meter Temperatursensor Aufnehmer Verstellmotor Aufnehmer Beschleunigung links Prop−Ventil Erreger auf
Evib−meter
diagnostics
ZA E−VIB−Meter
option EVIB−meter
12.06.2006
1 1 920 100 07
Seis Asphalt Manager, Evib−Meter, Temperatur Asphalt
21.7
13.06.2006
1029
Vogt asphalt manager, Evib−meter, temperature asphalt 011
1030
2:6 K30 K30 16:1
21.7
11:15 F101
11:9 CAN3−
11:9 CAN3+
11:19 RXD
TXD
11:19
X103:F X103:E

option TM2
Switch, GPS
1
CAN3+ CAN3− S166
X101:2 X101:1 X74:7 X74:2 X75:1
5
ST2:4
ST2:3
GPS Antenne
X103:K
X105:1−32
X20:22 X100:K X101:4 1
F150 A93
32 A87 Sicherung
2
BOMAG
X106:1−20
20
ST2:5
ST2:6
ST1:1
ST1:2
ST2:1
ST2:2
X101:3 P11
X101:5 X102:1 X102:2 Drucker
3 printer A92
P15 5
S153
4
GPS Receiver
X75:2 GPS receiver
BCM 05 A94
X100:L X100:I BCM05 BCM 05
Papiervorschub
2:4 K31 K31 13:1
X20:26
GPS
11:15 AGND
GPS Antenne
GPS antenna
31 31 14:1
11:20
ZA
option
12.06.2006
1 1
008 910 92
Seis Drucker, BCM 05, GPS 920 100 07

13.06.2006
Vogt printer, BCM 05, GPS 012
11:20 B15.2 B15.2 14:1
13:7 X67:B X67:B 17:5

BW161 AD−4 BW141 AD−4
V2 BW161 ADH−4 V2 BW141 AD−4 AM
008 910 92
9:7 V2 13:10 BW190 AD−4 13:6 BW151 AD−4
Y57 BW202 AD−4 Y57 BW151 AD−4 AM
9:7 Y57 13:10 BW203 AD−4 13:6 BW151 AC−4
X1:188 X1:187 X1:189 BW161 AD−4 AM X1:188 X1:187 X1:189
BW190 AD−4 AM
BW203 AD−4 AM
2 3 BW144 AD−4 2 3
BW154 AD−4 1 X67:A
4 BW144 AD−4 AM A51 13:7 17:5
A51 BW154 AD−4 AM
5 1 5 4
P09:A3
13:14
5 4 4:1 1:3 2:1 1:2
A16 module, tachograph A16 module, tachograph
2 1 6 3 7.8.9
1:1
5:5
5:4
5:3
5:2
5:1
3:4
3:3
3:2
3:1
6:1
B3
B4
13:4 13:4 X67:B 13:10
13:14
13:4 13:4 X67:A 13:17
B3
B4
P09:A3
BOMAG
B4 B3 A2 A3 A1
A3 B1
A2 B2
P09
P09 C3 A1 B3
A5 B4
Anzeige
indicator
A6 C3
A5 A6 1 1
G02 17:9 Anzeige R33 R24
indicator
12:20 K31 2 2 K31 15:1

12.06.2006
1 1 920 100 07
Seis Tachograph
21.7
13.06.2006
1031
Vogt tachograph 013
1032
F04 F04
11:8 19:1
21.7
Lernmodus
to learn
Anzeigetest
diagnose
Lern Test
15/54
15/54
13:20 B15.2
IN A05
9:3 8,5VOLT OUT+ 1

OUT−
X2:58 X1:32 + X1:33
FM1
Multifuse P04
−
X2:59
X2:59 ZA
option
speedometer
X24:4 X24:3 X24:1 X24:4 X1:53
BOMAG
X30:1
X30:3
X30:2
BW202 AD−4 BW154 AD−4
BW203 AD−4 BW151 AC−4 AM
BW190 AD−4 AM
BR/BN
SW/BK
SW/BK
BR/BN
WS/white
SW/BK
BR/BN
BW203 AD−4 AM
B15 B15 B15 B15
X30:4 X32:3
BL/BU
BL/BU
BL/BU
X24:2
X1:191
12:20 31 31 15:12
transducer speed
12.06.2006
1 1
008 910 92
Seis Geschwindigkeitsanzeige 920 100 07

13.12.2006
Vogt speedometer 014
F31 16:1
D
F31 F40
Box 1 G 16:2
4 F68 H F F15 16:1
008 910 92
B Box 1
F40 F15
BOX 1 BOX 1
3
L M H C
4 2 A72:2 5
16:15
low
mid
high
A72
Steuergerät S28
control unit 1
6 11 12 6 2 1 3
ZA
X65:3
X65:2
30 option
X65:4
K85 X63:7 X63:4 X63:6 X53:6

16:18
X52:1 15 1 4 7 6
87 87a 1
Diagnose
X52:2
_t B131
X40:1
X50:1 P18
X40:3
X40:2
2
B104 P
3
BOMAG
X43:3 X43:4 5 8 10
X53:3
X53:5
X1:207
X1:18 X43:2
X45:3
X42:3
X45:2
X42:2
X45:4
X42:4
X55:1
X21:1 Y15 1 E30 15:18 15:14 E30
M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
9:11 M− Magnetventil Heizung 14:20 31 31 19:1
X56:2
X40:4 X55:2
13:20 K31 K31 16:1
Kabinenlüfter
Klimakompressor
ZA ZA
option option
12.06.2003
1 1 920 100 07
Seis Heizung, Klimaanlage
21.7
13.06.2006
1033
Vogt heating, air conditioning 015
X91:A
1034
12:20 K30 K30 18:1
F40 8:16 F09 X51:B F09

15:19 18:7
21.7
X65:1 30 X51:A
10:19 F119
K32
16:17 X63:8
A72:2
87 15:11
15:19 F31 F31 17:1

15:19 F15 F15 17:1
E
F110
Box 1
F113 F114 S147 13 X63:5
5 20A
30 30 14 S26 13
K 127 K 128 F115 F116
20A 20A
16:12 16:13
87 87a 87 87a 14 1
X66:1 K 129 30 K 130 30 S53
16:14 16:16
87 87a 87 87a
30 5
K118
16:20
X73:B
87 87a
X72:B
X64:2
A88 A89
X75:B
X74:B
BOMAG
A90 A91
X73:A
X72:A
86 86
K 127 K 128
+ +
X69:1
X70:1
X71:1
X39:1
X75:A
X74:A
E23 E25
E23 + + E25 − − 85 85
86 86
+ + K 129 K 130 86 K32 86 K85 86 K118
+ +
− −
E28 E27 E28 E27
− − 85
− − 85 85 85 85
X69:2
X70:2
X71:2
X39:2
15:19 K31 K31 17:1

12.06.2006
1 1
008 910 92
Seis Kabine 920 100 07

13.06.2006
Vogt cab 016
16:12 F31 Wischer vorne Wischer hinten
16:12 F15
A B C 1
008 910 92
15:11 F42 F27 F28 F143
F41
Box 1 X67:A X67:A Box 1 Box 1 Inline−Fuse
13:18 X67:A
1 option Tachograph 2 3 2
X67:B
13:14 X67:B
S20 S21
0 1 2 7 2 0 1 2 7 2
01 S163 5
01
30
K141 1
5 4 5 4
X67:B 17:19
87 87a
X67:B X67:A
1 +
X63:1
X62:1
X63:2
X62:2
+ S45
X64:5
X64:3
X64:6
X64:8
S38 A12 Radio
E72
radio
− 1
5 15 30 E71 1
4Stck/4pcs
X64:4 S158 + R80
B51 31 B51 2
2
X64:7
max. 13A
BOMAG
+
E32 X67:C
X46:31b
X46:53
X44:31b
X44:53
X46:53a
X44:53a
E70 I 15
K141
− − G02 31
13:8
X67:C X46 +
53
53a
31b
53
53a
31b
3 min
+
XS option X44
+ X67:C
53a
Tachograph
Abfallverzögert
12V
E29 M04 M06 M05 M07
53a
31b 53
31
− 2,5A
− 31 − 31 −
31b 53
31
X61:2 X61:2
17:16 17:14
X48:2 X64:1 X44:31 X46:31 X61:B
16:20 K31 K31 18:1

Schalterbeleuchtung Kabinenleuchte Wischermotor vorn Wischermotor hinten 17:18
switch−illumination cabin inside light wiper motor front wiper motor rear
Wascher hinten
indicator
12.062006
1 1 920 100 07
Seis Kabine
21.7
13.06.2006
1035
Vogt cab 017
1036
16:20 K30
21.7
switch, worklamp
16:20 F09
A
13 11
S147 S53 F108
1−0 1
14 12
A B 30
13 K135
F113 F114 S26
18:14
1 2,5qmm 2 87 87a
30 C D 14
K127 30
K128
18:7 F115 F116
18:9
87 87a 87 87a 3 4
K129 30 30
K130
18:10 18:11
87 87a
87 87a
2,5qmm
BOMAG
86
+ + K127 86 K128 + +
E23 E25 E23 E25
− − − −
85 85 86 86 86
K135
+ + K129 K130 + +
E28 E27 E28 E27
− − 85 85 85 − −
17:20 K31



12.06.2006
1 1
008 910 92
Seis Arbeitsscheinwerfer ROPS 920 100 07

13.06.2006
Vogt worklamp RORS 018
6:20 F25
6:17 F06
F04
14:20
008 910 92
Taster Hundegang
X1:131 X9L:3 X9L:5
S115 3 3
S116
X12:A
4
4
K138 30 K03 30
BR/BN
B10 19:16 19:18
87 87a 87 87a
BL/BU
SW/BK
X12:B X12:C X9L:4 X9L:6
X1:113 X1:115 X1:141 X1:142

X1:130
BOMAG
X1:56
X7:13
86 86
+ 1 Y19 Y18 1 K138 K03
H02
2 2
−
V16 V17 85 85
5:20 X7:−
X1:127 X1:114 X1:116 X1:127
15:15 31 31 20:1

ZA
option
12.06.2006
1 1 920 100 07
Seis Hundegang
21.7
13.06.2006
1037
Vogt crab walk 019
1038
21.7
A67 1 2 3
Keyboard
keyboard
4 5 6
7 8 9
* 0
X22:1
X22:2
A66
Steuereinheit
control unit
BOMAG
ZA
option
12.06.2006
1 1
008 910 92
Seis
13.06.2006
Vogt 020
A68 A05 A101
Steuerung Phase−Synchro
controller phase−synchro
008 910 92
option
A71 A04
AC−Maschine
A83
A03
option
P16
BOMAG
P35
8 16 26 40 51 57
5 6 7 13 14 15 22 23 24 25 31 32 33 34 38 39 50 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 9 10 11 12 17 18 19 20 21 27 28 29 30 35 36 37 52 53 58 59 6061
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
X20
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
X88:1−68
blau blau
(Buchse) blue blue
blau
blue
blau
blue
blau
blue

asphalt manager
12.06.2006
1 1 920 100 07
Seis Elektrokasten
21.7
13.06.2006
1039
Vogt cross−bonding box 021
1040
V48
21.7
A02
V47
2 2
K11 K05 K114 K03 K22 K35 K62 K79 K80 K82 K83 K138 K139 K104
V46
V45
2 2
V44 ZA
option
2
V43 ZA
1 1 1 1 1 1
2
3 4 5 6 7 8
option
V42
1
2
ZA
2
option FM1
X2:1−61 asphalt
V41 manager
1
2
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 49
V22
V01
V25
V26
V27
V28
51 52 53 54 55 56 57 5859 X2
60 61
F07
F61
F11
F01
F10
F12
F14
F05
F93
F37
F03
F06
F09
F25
F23
F08
F04
F119
F101
F105
F129
R09
BOMAG
X13:A−C
X14:A−B
X89:A−B
X1:1−208
V49
76 78 80 82 84 86 88 90 110 112 114 116 118 122 127 137 147 148 156 174 191
75 77 79 81 82 83 100 101 102 103 104 105 106 107 108 109 111 113 115 117 119 120 121 123 124 125 126 128 129 130 131 132 133 134 135 136 138 139 140 141 142 143 144 145 146 151 152 155 173 185186 192 193194 198 199 200 204 205 206 208
85 87 89 91 92 93 94 95 96 97 98 99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 149 150 153154 171 172 183 183 187 188 189 190 195 196 197 201 202 203 207
X1

blau
blue

blau
blue
blue
blau
blau
blue
blau
blau
blau
blue
blue
blau
blue
blue
blau
blue
12.06.2006
1 1
008 910 92
Seis Elektrokasten 920 100 07

13.06.2006
X7:1−20 X6:1−20
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
008 910 92
201918 1716151413 121110 201918 1716151413 121110
A15 A15
1 4 6
BOMAG
3 2 1 3 2 1 2 1
5 4 3 2 1
5 3
1
4 3 2 1
2 3 4 5
A16
12.06.2006
1 1 920 100 07
Seis Elektrokasten
21.7
13.06.2006
1041
21.7 022 14
022 14 Wiring diagram 920 100 07
A01 006 11
A02 008 8 Blinkrelais indicator relay 4/6X21 WATT
A02 022 17 Blinkrelais indicator relay
Vogt
13.06.2006
Seis
12.06.2006

component listing

Bauteilliste
A101 010 11 Steuergerät Phasensynchronisation control unit phase−synchronisation

A101 021 16 Steuergerät Phasensynchronisation control unit phase−synchronisation

B16 010 15 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B17 010 16 Aufnehmer Vibrationsfrequenz hinten Transducer, vibration frequency, rear

1

12

920 100 07

101
1042 E25 016 3 Arbeitsscheinwerfer vorne rechts BOMAG
Working head light, front, rh. 55W 008 910 92
E25
E25
016
E25 018
018
9
4
18
3,5A
3,5A
55 WATT
21.7
E28 016 2 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
Vogt
13.06.2006
Seis
12.06.2006

E72 017 2 Beleuchtung Bedienschalter illum. Switches 24V/1.2W

component listing
F48 003 3 Sicherung Gluehanlage Fuse, glow plug system 125A

Bauteilliste

F143 017 18 Sicherung Heckscheibenheizung fuse rear screen heating unit 15A
F158 003 15 Sicherung Gluehkerze 1 fuse glow plug 1 50A
F159 003 17 Sicherung Glühkerze 2 fuse glow plug 2 50A


2

12


920 100 07

102

K14 003 16 Relais Vorgluehen Relay, glow plug system BOSCHW
008 910
K22 92 004 10 Relais Hubmagnet Motor BOMAG
Relay, shut off solenoid, engine BOSCHW 1043
21.7 K22
K32
K35
022
016
007
7
17
12
Relais Hubmagnet Motor
Relais Kabine
Relay, shut off solenoid, engine
Relay, cabin
Wiring diagramBOSCHL
920 100 07
BOSCHW
K35 022 8 Relais Selbsthaltung Relay, holding contact
K62 002 7 Relais D+ Relay, D+ BOSCHW
Vogt
13.06.2006
Seis
12.06.2006


M02 006 1 D*Berieselungspumpe E*Sprinkler pump 11A
component listing

Bauteilliste

P33 011 3 Opus 21 Opus 21
P35 010 9 Diagnose Phasensynchronisation diagnosis phase−synchronisation BMFSA
P35 021 12 Diagnose Phasensynchronisation diagnosis phase−synchronisation

R23 003 13 Widerstand Resistor 220K−OHM
3


12

920 100 07
103

1044 S26 008 4 Schalter Arbeitsbeleuchtung hinten BOMAG
Switch, working head lights, rear 008 910 92
S26
S28
016
S26 018
015
16
11
17
Schalter Arbeitsbeleuchtung hinten
Schalter Arbeitsbeleuchtung hinten
Schalter Kabinenheizung
Switch, working head lights, rear
Switch, working head lights, rear
Switch, cabin heating
21.7
S49 010 3 Schalter Bremse Switch, brake
Vogt
13.06.2006
Seis
12.06.2006

S182 002 9 Schalter Startmehrmengenunterdrückung switch boost−fuel rejection LU DEUTZ
S182 002 11 Schalter Startmehrmengenunterdrückung switch boost−fuel rejection

component listing

Bauteilliste


4

12

920 100 07

104

008 910
X1:21 92 005 9 ELEKTROKASTEN BOMAG
21.7 X1:22
X1:23
X1:24
005
005
005
11
12
15
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
Vogt
13.06.2006
Seis
12.06.2006

component listing

Bauteilliste

5

12

920 100 07

105

X1:118
X1:118
006
X1:118 009
009
6
1
14
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
21.7
Vogt
13.06.2006
Seis
12.06.2006

component listing

Bauteilliste

6

12

920 100 07

106

008 910 92
X2:10−2 004 11 ELEKTROKASTEN BOMAG
21.7 X2:11−1
X2:11−2
X2:12−1
004
004
005
2
3
1
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
Vogt
13.06.2006
Seis
12.06.2006

component listing

Bauteilliste

X6:1−20 023 16
7

X7:1−20 023 8
12

920 100 07

107

1048 XS 002 20 Steckdose BOMAG
Socket 008 910 92
XS
X10:2
017
X10:1 005
005
5
16
15
Steckdose
KRAFTSTOFFTANK
KRAFTSTOFFTANK
Socket
Fuel tank
Fuel tank
21.7
X12:A 019 6 KNICKGELENK Articulated joint
X12:B 019 6 KNICKGELENK Articulated joint
X12:C 019 6 KNICKGELENK Articulated joint
Vogt
13.06.2006
Seis
12.06.2006

component listing

Bauteilliste

8

12

920 100 07

108

008 910
X24:2 92 014 6 Bandage BOMAG
Roller drum 1049
21.7 X24:3
X24:4
X24:4
014
014
014
6
5
11
Bandage
Bandage
Bandage
Roller drum
Roller drum
Roller drum
Vogt
13.06.2006
Seis
12.06.2006

component listing

Bauteilliste

9

12

920 100 07

109

1050 X63:7 015 7 Kabine BOMAG
cabin 008 910 92
X63:8
X64:2
016
X64:1 017
016
17
7
20
KABINE
Kabine
Kabine
Cabin
cabin
cabin
21.7
Vogt
13.06.2006
Seis
12.06.2006

X74:2 012 15 BCM05 BCM05
X74:7 012 14 BCM05 BCM05
component listing
X75:1 012 16 BCM05 BCM05

X75:2 012 16 BCM05 BCM05
Bauteilliste

10

12

920 100 07

110

008 910
X88:5592 011 17 ELEKTRONIK VARIOMATIC BOMAG
Electronic variomatic 1051
21.7 X88:56
X88:57
X88:58
011
011
011
14
15
15
ELEKTRONIK VARIOMATIC
Electronic variomatic
Vogt
13.06.2006
Seis
12.06.2006

component listing

Bauteilliste

X109:1 010 9 STEUERUNG PHASENSYNCH controller phase−synchro
X110:1 010 14 VIB−AUFNEHMER VORNE vib−sensor front
X111:1 010 15 VIB−AUFNEHMER HINTEN vib−sensor rear
11

Y11 010 3 Magnetventil Stellkammer Fahrpumpe Sol. valve, control chamber travel pump 2.41A
12
920 100 07

111

1052 Y66 009 15 Magnetventil Hydromotor BOMAG
Solenoid valve, hydraulic motor 1,5A 008 910 92
Y67
Y120
009
Y99 006
007
16
8
12
Magnetventil Verstellzylinder
Magnetventil Berieselung Kantenschneidgeraet
Magnetventil Motordrehzahl hoch
Solenoid valve, ajustable zylinder
So.valve,sprinkler.sys.edge cutter
Solenoid valve, rpm engine high
1,5A
1,5A
70A/1A
21.7
Y165 010 11 Magnetventil Phasensynchronisation 1 solenoid phase−synchro 1 2.41A
Y172 010 12 Magnetventil Phasensynchronisation 2 solenoid phase−synchro 2 2.41A
Vogt
13.06.2006
Seis
12.06.2006
component listing
Bauteilliste
12
12
920 100 07
112
008 910 92 BOMAG 1053

1054 BOMAG 008 910 92

22 Supplement to circuit diagram
008 910 92 BOMAG 1055

22.1 Control elements, old design
22.1 Control elements, old design
Fig. 1
Pos. Designation in circuit diagram Designation in circuit diagram

1 P34 / E73 Evib-meter / illumination Evib-meter
2 A15 Monitoring board
3 S01 Emergency stop switch
4 S14 Hazard light switch
6 P04 / E04 Speedometer / illumination of speedometer
7 S00 Start switch
8 S73 Switch for chip spreader
9 S74 Switch, chip quantity
10 S120 Switch, engine speed
11 S02 (BW161-4 family) Travel speed range selector
12 S19 Switch, emulsion sprinkling system
13 S114 Switch for water pump
14 S36 Switch, vibration front / both / rear
15 S08 Switch, vibration manual / automatic
1056 BOMAG 008 910 92

Control elements, old design 22.1
16 S35 Switch, vibration low/high
17 S37 Switch, direction indicator
18 S15 Light switch (StVZO)
19 S26 Switch for working lights
20 Lever, swivelling of driver’s seat
21 S83 Button, edge cutter up
22 S82 Button, edge cutter down
23 Travel lever, right
24 S13 Vibration button, travel lever right
25 S03 Button for warning horn
26 S108 Switch for edge cutter sprinkling system
27 A01 Interval switch
28 B63 Proximity switch, brake
29 S115 Button, crabwalk left
30 S116 Button, crabwalk right
31 S12 Vibration switch, travel lever left
32 Lever, lateral sliding of driver’s seat
33 Rotation stop for travel lever movement
34 XS Socket
35 S06 Seat contact switch
36 B39 Transducer, travel lever
008 910 92 BOMAG 1057

22.2 Control elements, new design
22.2 Control elements, new design
Fig. 1

1 not used
2 not used
3 P34 / E73 Evib-meter / illumination Evib-meter
4 P04 / E04 Speedometer / illumination of speedometer
5 S01 Emergency stop switch
6 S14 Hazard light switch
8 not used
9 S00 Start switch
10 S73 Switch for chip spreader
11 S74 Switch, chip quantity
12 S120 Switch, engine speed
13 S02 (BW161-4 family) Travel speed range selector
14 S19 Switch, emulsion sprinkling system
15 S114 Switch for water pump
16 S36 Switch, vibration front / both / rear
17 S08 Switch, vibration manual / automatic
18 S35 Switch, vibration low/high
19 S37 Switch, direction indicator
1058 BOMAG 008 910 92

Control elements, new design 22.2
20 S15 Light switch (StVZO)
21 S26 Switch for working lights
22 Lever, swivelling of driver’s seat
23 S83 Button, edge cutter up
24 S82 Button, edge cutter down
25 Travel lever, right
26 S13 Vibration button, travel lever right
27 S03 Button for warning horn
28 S108 Switch for edge cutter sprinkling system
29 A01 Interval switch
30 B63 Proximity switch, brake
31 S115 Button, crabwalk left
32 S116 Button, crabwalk right
33 S12 Vibration switch, travel lever left
34 Lever, lateral sliding of driver’s seat
35 Rotation stop for travel lever movement
36 XS Socket
37 S06 Seat contact switch
38 B39 Transducer, travel lever
008 910 92 BOMAG 1059

22.3 Control elements, cabin
22.3 Control elements, cabin
Fig. 1

a S38 Switch, flashing beacon
b S20 Switch, front windscreen wiper
c S21 Switch rear windscreen wiper
d F41..... Fuse, cabin
e S44 Switch cabin fan
f A72 Control unit air conditioning, heater
g A72 Control unit air conditioning, heater
h S53 Switch for working lights
i E29 Cabin light
j E70 Night light
k S45 Switch, cabin light
l S158 Switch, night light
1060 BOMAG 008 910 92

Monitoring module A15, old design 22.4
22.4 Monitoring module A15, old design
Fig. 2 Monitoring module A15 left

a H49 Control light, overheating of engine
b H09 Engine oil pressure control light
c H15 Control light for engine air filter
d H08 Charge control light
e H23 Hydraulic oil filter control light
f H20 Control light, seat contact switch
g H01 Brake control light
h H05 Indicator control light
i H70 Control light, water in diesel filter
j H73 Control light, coolant provision
k H52 Control light, preheating monitoring
l H06 Hazard light control light
m P00 Operating hour meter
n P01 Fuel gauge
008 910 92 BOMAG 1061

22.4 Monitoring module A15, old design
Fig. 3 Monitoring module A15 right

a not connected Control light, immobilizer
b not used
c H79 Control light, remaining water quantity
d not connected Control light, fast travel speed range
e H02 Crabwalk control light
f not connected Air conditioning control light
g not connected Control light for electronic control
h not connected Control light, chip spreader
i not used
j H60 Control light, engine speed
k not connected Control light min. fuel level
l not connected Control light, hydraulic oil temperature
m P19 Water level gauge
1062 BOMAG 008 910 92

Monitoring module A15, new design 22.5
22.5 Monitoring module A15, new design
Fig. 4 Monitoring module A15

a H20 Control light, seat contact switch
b H70 Control light, water in diesel filter
c H52 Control light, preheating monitoring
d H79 Control light, remaining water quantity
e H09 Engine oil pressure control light
f H73 Control light, coolant provision
g H08 Charge control light
h H15 Control light for engine air filter
i H49 Control light, overheating of engine
j H23 Hydraulic oil filter control light
k H05 Indicator control light
l H02 Crabwalk control light
m H01 Brake control light
o P19 Water level gauge
p P00 Operating hour meter
q P01 Fuel gauge
008 910 92 BOMAG 1063

22.6 Machine
22.6 Machine
1064 BOMAG 008 910 92

Machine 22.6
008 910 92 BOMAG 1065

22.6 Machine
1066 BOMAG 008 910 92

Machine 22.6
008 910 92 BOMAG 1067

22.6 Machine
1068 BOMAG 008 910 92

Machine 22.6
008 910 92 BOMAG 1069

22.6 Machine
1070 BOMAG 008 910 92

Machine 22.6
008 910 92 BOMAG 1071

22.6 Machine
1072 BOMAG 008 910 92

Machine 22.6
008 910 92 BOMAG 1073

22.6 Machine
1074 BOMAG 008 910 92

Machine 22.6
008 910 92 BOMAG 1075

22.6 Machine
1076 BOMAG 008 910 92

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Service - Manual

BW 141 AD-4 / BW 151 AD-4

Tandem Vibratory Roller

008 910 92 BOMAG 3

7.5 Resistance 121

4 BOMAG 008 910 92

12.18 Air filter, differential pressure switch 463

008 910 92 BOMAG 5

17.2 Repair overview AD-drum 570

6 BOMAG 008 910 92

008 910 92 BOMAG 7

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

You should only use genuine BOMAG spare parts.

Please observe strictly the safety regulations in

8 BOMAG 008 910 92

by attaching a clearly visible warning tag to the

Repair work shall only performed by appropriately

Workshop equipment and facilities as well as the

008 910 92 BOMAG 9

Behaviour in case of faults

10 BOMAG 008 910 92

008 910 92 BOMAG 11

12 BOMAG 008 910 92

Special safety regulations

008 910 92 BOMAG 13

Diagnostics according to plan

14 BOMAG 008 910 92

Electrical system and welding work

008 910 92 BOMAG 15

Hydraulic system ● After changing a component perform a high and

16 BOMAG 008 910 92

Old systems should be converted to refrigerants

008 910 92 BOMAG 17

tion colouring matter makes any warranty claims Fuel hoses

18 BOMAG 008 910 92

008 910 92 BOMAG 19

Feather keys and keyways Ball and roller bearings

20 BOMAG 008 910 92

008 910 92 BOMAG 21

Strength classes of metric screws Strength classes of metric nuts

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

Fig. 8 Identification of nuts

Strength class of Strength class of associated

Nuts for screw joints without specified load factor

22 BOMAG 008 910 92

Fig. 9 Identification of nuts in clock system

008 910 92 BOMAG 23

The values specified in the table apply for screws:

Tightening torques for screws with metric unified thread1

Tightening torques for screws with metric unified fine thread1

24 BOMAG 008 910 92

Tightening torques for wheel nuts (fine thread) 1 2

008 910 92 BOMAG 25

The values specified in the table apply for screws:

26 BOMAG 008 910 92

008 910 92 BOMAG 27

28 BOMAG 008 910 92

008 910 92 BOMAG 29

Notes on the fuel system

Notes on the engine performance

30 BOMAG 008 910 92

Lubrication oil change intervals

008 910 92 BOMAG 31